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 5.1A 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

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

6 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

Index 257

8 Contents Models FlexTest® IIm/GT/SE Controller Hardware

 How to Get Technical Support

Technical Support
How to Get Technical Support
Start with your The manuals supplied by MTS provide most of the information you need to use
manuals 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.

Technical support MTS provides a full range of support services after your system is installed. If
methods 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 [email protected]

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 The site number contains your company number and identifies your equipment
number and system type (such as material testing or simulation). The number is typically written on a
number 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

Know information from If you have contacted MTS about this problem before, we can recall your file
prior technical 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?

• What are the equipment model numbers?

• What is the controller model (if applicable)?

• What is the system configuration?

10 Technical Support Models FlexTest® IIm/GT/SE Controller Hardware

 If You Contact MTS by Phone

Know relevant For a computer problem, have the following information available:
computer information
• 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

Know relevant For software application problems, have the following information available:
software information
• 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.

12 Technical Support 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

14 Technical Support 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

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

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

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

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.

16 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 This manual is available as an electronic document in the Portable Document
conventions 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
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.

Contents 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 Introduction 19

Model 493.10 Chassis

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.

10 9 8 7 6 5 4 3 2 1 B A

498.98-2 493.40 493.40 493.40 493.40 498.71B 493.71 493.73 493.74 493.74 493.72 493.75 493.76
Power PC I/O Carrier I/O Carrier I/O Carrier I/O Carrier GRES III Serial HPU HSM HSM Digital I/O Analog In Analog Out
Interface

J3 Service J3 Service J3 Service J3 Service +12V J50A +12V

Ch 1 Ch 1
SERVICE J43A Intlk J43B J43A Intlk J43B
CLOCK OUT

J23
E-STOP OUT
Shunt Cal Shunt Cal Shunt Cal Shunt Cal Ch 2 Ch 2
BFL EVENT OUT
ABT

CPU
J3 IN
RST EVENT IN
PMC J50B
J4 I/O J4 I/O J4 I/O J4 I/O J44A Run/Stop J44B J44A Run/Stop J44B Ch 3 Ch 3

J3 IN

J24
E-STOP IN Ch 4 Ch 4

J4 OUT

J50C J49A Aux Pwr J49B J49A Aux Pwr J49B Ch 5 Ch 5

J5 I/O J5 I/O J5 I/O J5 I/O

J5 DEBUG
Ch 6 Ch 6

J25 HPS

J6 STATION J50D J29A Load Unit J29B J29A Load Unit J29B

J6 I/O J6 I/O J6 I/O J6 I/O

J4 OUT

J7 SERIAL
J54 J11 J11
J7 SERIAL SYS I/O (Ch 1-4) (Ch 1-4)
J28A HSM J28A HSM

J7 I/O J7 I/O J7 I/O J7 I/O

J12 J12
(Ch 5-6) (Ch 5-6)
J28B HSM J28B HSM

m m m m m m m m m m m m m

1 2 3 4 5 6 7 8 9 10
l Power Over
OK Temp

l MTS Sysrtems Corp J39 Power Monitor

14000 Technologyu Dr.
Eden Prairie, MN 555344-2290 USA
Assy No:
Model: S/N Power

Front Panel Rear Panel

(with VMEbus Modules) (with Transition Modules)

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
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
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.

Interlocks
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

Specifications

FlexTest GT Specifications
PARAMETER SPECIFICATION
Environmental For indoor use only

Temperature 5ºC–40ºC (41ºF–104ºF)

Relative humidity 10%–85%, noncondensing

Altitude For use at altitudes up to 2000 m

(6500 ft)

Power input power factor corrected universal input

Input voltage* 100–240 V AC

Input frequency 47–63 Hz

Input surge <100 A

Power <1000 W

Insulation over Category II

voltage

Pollution degree 2

Power supply #1 maximum draw is 400 W total

+5 V DC 40 A

±15 V DC 7.5 A

Power supply #2 maximum draw is 400 W total

±12 V DC 4A

+24 V DC 10 A

Weight approximately 45 kg (100 lb) in stand

alone configuration

* 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 23

Specifications

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 Operations are controlled through the controller’s front panel. An easy-to-read
controls 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.

FlexTest SE A FG
7 8 9 Rewind Run Hold Stop

B Setup
Recall
Status
4 5 6 Program
Hydraulic
Scope
1 2 3 Interlock

Enabled Meters Program reset

Tuning
+/- 0 . Interlock

Off Low High

Emergency Stop Config
enter HPU
Limits

Log
cancel Off Low High

HSM
Monitor 1 Monitor 2
Navigate ? Menu
Power

TS-G436

FlexTest SE Front Panel

24 Introduction Models FlexTest® IIm/GT/SE Controller Hardware

 Specifications

FlexTest SE stand-alone A function generator (with a built-in cycle counter) in the controller provides
function generation 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.

FlexTest SE automated In the automated configuration, the FlexTest SE Controller has added
configuration 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

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 Except for two front panel BNC connectors, all cabling is accessed through the
rear panel 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.

Power

100–240 VAC
50–60 Hz, 12–6A
RUN 6TS BFL

ABT RST

TYPE E PC-MIP DEBUG

TYPE E PC-MIP PCI MEZZANNE CARD

TS-G435

FlexTest SE Rear Panel

Hydraulic Control
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
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.

26 Introduction Models FlexTest® IIm/GT/SE Controller Hardware

 Specifications

Specifications

FlexTest SE Specifications
PARAMETER SPECIFICATION
Environmental For indoor use only

Temperature 5ºC–40ºC (41ºF–104ºF)

Relative humidity 10%–85%, noncondensing

Altitude For use at altitudes up to 2000 m

(6500 ft)

Power input power factor corrected universal input

Input voltage* 100–240 V AC

Input frequency 47–63 Hz

Input surge <50 A

Insulation over Category I

voltage

Pollution degree 2

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.

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 The FlexTest IIm configuration provides complete control of up to sixteen
Controllers 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.

• Model 498.22 Test Processor Chassis

– Model 498.65 ADDA module

– Model 498.71B GRES III module

– Model 498.96-X Processor module

28 Introduction Models FlexTest® IIm/GT/SE Controller Hardware

 Specifications

FT IIm standard • 4, 6, 8, 12, or 16 channels of control

configurations • 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

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.

497.34 497.35 497.14 497.14 497.14 497.14 497.22 497.22 497.22 497.22 497.26 497.26 497.26 497.26
Station Cntrl RS422 Com AC Cond AC Cond AC Cond AC Cond DC Cond DC Cond DC Cond DC Cond Dual Valve Dual Valve Dual Valve Dual Valve

Station
Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch
Interlocks
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
1 Fault
+15V U Lim U Lim U Lim U Lim U Lim U Lim U Lim U Lim

2 Xmit L Lim LLim L Lim L Lim L Lim L Lim L Lim L Lim

3 Excit Excit Excit Excit Excit Excit Excit Excit

-15V Ready
Fail Fail Fail Fail Fail Fail Fail Fail
4

-5V Power OK
Reset
R-Cal R-Cal R-Cal R-Cal
1 1 1 1

R-Cal R-Cal R-Cal R-Cal

2 2 2 2
Out 1 Out 1 Out 1 Out 1

Gnd Gnd Gnd Gnd

x10
Out1 Out1 Out1 Out1
Out Out Out Out Out 2 Out 2 Out 2 Out 2
Out2 Out2 Out2 Out2
Gnd Gnd Gnd Gnd Gnd Gnd Gnd Gnd
x1
Gnd Gnd Gnd Gnd

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.

Analog Chassis (Front Panel)

30 Introduction Models FlexTest® IIm/GT/SE Controller Hardware

 Model 497.05 Hydraulic Control Panel

Model 497.05 Hydraulic Control Panel

The hydraulic control panel provides the following functions.

• Control of up to four independent hydraulic service manifolds

• Hydraulic power supply control

• Interlock shutdown and latched indicators to show interlock status

• Programmable interlock station assignment

• Electrical power outputs to the hydraulic service manifolds and a 497.01

Analog Chassis

• Built-in Emergency Stop button and connections for a remote emergency

stop button

For details about configuring the hydraulic control panel for your system, see the
Series 497 Electronics Product Information manual (PN 100-036-577.)

m Hydrauli c Power S upply

Emerg en c y St op
E mergency Stop HSM 1 HS M 2 HSM 3 HS M 4

Ov er T emp
497.05 Low L ev el
Hydraul ic In t er loc k 1 Inte rlock 1 Int erlo c k 1 Inte rlo ck 1
Control Filte r Di rt y
In t er loc k 2 Inte rlock 2 Int erlo c k 2 Inte rlo ck 2
Re se t Shu tdo wn Shu t do w n Shu tdo wn Shu t do w n
Inte rlo ck s H yd rau lic Di sa bl ed Hy dra ul ic Dis able d H yd rau lic Di sa bl ed Hy dra ul ic Dis ab le d

Off L ow Hig h Off Pi lot Lo w Hig h Off Pilo t Low High Off Pi lot Lo w Hig h Off Pilo t Low High

Hydraulic Control Panel

Models FlexTest® IIm/GT/SE Controller Hardware Introduction 31

Model 498.22 Chassis with Test Processor (FTIIm)

Model 498.22 Chassis with Test Processor (FTIIm)

The Model 498.22 test processor chassis is a VMEbus chassis that houses up to
twelve plug-in modules (including processor modules, ADDA modules, digital I/O
modules, and so forth). It also accommodates various rear-panel transition modules
(for connections to other hardware chassis and external equipment).

Note The test processor is covered by a tinted, removable front panel. For
more information, see the Series 498 Electronic Product Information
manual (PN 100-036-578).

498.71
498.93-1 498.93-2 GLOBAL 498.65
Processor Processor RESOURCES ADDA

RUN FAIL A
D
R
ABT ABT ABORT S
FAIL

RST RST RESET RESET

CHS CHS
J4 NET J
BFL BFL 1
1
CPU CPU

PCI PCI J
1
FUS FUS
2

SYS SYS

J5 CONSOLE J
1
3

J
1
4

E
X
J4 NET T

J
1
5

J7 SERIAL
J
1
6

J
1
7

J
1
8

MOTOROLA MOTOROLA
mm

Model 498.22 Test Processor Chassis (Front Panel)

32 Introduction Models FlexTest® IIm/GT/SE Controller Hardware

 Specifications

Specifications

Model 497.01 Specifications

PARAMETER SPECIFICATION
Environmental For indoor use only

Temperature 5ºC–40ºC (41ºF–104ºF)

Relative humidity 10%–85%, relative, noncondensing

Power requirements +15 V at 6 A; -15 V at 6 A; +5 V at 6 A

(standard supply maximum output,
actual load depends on installed
modules)

Dimensions

Height 17.8 cm (7 in)

Width 48.3 cm (19 in)

Depth 31.1 cm (12.25 in)

Model 497.05 Specifications (part 1 of 2)

PARAMETER SPECIFICATION
Individual solenoid current 2 A max

Total HSM solenoid current 6 A max

Solenoid operating voltage 24 V DC or 115 V AC (switch

selectable)

497.05 power supply output +24 V at 7.5 A

497.01 power supply output +5 V at 6 A

+15 V at 6 A

-15 V at 6 A

Power requirements 90–132 V AC/180 - 264 V AC

47–63 Hz

500 W

Models FlexTest® IIm/GT/SE Controller Hardware Introduction 33

Specifications

Model 497.05 Specifications (part 2 of 2)

PARAMETER SPECIFICATION
Interlock logic level inputs 0 = 0 V DC

1 = 3.2 to 24 V DC

Dimensions

Height 8.9 cm (3.5 in)

Width 48.3 cm (19 in)

Depth 54.6 cm (21.5 in)

34 Introduction Models FlexTest® IIm/GT/SE Controller Hardware

 Specifications

Model 498.22 Chassis Specifications

PARAMETER SPECIFICATION
Dimensions

Height 40 cm (15.75 in)

Width 48.3 cm (19 in)

Depth 55.9 cm (22 in)

Weight 18 kg (40 lb) plus 0.5 kg (1 lb) per

module

Rack mounting requirements:

Clearance-each side 5.7 cm (2.25 in) for air flow

Clearance-back 15.3 cm (6.0 in) for cabling

Clearance-top/bottom No restrictions

Number of slots 12 VMEbus slots

Power requirements 100–120 V AC at 12 A between 50–60

Hz

220–240 V AC at 6 A between 50–60

Hz

LED Classification Class 1

Environmental For indoor use only

Temperature 5ºC–40ºC (41ºF–104ºF) ambient

Relative humidity 0%–85%,relative, noncondensing

Maximum altitude 2000 m (6562 ft)

Insulation over Category II

voltage

Pollution degree 2

Models FlexTest® IIm/GT/SE Controller Hardware Introduction 35

Specifications

36 Introduction Models FlexTest® IIm/GT/SE Controller Hardware

Chapter 2
Installation
This chapter describes how to install the Controller chassis and connect it to
system components.

Contents Installing the Model 493.10 Chassis (FTGT) 37

Installing the 493.02 Chassis (FlexTest SE) 49
Installing 497/498 Electronics (FTIIm) 61

Installing the Model 493.10 Chassis (FTGT)

The chassis can be installed in an equipment rack console or in a standalone
configuration.

CAUTION

The Model 493.10 Chassis weighs about 45 kg (100 lb) in stand-alone

configuration.

Improper lifting techniques can cause strained muscles and back injuries.

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

Models FlexTest® IIm/GT/SE Controller Hardware Installation 37

Connecting Electrical Power

Stand-alone The stand-alone chassis can be placed on the floor. The chassis location is limited
installation only by the length of the system cables. The front panel of the chassis can be
removed to access the VMEbus plug-in modules.

Console installation The rack-mounted chassis can be installed in any Model 490.8x console. Install
the console with the 493.10 Rack Mounting kit (056-139-502 for FlexTest GT).
The Rack Mounting kit provides the hardware (L-shaped brackets) to support the
chassis and mounting screws to secure the chassis to the console rack.

Connecting Electrical Power

Electrical connections must be made by qualified personnel and conform to local
codes and regulations. An electrical service panel to provide the electrical power
feed (line voltage) to the chassis is not necessary, but may be required by local
electrical codes.

38 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Connecting Electrical Power

Note Local electrical codes supersede any information found here.

Grounding The chassis will not function correctly if it is not grounded as shown. Be sure
your power source is also properly grounded. The chassis includes two grounds:
a chassis ground and a signal ground. The two grounding lugs are connected
together with an external shorting bar when the chassis is manufactured.

Signal
Ground

Chassis
Ground

• For the console configuration, remove the shorting bar from the ground lugs
and connect the chassis ground to the console rail.

• For a stand-alone configuration, always connect the shorting wire to both

ground lugs.

Stand-alone Console
Configuration Configuration

Chassis ground cable

(PN 037-766-102)
System ground cable
connected to the vertical
(PN 039-709-2xx)
conductive rail.
connected to other
components.
Signal common cable
(PN 037-766-101)
connected to the power
panel.
Chassis
System ground cable
ground is connected
(PN 005-402-3xx) connected
through the power cord
to the load frame or other
connector.
components.

AC grounding The AC power ground is through the power cord. The power cord must be
plugged into both the chassis and the power source for proper grounding.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 39

Connecting Electrical Power

CAUTION

Proper grounding is required for safe operation.

It is also required to meet EMC emission and susceptibility requirements.

Power All equipment related to the chassis should be connected on the same fused
power circuit.

The power supply can accept single-phase voltages within 90–264 V AC at

frequencies between 47–63 Hz.

• The maximum continuous power usage is approximately 1000 W. The

current draw depends on the local voltage supply. A 15 amp line should be
adequate for the chassis and the computer.

• The power supply automatically selects the proper voltage range and line
frequency.

• 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.

• An outlet strip is supplied with the floor-standing chassis.

• The computer components may be plugged directly into the outlet strip of a
vertical console or a floor-standing console.

AC power disconnect Turn off the AC power switch. Remove the AC power cord from the unit. This
will remove all AC power from the Model 493.10 Chassis.

40 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Connecting Electrical Power

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

disconnect the power cord from the chassis.

Outlet Strip

vertical outlet strip

or
l Power Over
OK Temp
J39 Power Monitor

Power

Line
l

Voltage
Outlet Strip Outlet Strip
Power

Power Over
OK

(printer, etc) w/ circuit breaker

Temp
J39 Power Monitor

Outlet Strip
Power Panel Line
Voltage

Models FlexTest® IIm/GT/SE Controller Hardware Installation 41

Installing the Plug-in Modules

Installing the Plug-in Modules

This section describes how to install the plug-in modules into the chassis. The
modules plug into a backplane connector and are secured to the chassis with a
screw at the top and at the bottom of the module faceplate.

A hardware interface file (.hwi file extension) defines each type of module and
maps each module location for the system software. The .hwi file and the
physical locations for each type of module must match. Recommended standard
module locations are described in the following sections. For more information
on the .hwi file, see the Hwi File Editor manual.

CAUTION

The plug-in modules contain static-sensitive components.

Improper handling of the module can cause component damage.

Be sure to follow these precautions when handling modules:

• Turn off electrical power before installing or removing a module.

• Use a static ground strap to ground yourself to the chassis ground

before touching the chassis or a module.

• Keep unused modules in conductive bags. Also be sure you are

grounded when removing a module from a conductive bag.

• Handle modules with their front panel or circuit card edges. Do not
touch any circuit card components, pins, or circuit connection points.

42 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 VMEbus Modules

VMEbus Modules
The VMEbus compatible modules should be installed in the front panel chassis
slots according to the following guidelines.

• The processor module(s) must be located in the first (and second) slots.

• The GRESIII module (if used) should be located in slot 10. It may also be
located in slot 2 if a second processor is not used.

• I/O carrier modules and/or ADDA II modules can be installed in slots 3 to

10. Install a module in slot 3 and any additional modules to the right of it.

Placement of 498.98-2 498.98-2 493.40 493.40 493.40 493.40 493.40 493.40 493.40 498.71B

VMEbus modules in Power PC Power PC I/O Carrier

J3 Service
I/O Carrier

J3 Service
I/O Carrier

J3 Service
I/O Carrier

J3 Service
I/O Carrier

J3 Service
I/O Carrier

J3 Service
I/O Carrier

J3 Service
GRES III

+12V

the front panel CLOCK OUT

chassis Shunt Cal Shunt Cal Shunt Cal Shunt Cal Shunt Cal Shunt Cal Shunt Cal EVENT OUT
BFL BFL
ABT ABT

CPU CPU
RST RST EVENT IN
PMC PMC
J4 I/O J4 I/O J4 I/O J4 I/O J4 I/O J4 I/O J4 I/O

J3 IN

J4 OUT

J5 I/O J5 I/O J5 I/O J5 I/O J5 I/O J5 I/O J5 I/O

J5 DEBUG

J6 STATION

J6 I/O J6 I/O J6 I/O J6 I/O J6 I/O J6 I/O J6 I/O

J7 SERIAL

J7 I/O J7 I/O J7 I/O J7 I/O J7 I/O J7 I/O J7 I/O

m m m m m m m m m m

1 2 3 4 5 6 7 8 9 10

Models FlexTest® IIm/GT/SE Controller Hardware Installation 43

VMEbus Modules

Setting I/O Carrier Use the dipswitch (S1) and rotary dipswitch (S2) on each I/O Carrier module to
addresses set its address in accord with its installed chassis slot as follows:

SLOT 1 2 3 4 5 6 7 8 9 10

ADDRESS PPC C20 C22 C24 C26 C28 C2A C2C C2E

Setting I/O Carrier The dipswitch settings for address C20 is shown below. Increment the rotary
module addresses dipswitch as required to complete I/O Carrier module addressing.

C 2 0
F 1
ON 1 2 3 4 5 6 7 8 E 2
C 3
A 4
9 5
8 7 6

S1 S2

Setting GRES III The dipswitch settings for address C08 is shown below. Increment the rotary
module addresses dipswitch as required to complete GRES III module addressing.

F 0 1 F 0 1 F 0 1
E 2 E 2 E 2
C 3 C 3 C 3
A 4 A 4 A 4
9 5 9 5 9 5
8 7 6 8 7 6 8 7 6

S3 S2 S1

Setting ADDA II Use the onboard rotary dipswitches (S3, S2) and front panel rotary dipswitch on
addresses each ADDA II module to set its address in accord with its installed chassis slot as
follows:

SLOT 1 2 3 4 5 6 7 8 9 10

ADDRESS PPC PPC C40 C41 C42 C43 C44 C4A C4C

44 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 VMEbus Modules

The rotary dipswitch settings for address C40 are shown below. Increment the
front panel dipswitch as required to complete ADDA II module addressing.

F 0 1 F 0 1 F 0 1
E 2 E 2 E 2
C 3 C 3 C 3
A 4 A 4 A 4
9 5 9 5 9 5
8 7 6 8 7 6 8 7 6

S3 S2 On ADDA II
Front Panel

Front Panel VMEbus Modules

MODEL MODULE NAME FUNCTION
493.40 I/O Carrier Supports up to four mezzanine cards.

493.43 Multi-Box I/O The optional module allows multiple controllers to share a
master hardware synchronization clock and pass station
interlock state information between each other.

493.50 ADDA II This optional module supports up to four 8-channel A/D

(Model 493.55) or D/A (Model 493.56) mezzanine cards. This
module also supports the 8-channel DSPAD, 8-channel
Delta-Sigma A/D, and 4-channel Universal Encoder
mezzanine cards.

498.96-X Processor Provides an interface between the controller and an external

computer. The processor module also manages the plug-in
modules and transition panels.

498.71B GRES III Interfaces with a Remote Station Control (RSC) module and
temperature controllers.

I/O Carrier Mezzanine Cards (part 1 of 2)

MODEL MODULE NAME FUNCTION
493.14 Valve Driver Produces the control signal for a Series 252 Servovalve.

493.15 3–Stage Valve Driver Produces the control signal for a Series 256 or 257
Servovalve.

493.21B Universal Conditioner Processes the signals from either an AC or DC-type sensors.

493.25 Universal Conditioner Processes the signals from either an AC or DC-type sensors.

493.45 A/D Converts up to six external analog signals to digital signals for
use by the controller.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 45

VMEbus Modules

I/O Carrier Mezzanine Cards (part 2 of 2)

MODEL MODULE NAME FUNCTION
493.46 D/A Converts up to six internal digital signals to analog signals for
use by external devices.

493.47 Encoder Processes the signals from an encoder or a Temposonics III

transducer with an SSI interface.

493.48 Acceleration Conditioner Processes the signals from an accelerometer. Each

Acceleration Conditioner mezzanine card can support up to
three accelerometers. Before installing this board, specific
jumpers must be set on the I/O Carrier module. See “I/O
Carrier jumper settings” on page 119 for more information on
jumper settings.

ADDA II Mezzanine Cards

MODEL MODULE NAME FUNCTION
493.55 A/D Converts up to eight external analog signals to digital signals
for use by the controller. This board requires the optional
ADDA II module.

493.56 D/A Converts up to eight internal digital signals to analog signals

for use by external devices. This board requires the optional
ADDA II module.

493.57 DSPAD Converts up to eight external analog signals to digital signals

for use by the controller. A DSP chip provides digital filtering.

This board requires the optional ADDA II module.

493.59 Universal Encoder Processes the signals from incremental, absolute, and
Temposonics III encoders. This board requires the optional
ADDA II module.

46 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Installing the Transition Panels

Installing the Transition Panels

The transition panels need to be installed in specific slots of the rear panel
chassis. This is done to allow proper air flow in the chassis. For consistency,
install the modules according to the following guidelines.

Starting from the left chassis slot (slot 10) and working to the right, install the
modules as shown. If you do not have one of the modules, install the next one
you do have. Install multiple modules of the same model number next to each
other.

Placement of 10 9 8 7 6 5 4 3 2 1 B A

transition panels 493.71 493.73 493.74 493.74 493.72 493.78 493.77 493.76 493.75

in the rear panel

Serial HPU HSM HSM Digital I/O Accel. Filtered In Analog Out Analog In
Interface Transition

J50A +12V

chassis SERVICE J43A Intlk J43B J43A Intlk J43B

Ch 1A In Ch 1 Ch 1 Ch 1

J23
E-STOP OUT
Ch 2A In Ch 2 Ch 2 Ch 2

J3 IN

J50B
J44A Run/Stop J44B J44A Run/Stop J44B Ch 3A In Ch 3 Ch 3 Ch 3

J24
E-STOP IN Ch 1B In Ch 4 Ch 4 Ch 4

J50C Ch 5 Ch 5 Ch 5
J49A Aux Pwr J49B J49A Aux Pwr J49B

Ch 2B In
Ch 6 Ch 6 Ch 6

J25 HPS

J50D J29A Load Unit J29B J29A Load Unit J29B

Ch 3B In

J4 OUT

J7 SERIAL
J54 J11 J11 J11
SYS I/O (Ch 1-4) (Ch 1-4) (Ch 1-4)
J28A HSM J28A HSM

J11 B Out

J12 J12 J12

J12 B Out (Ch 5-6) (Ch 5-6) (Ch 5-6)
J28B HSM J28B HSM

m m m m m m m m m

Models FlexTest® IIm/GT/SE Controller Hardware Installation 47

Installing the Transition Panels

Note Other transition modules may be used, contact MTS Systems

Corporation for additional information.

Rear Panel Transition Panels

MODEL MODULE NAME FUNCTION
493.71 RS485 Provides four channels of RS-485 interface, four channels of
station stop interlocks, and four channels of emergency stop
interlocks. The RS-485 interface channels are used for the
Remote Station Controller and/or temperature controller.

493.72 Digital I/O Contains sixteen general purpose digital input channels and
sixteen general purpose digital output channels.

493.73 HPU Transition Board Interfaces the controller with a hydraulic power unit.

493.74 HSM Transition Board Interfaces the controller with a hydraulic service manifold and
other devices, up to two stations.

493.75 Analog In BNC Provides six BNC channels for analog input signals. The
input signals must be within ±10 V DC.

493.76 Analog Out BNC Provides six BNC channels for analog output signals. The
output signals are within ±10 V DC.

493.77 Filtered Analog Input Provides filtering for the Model 493.45 A/D (analog-to-digital)
modules.

493.78 Accelerometer Transition Interfaces with up to three low impedance voltage mode
Board (LIVM) accelerometers and three signal conditioned type
accelerometers.

493.79 Multiple Universal Driver Provides up to six drivers that can be used to drive standard
Board 252 servovalves. Inputs to this board can originate from
either a ADDA II board (6 outputs) or a Model 493.46
D/A board (6 outputs).

493.80 Encoder Transition Interfaces with up to four encoders.

493.81 Analog In BNC Provides up to eight channels of analog input to each Model
493.55 A/D module. The input signals must be within ±10 V
DC.

493.82 Analog Out BNC Provides eight channels of analog output from the Model
493.56 D/A modules. The output signals are within ±10 V DC.

493.83 Filtered Analog Input Provides up to eight channels of filtered analog input to each
Model 493.55 A/D module.

48 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Installing the Plug-in Modules

Installing the 493.02 Chassis (FlexTest SE)

This section describes how to install the MTS FlexTest 493.02 chassis and
connect it to your system components.

Contents Installing the Plug-in Modules 42

VMEbus Modules 50
Chassis Installation Options 51
Connecting Electrical Power 53
Installing the Handle Kit 58

Installing the Plug-in Modules

This section describes how to install the plug-in modules into the chassis. The
modules plug into a backplane connector and are secured to the chassis with a
screw at the top and bottom of the faceplate.

CAUTION

The plug-in modules contain static-sensitive components.

Improper handling of the module can cause component damage.

Be sure to follow these precautions when handling modules:

• Turn off electrical power before installing or removing a module.

• Use a static ground strap to ground yourself to the chassis ground

before touching the chassis or a module.

• Keep unused modules in conductive bags. Also be sure you are

grounded when removing a module from a conductive bag.

• Handle modules with their front panel or circuit card edges. Do not
touch any circuit card components, pins, or circuit connection points.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 49

VMEbus Modules

VMEbus Modules
The VMEbus compatible modules should be installed in chassis slots according
to the following guidelines.

• The processor module is installed in slot 1

• The I/O carrier module is installed in slot 2.

• The System I/O module is installed in slots 4 and 5.

Placement of 5
VMEbus modules
in the chassis 4

RUN 6TS BFL

1 ABT RST

TYPE E PC-MIP DEBUG

TYPE E PC-MIP PCI MEZZANNE CARD

VMEbus Modules
SLOT MODULE NAME FUNCTION
Slot 1 Processor Provides PIDF processing for the Controller and
management of the other plug-in modules in the standalone
configuration. Provides an interface between the Controller
and an external computer in the automated configuration.

Slot 2 Model 493. 40 I/O Carrier Supports up to four mezzanine cards that can be used for
sensor conditioning, driving a servovalve, and in the
automated configuration, providing A/D and/or D/A channels.

Slot 3 Blank in standard Additional carrier chassis that can house up to four
configurations. mezzanine cards for expanded sensor conditioning and A/D
and D/A channels
May be used for additional
Model 493.40 I/O Carrier Note This is not a standard option. It is available only for
(factory installed option for automated systems and must be configured at the
automated systems) factory. For more information, contact MTS.

Slots 4, 5 Model 493.42 System I/O Provides box-in and box-out connections for daisy chaining
multiple Controllers, analog and digital I/O, E-Stop, and HSM
and HPU control.

50 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Chassis Installation Options

Model 493.40 I/O Carrier Mezzanine Cards

MODEL MODULE NAME FUNCTION
493.14 Valve Driver Produces the control signal for a Series 252 Servovalve.

493.15 3–Stage Valve Driver Produces the control signal for a Series 256 or 257
Servovalve.

493.25 Universal Conditioner Processes the signals from either an AC or DC-type sensors.

493.45 A/D Converts up to six external analog signals to digital signals for
use by the controller.

493.46 D/A Converts up to six internal digital signals to analog signals for
use by external devices.

493.47 Encoder Processes the signals from an encoder or a Temposonics III

transducer with an SSI interface.

Chassis Installation Options

The chassis can be fitted with the optional handle kit for table-top use in the
stand-alone configuration (shown below), and for the automated configuration it
can be installed without the handle-kit in a standard MTS equipment rack.

Note For information about installing the optional handle kit, see page 58.

FlexTest SE
7
FlexTest SE 8 9
A FG Rewind Run Hold Stop

FlexTest SE B

47 58 69
A Setup
FG Rewind Run Hold Stop

Recall
Controller B

Recall
Status
Setup

Scope
Status 1
4 25 36
Hydraulic
Interlock
Program
Program

with optional Enabled

Enabled
Meters
Scope 1
+/- 02 .3
Hydraulic
Program
Interlock
Interlock
reset
reset
Tuning Program

handle kit
Meters

Emergency Stop Config

Tuning
+/- 0
enter
. Off
Interlock
Low High

HPU
Off Low High
Emergency Stop Limits
Config
enter HPU
Log
cancel Off Low High
Limits
HSM
Monitor 1 Monitor 2
Navigate ? Menu
Log
cancel Off Low High
PowerHSM
Monitor 1 Monitor 2
Navigate ? Menu
Power

TS-G436

TS-G436

Models FlexTest® IIm/GT/SE Controller Hardware Installation 51

Chassis Installation Options

Rack mounting When installing the chassis in an equipment rack allow a minimum of 2 in. (5.1
requirements cm) on either side of the controller for air flow. There are no spacing
requirements for the top or bottom of the controller. If the equipment rack is
equipped with doors, allow adequate clearance for the front and rear of the
controller. The rear of the controller requires a minimum clearance of 6 in. (15.24
cm) to accommodate cables.

The chassis can be installed in any Model 490.8x console. Install the console
with the Model 493.02 Chassis Rack Mounting Kit (PN 100-063-209).

The rack mounting kit provides the hardware (L-shaped brackets) to support the
chassis and mounting screws to secure the chassis to the console rack.

Rack Mount Option

The Controller chassis is
designed to fit into a standard
electronics rack.

52 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Connecting Electrical Power

Connecting Electrical Power

Electrical connections must be made by qualified personnel and conform to local
codes and regulations. An electrical service panel to provide the electrical power
feed (line voltage) to the chassis is not necessary, but may be required by local
electrical codes.

Note Local electrical codes supersede any information found here.

Grounding The chassis will not function correctly if it is not grounded as shown. Be sure
your power source is also properly grounded. The chassis includes two grounds:
a chassis ground and a signal ground. The two grounding lugs are connected
together with an external shorting bar when the chassis is manufactured.

Signal Chassis
Ground Ground

• For the console configuration, remove the shorting bar from the ground lugs
and connect the chassis ground to the console rail.

• For a stand-alone configuration, always connect the shorting bar to both

ground lugs.

Grounding the
chassis Power

100–240 VAC
50–60 Hz, 12–6A
RUN 6TS BF L

ABT RST

T YP E E PC-MIP DEBUG
T YPE E PC-MIP PCI MEZZANNE CARD

TS-G435

System ground cable

(PN 037-766-102)
connected to other
components.

Chassis ground is
connected through the
power cord connector.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 53

Connecting Electrical Power

Rack Mount Configuration

Chassis ground cable

(PN 037-766-102) connected
to the vertical conductive rail.

Signal common cable

(PN 037-766-101) connected
to the power panel.

System ground cable

(PN 005-402-3xx) connected to
the test frame or other
components.

The AC power ground is through the power cord. The power cord must be
plugged into both the chassis and the power source for proper grounding.

CAUTION

Proper grounding is required for safe operation.

It is also required to meet EMC emission and susceptibility requirements.

54 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Connecting Electrical Power

Power All equipment related to the chassis should be connected on the same fused
power circuit.

• The power supply can accept single-phase voltages within 90–264 V AC at

frequencies between 47–63 Hz.

• The maximum continuous power usage is approximately 300 W. The

current draw depends on the local voltage supply. A 15 amp line will be
adequate for the chassis and the computer.

• The power supply automatically selects the proper voltage range and line
frequency.

• The power supply is protected with an external circuit breaker in the On/Off
switch that trips at a 5 amp overload. An internal fuse in the power supply is
not user accessible or repairable.

AC power disconnect Turn off the AC power switch. Remove the AC power cord from the unit. This
will remove all AC power from the Model 493.02 Chassis.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 55

Connecting Electrical Power

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

disconnect the power cord from the chassis.

Stand-Alone Configuration

Power

100–240 VAC
50–60 Hz, 12–6A
RU N 6TS BFL

ABT RST

TYPE E PC- MIP DEBUG

TYPE E PC-MIP P CI MEZZANNE CARD

Line
Voltage
Outlet Strip
w/ circuit breaker
Automated Configuration

Power

100–240 VAC
50–60 Hz, 1 2–6A
RUN 6TS BFL

ABT RST

TYPE E PC-MIP DEBUG

TYPE E PC-MIP PCI MEZZANNE CARD

Line
Voltage
Outlet Strip Outlet Strip
(printer, etc) w/ circuit breaker

56 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Connecting Electrical Power

Rack Mounted Configuration

Outlet Strip

or

Power

100–240 VAC
50–60 Hz, 12–6A
R UN 6TS BFL

ABT RST
TYP E EP C-M IP DEBUG
TYPE E PC-M IP PC I M E ZZ AN NE C ARD

Power Panel

Models FlexTest® IIm/GT/SE Controller Hardware Installation 57

Installing the Handle Kit

Installing the Handle Kit

The controller may be equipped with an optional handle kit.

The following procedure provides assembly and installation instructions for the
handle kit (MTS PN 100-061-494). The following table and figure show the
handle kit assembly components described in the procedure.

Handle Kit Parts

ITEM DESCRIPTION QUANTITY
1 Support arm 2

2 Handle side leg 2

3 Clip 2

4 Washer 4

5 Screw 2

6 Spring 2

7 Button 2

8 Ratchet 2

9 Ratchet housing 2

10 Lock washer 2

11 Handle screw 2

12 Handle 1

13 Cover 2

58 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Installing the Handle Kit

1
2

4 3

5
12 (handle-not shown)

10
11
13

Handle Kit

1. Place one support arm (1) into one handle side leg (2), as shown in the
handle kit assembly figure.

2. Set one of the clips (3) in place over the slender, straight portion of the
support arm (1), just behind the circular end of the support arm.

3. Insert two washers (4) and a screw (5) through the mounting hole in the
handle side leg (2).

4. Insert a spring (6) and a button (7) into the handle side leg mounting hole,
over the screw (5) and washers (4).

5. Press the button (7) into the handle side leg, as far as you can and push a
ratchet (8) over the button (7) leg detentes, until it snaps into place over the
first set of detentes. Make certain the burred or sharper edges of the ratchet
are pointing toward the handle side leg.

6. Hold a ratchet housing (9) in place over the ratchet (8) and press the posts on
the back side of the ratchet housing (9) into the mounting holes on the side
panel of the controller.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 59

Installing the Handle Kit

7. Insert a Phillips screwdriver through the hole in the button (7) and lightly
tighten the screw (5).

8. Assemble the remaining handle kit components to the other handle side leg
(2) according to steps 1 through 7 and mount the side leg to the mounting
holes on the opposite side of the controller.

9. Insert a lock washer (10) and handle screw (11) through the mounting hole
at the end of one handle side leg (2) and lightly tighten to handle (12).
Repeat this step for the other handle side leg, then secure both screws (11).
(The mounting screw for the first handle side leg may have to be loosened
slightly to allow the second handle side leg to be mounted.)

10. Snap cover (13) in place over the handle screw (11) and lock washer (10).

11. Secure mounting screws (5) on each side of the controller.

12. Press in both buttons (7) and rotate the handle assembly. The assembly
should rotate up and down easily. When the buttons (7) are released, the
handle should lock into a detente position and remain there. If the handle
does not move easily, or if it does not lock into a detente position, an error
may have been made during the assembly. Take a small straight blade screw
driver and carefully remove the covers (13), loosen all screws and remove
the handle assembly from the controller. Reassemble the handle side leg
assemblies according to steps 1 through 7.

60 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Connecting the Console and Chassis Power

Installing 497/498 Electronics (FTIIm)

Contents Connecting the Console and Chassis Power 61
Grounding the Console and Chassis 62
Model 497.01 Analog Chassis 63
About Analog Chassis Slots 63
Analog Chassis Plug-in Modules 64
Analog Chassis Transition Modules 66
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

Connecting the Console and Chassis Power

Each chassis installed in your console can be configured for 115 or 230 V AC
service. To configure each chassis for 230 V AC service, refer to the following
product manuals.

• Model 497.05 Hydraulic Control Panel (100-036-577)

• Model 497.01 Analog Chassis (100-036-577)

• Model 498.22/498.23 Test Processor (100-036-578)—for FlexTest IIm

How To Connect the Chassis Power Cables

You can plug the hydraulic control panel and the test processor chassis into the
AC power strip inside the console.

The analog chassis requires an external power supply. Typically, it is connected

to the hydraulic control panel. If you have more than one analog chassis, you
must plug each additional analog chassis into a remote power supply.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 61

How To Cable the Analog Chassis to the Hydraulic

How To Cable the Analog Chassis to the Hydraulic Control Panel

Connect J50 DC Pwr on the 497.01 Analog Chassis rear panel to J50 on the
497.05 Hydraulic Control Panel rear panel.

497.05 Hydraulic Control Panel

PN 046-239-1xx
J1

497.01 Analog Chassis

J50

Grounding the Console and Chassis

The system will not function correctly if it is not grounded properly.

The power ground and chassis ground terminals are wired together when the
chassis is manufactured.

Remove the jumper between the two grounds and connect each terminal as
follows:

• Each chassis ground should be connected to the console with a short ground
cable (PN 037-766-102).

• Each power ground should be connected at a common location on the power

panel (PN 037-766-1xx).

• The power panel ground should be connected to the console (PN 037-766-
101).

The system ground cable connects the console to other system components (PN
005-402-3xx).

62 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Model 497.01 Analog Chassis

Model 497.01 Analog Chassis

About Analog Chassis Slots

Slot pairing Chassis slot assignments are grouped in pairs. If you have a conditioner in a slot,
then you cannot have a valve driver installed in the slot paired with it. Slots are
paired as follows:

Slots 1–2 Slots 9–10

Slots 3–4 Slots 11–12
Slots 5–6 Slots 13–14
Slots 7–8 Slots 15–16

Slot assignments The analog chassis contains 18 bus-board slots for plug-in modules. Each slot is
reserved for a particular type of plug-in module.

Slot A Reserved for the Model 497.34 Multistation Interlock Module.

Slot B Reserved for the Model 497.36 Communications Module.

Slots 1–4 These slots are reserved for up to four AC conditioners.

Slots 5–8 These slots are reserved for up to four DC conditioners.

Slots 9–12 These slots are reserved for options (not used with standard systems).

Slots 13–16 These slots are reserved for up to four valve drivers.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 63

Analog Chassis Plug-in Modules

Analog Chassis Plug-in Modules

Before you install any plug-in modules, be sure they are configured properly for
your system. The following is a brief description of the plug-in modules available
for the chassis.

Plug-in Modules
MODEL # PLUG-IN MODULE NAME FUNCTION

497.13* AC Conditioner Processes signals from AC-type sensors such as LVDTs or

RVDTs.
Note This module was designed to replace the Model
497.14 AC Conditioner.

497.15 Three-Stage Valve Driver Produces the control signal and inner control loop for a Series
256 Servovalve or Series 257 Servovalve.
497.22* Dual DC Conditioner Processes the signals from two DC-type sensors such as a
force transducer or extensometer.
497.26 Two-Stage Valve Driver Produces the control signal for one Series 252 Servovalve.
The second valve driver is not used in standard systems.
497.34 Multistation Interlock Monitors the plug-in modules for interlocks. This is a part of
Controller the interlock chain between Model 497.05 Chassis and any
other 497.01 chassis.
497.36 Communication Module Provides communications between the Model 497.01 Analog
Chassis and the Model 498.22 Test Processor.

* This conditioner is normalized and can be swapped (with a conditioner of the same model number)
without recalibrating the sensor/conditioner pair. Normalized conditioners contain an EEPROM in
which normalization values are stored during manufacturing. These values compensate for
variations in conditioner components.

64 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 How to Install or Remove a Plug-in Module

How to Install or Remove a Plug-in Module

CAUTION

Plug-in modules are static sensitive.

Do not install or remove a module with electrical power on. Do not place modules
that contain battery backup on a metal surface. Touch the console or other ground
point before handling a module. Avoid making physical contact with any circuitry
on the modules. Maintain the same potential between the module circuitry and the
equipment or surfaces it contacts by touching the surfaces first or wearing a wrist
strap connected to chassis ground.

To install a module in the chassis:

1. Fully retract the two screws near the handles.

2. Insert the module assembly, and gently slide the module in until it connects
with the backplane.

3. Ensure that the circuit card is seated in the backplane connectors and tighten
the two screws.

To remove a module from the chassis:

1. Loosen the two screws near the module handles.

2. Tug gently on the module to unseat it from the backplane connectors.

3. Slide the module straight out of the chassis.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 65

Analog Chassis Transition Modules

Analog Chassis Transition Modules

Transition modules located on the Model 497.01Rear Panel provide signal
transfer between the Model 497 modules and external devices. One digital
transition module and up to eight analog transition modules can be installed in
this chassis. Each transition module plugs into the backplane connectors and
connects to two chassis slot locations.

Chassis Slot Number

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 A B
J38 J28 J37 J27 J36 J26 J35 J25 J34 J24 J33 J23 J32 J22 J31 J21 J41 J42
Aux I/O Aux I/O Aux I/O Aux I/O Aux I/O Aux I/O Aux I/O Aux I/O Com In Com Out

System J43 J51 J50

J1601 J1501 J1401 J1301 J1201 J1101 J1001 J901 J801 J701 J601 J501 J401 J301 J201 J101 XPTR In Intlk In DC Pwr

J44 J52
J1602 J1502 J1402 J1302 J1202 J1102 J1002 J902 J802 J702 J602 J502 J402 J302 J202 J102 XPTROut IntlkOut

Analog Transition Modules Digital Transition

Modules
Transition modules in the rear panel chassis

How To Install a Transition Module

1. To install a transition module, remove the appropriate panel cover from the
analog chassis.

2. Plug the transition modules into the backplane connectors. Refer the
following table for transition module slot assignments.

Slot Assignment
MODULE TYPE SLOT ASSIGNMENT
Analog Transition 1–2, 3–4, 5–6, 7–8, 9–10, 11–12, 13–14, 15-16
Digital Transition A–B

3. Replace the panel cover and fasten the screw locks on all D connectors.

66 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Transition Module Connectors

Transition Module Connectors

Cable connections to external devices are made from the 497.01 chassis rear
panel connectors.

J101–J1601 System connectors J101 through J1601 (JX01) are 15-pin D-type connectors
located on the chassis rear panel. They connect either a valve driver to a
servovalve or a conditioner to a transducer. The cable that is plugged into these
connectors depends on whether a valve driver or a conditioner is installed in the
corresponding chassis slot location.

J102–J1602 Connectors J102 through J1602 (JX02) provide a second connection for dual
conditioners, dual valve drivers, or three-stage valve drivers. Each module has
four rear panel connectors associated with it (Jx01, Jx02, J2x, and J3x).

J21–J28 Rear panel I/O connectors J21 through J28 (J2X) are 15-pin D-type connectors
located on the chassis rear panel. They are used to connect either a valve driver to
D/A converters (command) or a conditioner to A/D converters (feedback).

J31–J38 Rear panel Aux connectors J31 through J38 provide the same signals as J21
through J28 and are used to connect external readout devices.

J41 and J42 Rear panel communication connectors J41 Com In and J42 Com Out are
associated with the communication module installed in slot B. This connector
allows serial communication with a host computer.

Single chassis If you have a single analog chassis, install a cable (PN 056-027-101) from a
configuration Series 498 host computer serial port (debug) to J41 Com In on the Model 407.05
Hydraulic Control Panel, then from J42 Com Out to J41 Com In on the Model
497.01 Analog Chassis.

Multichassis If you have a multiple analog chassis:

configuration
1. Install a cable from a Series 498 host computer serial port (debug) to J41
Com In on the Model 497.05 Hydraulic Control Panel, then from J42 Com
Out to J41 Com In on the first Model 497.01 Analog Chassis.

2. Install a chassis interconnect cable (PN 046-350-902) from J42 Com Out of
the first Model 497.01 Analog Chassis to J41 Com In of the next analog
chassis. Install as many cables as needed to connect all the chassis.

J43 and J44 These connectors are not used.

J51 and J52 Rear panel interlock connectors J51 Intlk In and J52 Intlk Out are associated
with the interlock controller module installed in slot A. Each connector handles
up to four test stations.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 67

Transition Module Connectors

Single chassis If you have a single analog chassis:

configuration
First install a cable from a Series 498 host computer serial port (debug) to J51
Intlk In on the Model 497.05 Hydraulic Control Panel, then from J52 Intlk Out
to J51 Intlk In on the Model 497.01 Analog Chassis. Then install jumper plug
assembly (PN 046-350-701) to J52 Intlk Out on the analog chassis.

Multichassis If you have a multiple analog chassis:

configuration
1. Install the cable from the chassis to J51 Intlk In on the Model 497.05
Hydraulic Control Panel, then from J52 Intlk Out to J51 Intlk In on the
first Model 497.01 Analog Chassis (see “Interlock Connections” on page
192).

2. Install a chassis interconnect cable from J52 Intlk Out of the first analog
chassis to J51 Intlk In of the next chassis. Install as many cables as needed
to connect all the chassis.

3. On the last chassis, install jumper plug assembly (PN 046-350-701) to J52
Intlk Out.

68 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Adding an Analog Chassis to Your Console

Adding an Analog Chassis to Your Console

To accommodate higher channel counts, it may be necessary to add one or more
Model 497.01 Analog Chassis’ to your FlexTest IIm console.

Depending on the number of analog chassis installed, you may have to modify
switch settings and jumpers on the communication boards in your 497.05
Hydraulic Control Panel and in the 497.01 Analog Chassis.

The analog chassis and the hydraulic control panel use identical communication
boards. For jumper and switch locations, see “Jumper and switch locations” on
page 70. Configure the jumpers and switches for each chassis according to the
following table.

Communication Modules Switch and Jumper Settings

CHASSIS X1 SWITCH (S3) JUMPERS X1, X2, X3 JUMPER X5*
For a single analog chassis:

497.01 Analog Chassis 1 Set to 1 Remove Install 3 and 4

497.05 Hydraulic Control Set to 2 Install Install 1 and 2

Panel

For multiple analog chassis:

497.01 Analog Chassis 1 Set to 1 Remove Install 3 and 4

497.01 Analog Chassis 2 Set to 2 Remove Install 3 and 4

(optional)

497.01 Analog Chassis 3 Set to 3 Remove Install 3 and 4

(optional)

497.01 Analog Chassis 4 Set to 4 Remove Install 3 and 4

(optional)

497.05 Hydraulic Control Set to 5† Install Install 1 and 2

Panel

* Jumper X5 is used for the RS-232 communications link (between the first chassis and the test
processor) and the RS-422 communications link (between the 497 communications modules in each
chassis).
† The address switch on the hydraulic control panel should be set to the last number in the chassis
chain. For example, if you have a single 497.01 Analog Chassis, you should set the 497.05 Hydraulic
Control Panel address to 2. If you have two analog chassis, you should set it to 3, and so forth.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 69

Adding an Analog Chassis to Your Console

Jumper and switch The following graphic illustrates the jumper locations on the Model 497.36
locations Communication Module.

X1

3 X3 X2
X6
1 X5
4 1
3 2

X4
14 8
X10
S4
1 7
X1 S3 S3

Communication Module Jumper and Switch Locations

70 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Model 497.05 Hydraulic Control Panel

Model 497.05 Hydraulic Control Panel

The rear panel connectors of the hydraulic control panel are cabled to the
hydraulic components of your system. The connectors also interface with the
Model 497.01 Analog Chassis and Model 498.22 Test Processor chassis.

J9 J8 J41 J42 J51 J52

J15D J15C J15B J15A Mstr/Slv Hyd Enab Com In Com Out Intlk In Intlk Out

J16D J16C J16B J16A

I
O
J17D J17C J17B J17A

J28D J28C J28B J28A J25

J26 J1 HPS
Remote E-Stop 497.01 Power

Hydraulic Control Panel

J1 The 497.05 contains the power supply for a Model 497.01 Analog Chassis.
Connect your 497.01 Analog Chassis to J1.

J8 This connector communicates hydraulic status with the Model 498.22 Test
Processor chassis.

J9 This connector is not used in a standard FlexTest IIm system.

J15A–J17D Each HSM channel has a set of three user defined interlock inputs (Interlock 1,
Interlock 2, and Shutdown). These inputs can be configured to monitor contact
closure or to accept logic level inputs.

J25 This connector controls the hydraulic power supply (HPS).

J26 This connector accommodates a remote Emergency Stop switch.

J28A–J28D These connectors control up to four hydraulic service manifolds (HSMs).

J41 and J42 These connectors create a serial communications loop between all of the chassis
in your system.

J51 and J52 These connectors create an interlock communications loop with the other chassis
in your system.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 71

Test Processor Plug-in Modules

Test Processor Plug-in Modules

The following table provides a brief description of the plug-in modules installed
in your test processor chassis.

Test Processor Plug-In Modules

MODULE FUNCTION
Processor Modules Standard FlexTest IIm Controllers have two processors installed in the
Model 498.22 Chassis:
• The first processor (in slot 1) communicates with the external
computer.

• The second processor (in slot 3) performs the digital control

functions.

A third processor will be installed (in slot 3 or 5) to handle time history

data acquisition if you purchased the time history data acquisition
option.
498.71B Global Resources III Provides the digital input and output interface to devices like external
(GRES III) temperature controllers and remote station controllers. It provides four
serial ports and monitors interlocks from the 497 modules.
498.65 ADDA Provides analog-to-digital (A/D) processing and digital-to-analog (D/A)
processing. Each function is performed by a mezzanine card. The
standard ADDA module contains two A/D mezzanine cards and one D/
A mezzanine card. A fourth mezzanine card can be added as an option.
See the ADDA product manual.
493.50 ADDA II This optional module supports up to four 8-channel A/D (Model 493.55)
or D/A (Model 493.56) mezzanine cards. This module also supports the
8-channel DSPAD, and Universal Encoder mezzanine cards.
498.70 Digital I/O Provides the means to monitor external logic levels and contact status,
and to provide logic level outputs for external device control.

72 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Test Processor Plug-in Modules

ADDA II mezzanine cards

MODULE NAME FUNCTION
493.55 A/D Converts up to eight external analog signals to digital signals for use by the
controller. This board requires the optional ADDA II module.
493.56 D/A Converts up to eight internal digital signals to analog signals for use by
external devices. This board requires the optional ADDA II module.
493.57 DSPAD Converts up to eight external analog signals to digital signals for use by the
controller. A DSP chip provides digital filtering.
This board requires the optional ADDA II module.
493.59 Universal Encoder Processes the signals from incremental, absolute, and Temposonics III
encoders. Each type of encoder requires a specific encoder mezzanine
card.
This board requires the optional ADDA II module.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 73

Test Processor Transition Modules

Test Processor Transition Modules

Transition modules are screwed into the back of the test processor chassis. Each
rear-panel transition module corresponds to a plug-in module (or plug-in module
mezzanine card) installed in the front of the chassis.

Transition modules interface with the other test components via connectors for
external digital, analog, and communication cables.

498 498 DIGITAL I/O ACCESS PANEL 498

498 498 DIGITAL I/O
ANALOG INPUT RS-485 SYSTEM DIGITAL IN1-16
Transition DIGITAL I/O TRANSITION
OUT FILTER DIGITAL OUT1-16 MODULE
Module

+12V +5V +5V +12V

CH 1 CH 1 Digital Input Digital Output

+5V +12V
J50A J3A J3B Channels Channels
Sta 1 Sta 2
Intlk Intlk

CH 2 CH 2 1-2 9 - 10 1-2 9 - 10 J3 IN

CH 3 CH 3
J50B

J3C J3D
Sta 3 Sta 4
CH 4 CH 4 Intlk Intlk

3-4 11 - 12 3-4 11 - 12

J50C

CH 5 CH 5

J4 J5
CH 6 CH 6 497 497
Hyd Intlk

J50D

CH 7 CH 7
5-6 13 - 14 5-6 13 - 14 J4 OUT

CH 8 CH 8

J7 J6 J7
I/O I/O
J11 J11
(CH 1-4) (CH 1-4)

7-8 15 - 16 7-8 15 - 16
J12 J12
(CH 5-8) (CH 5-8)

Transition Modules (Model 498.22 Chassis Rear Panel shown)

74 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 Test Processor Transition Modules

Test Processor Transition Modules

TRANSITION MODULE FUNCTION
498 Analog Out This module includes eight BNC connectors that provide
analog outputs from the Model 498.65 ADDA module. These
outputs are associated with a D/A mezzanine card.
Four analog outputs are available with the standard ADDA
module. Additional outputs require a second ADDA module
(or an optional fourth mezzanine card).
498 Input Filter This module includes eight BNC connectors that provide
filtered analog inputs to the Model 498.65 ADDA module.
These inputs are associated with an A/D mezzanine card.
Four-channel systems use a standard ADDA module which
provides four analog inputs. For 8-channel systems, a second
ADDA module (or an optional fourth mezzanine card) is
required to provide the other four inputs.
498 RS-485 Transition Module This module provides serial connections for use with remote
station controllers (RSCs) or Eurotherm temperature
controllers.
498 System Digital I/O The System Digital I/O Transition module is double-width
Transition Module module that provides connection to the system digital I/O and
the station interlocks on the Model 498.71B GRES III module.
498 Digital I/O Transition This transition module provides 16 channels of user-defined
Module digital inputs and outputs. In order to use these digital inputs
and outputs, this module must be connected to a Model 498
Digital I/O Access Panel.
Note On some custom FlexTest IIm Controllers, this module
must be connected to a Model 498 Remote Digital I/O
Access Panel.

493.80 Encoder Transition Interfaces with up to four encoders.

493.81 Analog In BNC Provides up to eight channels of analog input to each Model
493.55 A/D module. The input signals must be within ±10 V
DC.
493.82 Analog Out BNC Provides eight channels of analog output from the Model
493.56 D/A modules. The output signals are within ±10 V DC.
493.83 Filtered Analog Input Provides up to eight channels of filtered analog input to each
Model 493.55 A/D module.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 75

UPS Systems

UPS Systems

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 shut-
down. 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 A UPS with an AC Fail relay contact wired to the controller provides a
considerations 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.

76 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 UPS Systems for FlexTest 40 and FlexTest SE

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.

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 servocontroller and any
peripheral equipment that is instrumental in safe system operation and shut-
down. 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.

• 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 general-
use 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.)

Battery power A UPS with an AC Fail relay contact wired to the controller provides a
considerations 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.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 77

Specifications–UPS Systems Used with MTS

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
ITEM REQUIREMENT
Operating temperature 5–40 deg C

Operating humidity 5–85% non-condensing

Supported UPS output 100–240 V AC nominal, single phase,

voltage range sine-wave output

Input/output frequency 50–60 Hz

range

Output load regulation -/+5% nominal operating voltage (both in

battery and normal operation modes)

Switch-over time to battery 0 s (recommended), < 6 ms (required)

on power loss

UPS power The following UPS power requirements include power for the PC, MTS
requirements Controller (one chassis), and 25% capability for other subsystems.

UPS Power Requirements

CONTROLLER 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

78 Installation Models FlexTest® IIm/GT/SE Controller Hardware

 UPS Connections for the Model 493.73 HPU Board

UPS Connections for the Model 493.73 HPU Board (FT60, FT100, FT200, FTGT)
The following drawing shows UPS connections for the Model 493.73 HPU
board. Once connected, use your controller software to add UPS hardware
resources and configure the various UPS options.

Note Systems that use Series 793 Control Software have Hwi Editor and
station setup settings for UPS systems.

493.73
HPU

SERVICE

UPS 493.73 HPU Board

J23

J54
E-STOP OUT

SYS DI/O

1 +24 V DC
J24

AC Fail
E-STOP IN
Digital Input 1
Contacts 2
Open = Logic 0
3
J54 SYS DI/O
4
J25 HPU

5 +24 V DC
Low Battery Digital Input 2
Contacts 6 J54
SYS D I/O

Open = Logic 0
7

493.73
HPU Board

Cable specification To maintain EMC compliance, J54 SYS DI/O cables must comply with the
following specifications:

Connector–15-contact, type D male EMI connector.

Backshell–metallized plastic or metal.

Cable—26 to 22 AWG, 4-conductor with overall braided shield, with the braided
shield connected to the backshell at the chassis.

Models FlexTest® IIm/GT/SE Controller Hardware Installation 79

UPS Connections for the Model 493.42 System

UPS Connections for the Model 493.42 System board (FlexTest SE )

The following drawing shows UPS connections for the Model 493.42 System
board. Once connected, you must use your controller software to configure the
various UPS options.

UPS 493.42 System Board

J54
Dig In

1 +24 V DC
AC Fail Digital Input 1
Contacts 2
Open = Logic 0
3

5 +24 V DC
Low Battery Digital Input 2
Contacts 6
Open = Logic 0
7

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

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 overall braided shield, with the braided
shield connected to the backshell at the chassis.

80 Installation Models FlexTest® IIm/GT/SE Controller Hardware

Chapter 3
FlexTest GT Controller Connections
This section describes the cable connections to the Model 493.10 Chassis.

Note For information on connecting power cables, see “Connecting Electrical

Power” on page 38.

Contents CE EMC Compliant Cabling 83

Typical Cabling 84
Cable Part Numbers 85
Model 493.40 I/O Carrier Connections 87
Sensor Connections 88
Sensor Cables 100
Shunt Calibration/Bridge Completion Resistor Installation 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

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 81

 Digital I/O Connections 141
Workstation Connection 145
Remote Station Controller Connection 147
Service Connections 149
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
Cabling and Using External Readout Devices 169

82 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 CE EMC Compliant Cabling

CE EMC Compliant Cabling

CE EMC compliant cabling is required for all systems shipped to Europe. All
cabling specifications in this chapter conform to the European CE EMC
requirements.

Cable fabrication All of the cables listed on the Cable Selector drawing are CE EMC compliant
when used in an MTS system. Where possible, use standard cables listed on the
System Cable Plug 493 Package Selection drawing (PN 700-000-656). If it is not
possible to use standard cables or you are constructing custom cables, select
cables, backshells, and connection shields as described in the cable specification
for each connector. See the appropriate rear panel connector for fabrication
information.

Low-frequency ground It is possible that grounding both ends of the overall shield can produce a low
loops frequency ground loop current. If you experience an unacceptable low-frequency
noise level, try the following in the order given:

• Connect the system (chassis) ground of the external device directly to the
controller chassis.

• Disconnect the overall shield from the metallized back shell at the external
device and add a capacitor (approximately 0.01 μf) to one end of the cable
between the shield and the metallized backshell.

• Disconnect the overall shield from the metallized back shell at the external
device.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 83

Typical Cabling

Typical Cabling
For additional cables, see “Cable Part Numbers” on page 85.

r
Hydraulic
Power
Unit
Control

HPU
Workstation 039-713-7xx
051-996-8xx
039-708-3xx Servovalve
056-126-5xx
Load Unit Control

056-126-4xx
Actuator
l
Manifold
(HSM)
Power Over

lMTS Sysrtems Corp OK Temp

J39 Power Monitor
14000 Technologyu Dr.
Eden Prairie, MN 555344-2290 USA
Assy No:
Model: S/N Power

055-634-2xx (E-stop)
or 055-634-3xx (Station Stop

Remote Front Rear

Station
Control Connectors with
Transducer ID modules
Remote Station Control

052-544-2xx 052-543-1xx LVDT

F1 F2 F3 F4 Status

Interlock HSM HPS Test Manual Control

Enable /
Reset High High Run Disable

Emergency Stop

Low Low Hold

Force Sensor
Off Off Stop

052-544-2xx 052-542-5xx

Typical Cabling of a FlexTest System

84 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Cable Part Numbers

Cable Part Numbers

System cables The following is a list of the most common cables, see the System Cable/Jumper
Plug 493 Package Selection drawing (MTS PN 700-000-656) for the most
current and additional cable part numbers.

System Cables (part 1 of 2)

CABLE DESCRIPTION PART MODULE JUMPER PLUG†
NUMBER* CONNECTOR

Servovalve 252.xx single 039-708-300 493.40 J4–J7 N/A

Servovalve 252.xx dual 039-708-400 493.40 J4–J7 N/A

Servovalve 256.xx 3-stage N/A

Valve 055-439- 493.40 J4–J7
Valve LVDT 6XX 493.40 J4–J7
Calibration Cable Package 039-708- 493.40 J3
6XX
Y Adapter—Servovalve/Valve LVDT 100-026-- 493.40 J4–J7 N/A
(required for 256.xx or 257.xx servovalves) 213

039-710-501

Servovalve 257.xx 3-stage N/A

Valve 039-701-
448.16 to 257.XX 9XX 493.40 J4–J7
Valve Velocity 039700-2XX 493.40 J4–J7
Valve LVDT 039700-9XX 493.40 J3
Calibration Cable Package 039708-6XX N/A
100-026-- 493.40 J4–J7
Y Adapter—Servovalve/Valve LVDT 213
(required for 256.xx or 257.xx servovalves)
039-710-501

System ground (console) 005-402- N/A

System ground (floor standing) 3XX gnd lug
039-709-
2XX

E-stop 318 Load Unit with crosshead locks 056-126- 493.74 J29 100-007-947
E-stop 318 Load Unit without /crosshead locks 5XX 493.74 J29 100-007-947
056-126-
6XX

Emergency Stop 493.73 J24 039-713-201

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 85

Cable Part Numbers

System Cables (part 2 of 2)

CABLE DESCRIPTION PART MODULE JUMPER PLUG†
NUMBER* CONNECTOR

HPU 505 or 24V PLC Pump (for more information see 039-713- 493.73 J25 039-713-301
“Hydraulic Configurations” on page 243) 7XX

HSM 298.11 on/off 039-701- 493.74 J28 N/A

HSM Proportional 298.12 5XX
HSM 290.xx/293.xx/294.xx high/low 056-126-
4XX
039-701-
4XX

Interlock—Test Enclosure 056-126- 493.74 J43 100-007-948

3XX

Interlock—Station per system 493.74 J43 100-007-948

Remote Station Control—with E-Stop 055-634- 493.71 J50 055-634-101

2XX

Remote Station Control—with Station Stop 055-634- 493.71 J50 055-634-101

3XX

Workstation Link (Ethernet cable) 051-996- 10/100‡ N/A

8XX

Remote Setpoint Adjust Control 100-051-058 493.40 J4–J7 N/A

* -XX specifies cable length. –01 through –09 represent 10–50 ft. in 5 ft. increments. Higher numbers
represent custom cable lengths.
† Jumper plugs are required if a cable is not installed.
‡ The connector is the 10/100 BaseT connector on the power PC module.

86 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Model 493.40 I/O Carrier Connections

Model 493.40 I/O Carrier Connections

Each Model 493.40 I/O Carrier module can include up to four mezzanine cards.
Each installed mezzanine card is assigned a specific I/O Carrier module front
panel connector (J4–J7 I/O).

A hardware interface file (hwi) defines each type of module (and their associated
mezzanine cards) and maps each module location for the system software. The
.hwi file and the physical locations for each type of module and associated
mezzanine cards must match. Also, the I/O Carrier module address setting (on
the module) must match the .hwi file address. For more information on the .hwi
file, see the MTS 793 Utility Software manual.

• Transducer connections require a conditioner mezzanine card to be installed

in the I/O Carrier module. The following conditioners can be installed:

– Model 493.21B Digital Universal Conditioner

– Model 493.25 Digital Universal Conditioner

– Model 493.47 Encoder

– Model 493.48 Acceleration Conditioner

• Valve connections require a valve driver mezzanine card be installed in the

I/O Carrier module. The following valve drivers can be installed:

– Model 493.14 Valve Driver

– Model 493.15 3-Stage Valve Driver

• Analog I/O connections require an A/D or D/A mezzanine card be installed

in the I/O Carrier module. The following analog mezzanine cards can be
installed:

– Model 493.45 A/D Converter

– Model 493.46 D/A Converter

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 87

Sensor Connections

Sensor Connections
Sensor connections require a conditioner mezzanine card be installed in the I/O
Carrier module. The following conditioners can be installed:

Note Model 493.21B Digital Universal Conditioners are not compatible with
stand-alone FlexTest SE Controllers.

• Model 493.21B Digital Universal Conditioner

• Model 493.21BC Digital Universal Conditioner

• Model 493.25 Digital Universal Conditioner

• Model 493.47 Encoder

• Model 493.48 Acceleration Conditioner

Each Carrier module can include up to four mezzanine cards. Each installed
mezzanine card is assigned a specific I/O Carrier module front panel connector
(J4–J7 I/O). These connections can be used for any type of sensor (provided the
appropriate mezzanine card is installed).

A hardware interface file (.hwi) defines each type of module (and their associated
mezzanine cards) and maps each module location for the system software. The
.hwi file and the physical locations for each type of module and associated
mezzanine cards must match.

88 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Sensor Connections

Excitation and feedback signals are passed through to the transducer, as shown.

To/From
Conditioner J4 - J7

1 + Excitation
2 - Excitation
To/From
3 Guard Transducer
4 + Feedback
5 - Feedback

If purchased as an option, a transducer ID module is located in the transducer

cable. Excitation and feedback signals are passed through to the transducer.

To/From
Conditioner J4 - J7

1 + Excitation
2 - Excitation
To/From
3 Guard Transducer
4 + Feedback
5 - Feedback
6 Signal Common
8 Clock
11 Data to Sensor ID
14 Data from Sensor ID
10 + Excitation Sense To/From
Transducer
9 Remote Calibration ID Module
12 + Feedback Return
13 - Feedback Return
14
15 - Excitation Sense

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 89

Sensor Connections

LVDT connections An LVDT requires an AC conditioning mezzanine card.

E7 Backshell
7
AC Sensor
Inner E3 (LVDT)
Guard 3 3

-FB E5
5 5

Transducer
ID Module

4 E4
+FB 4

2 E2
-EX 2

1 E1
+EX 1

Remote Cal 9 9 Remote Cal

Clk 8 8
Data to ID 11 11
ID Circuit
Data from ID 14 14
Sig Gnd 6 6

Temposonics II The connection requires a DC conditioning mezzanine card.

+EX 1 1 +
-EX 2 2 EXC
-
FROM
3 DC TEMPOSONICS II
RETURN SENSOR
+FDBK 4 4 +
FDBK
-FDBK 5 _
5

REMOTE
CAL 9 9

SIG GND 6 6
CLK 8 8 ID
DATA TO ID 11 11 Circuit
DATA FROM ID 14 14

90 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Sensor Connections

Temposonics III The connection requires a DC conditioning mezzanine card.

TO +24 V
493.74
AUX POWER COM

+24 V

COM

+ +
TO Data Data
493.40 CARRIER MODULE - - FROM
(TEMPOSONICS III TEMPOSONICS III
DAUGHTER BOARD) + SENSOR
+
Clock Clock
- -

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 91

Model 493.21B (DUC B) Jumpers

Force/strain sensor Force and strain sensors require a DC conditioning mezzanine card.
connections

Backshell
GND 7 E7

Inner E3
Guard 3 3

-FB 5 E5
5 DC Sensor
-FBR 13 13 Future
Transducer
ID Module

4 E4
+FB 4
+FBR 12 12 Future
E2
-EX 2 2
-EXS 15 15 Future
+EX E1
1 1
+EXS 10 10 Future

Remote Cal 9 9 Remote Cal

Clk 8 8
Data to ID 11 11
ID Circuit
Data from ID 14 14
Sig Gnd 6 6

Model 493.21B (DUC B) Jumpers

The following jumpers are for the Model 493.21B Digital Universal
Conditioner). The jumpers are labeled W instead of X; the W jumpers are solder
pads. The following jumper descriptions are from the 493.XX Module Setup
configuration drawing (PN 049-336-301).

Active guard Jumper W1 enables or disables an active guard for the sensor cable.

Active guard is usually not required. In particular environments, active guard

drive may reduce transducer noise.

Enable Disable
W1 W1
Default

92 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Model 493.21B (DUC B) Jumpers

4- or 8-wire Jumpers W2 and W3 establish the correct shunt calibration connections for 4-
sensor cable wire and 8-wire sensor cables. The length of the sensor cable determines which
type of cable is used. Short cables are typically 4-wire cables while long cables
are typically 8-wire cables.

• Jumper W2 selects a 4- or 8-wire transducer for positive feedback.

• Jumper W3 selects a 4- or 8-wire transducer for negative feedback.

• The setting of jumper W8 (single ended excitation enable) may affect your
choices for these jumpers (W2 and W3).
Note +/– excitation (–excitation is standard).

3 2 1
Default
W2 -EX to +FB shunt in W2
–EX to –FB shunt 4-wire config
in 4-wire config W3 W3

–EX to –FBR shunt W2 -EX to +FBR shunt W2

in 8-wire config in 8-wire config
W3 W3

Bridge balance Jumper W4 changes the offset of the bridge balance circuit. If the zero offset is
too large when the sensor bridge is balanced, you should enable this feature (it
adds a 100 kΩ resistor to the input of the conditioner preamp).

Disable Disable Enabl

Default

W4 W4

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 93

Digital Universal Conditioner (DUC BC) Switches

Excitation Jumpers W5 and W7 select the local (on board) or remote (through a cable)
excitation sensor connection.

• The local selection is used with 4-wire transducer connections.

• The remote selection is used with 8-wire transducer connections.

• Jumper W7 configures the + excitation signal.

• Jumper W5 configures the – excitation signal.

• Both jumpers need to be set for the same configuration.

Remote Local
Default
W7 W7
W5 W5

Single ended Jumper W8 connects -EX to ground for situations requiring single- ended
excitation excitation.

–EX = –EX –EX = GND

Default
W8 W8

Digital Universal Conditioner (DUC BC) Switches

The following switch settings are for the Model 493.21BC Digital Universal
Conditioner. The switches are labeled S1 1-8 and replace the former solder pads.
The following descriptions are from the 493.XX Module Setup configuration
drawing (PN 049-336-301).

Active guard Switch S1-8 enables or disables the guard connection to ground (GND) for the
sensor cable.

Enable Disable
Short to Ground Cap to Ground
S1-8 ON S1-8 OFF
Default

94 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Digital Universal Conditioner (DUC BC) Switches

4- or 8-Wire Switches S1-1, S1-2, S1-3, and S1-4 establish the correct shunt calibration
sensor cable connections for 4-wire and 8-wire sensor cables. The length of the sensor cable
determines which type of cable is used. Short cables are typically 4-wire cables
while long cables are typically 8-wire cables.

• Switches S1-1 and S1-2 select a 4- or 8-wire transducer for positive

feedback.

• Switches S1-3 and S1-4 select a 4- or 8-wire transducer for negative

feedback.

• The setting of jumper W8 (single ended excitation enable) may affect your
choices for these switches.
Note +/– excitation (–excitation is standard).

Sensor Cable Settings (4/8-Wire)

REQUIRED CONNECTION SWITCH SETTINGS

-EX to -FB shunt in 4-wire S1-1 OFF

configuration
S1-2 OFF
DEFAULT
S1-3 ON

S1-4 OFF

-EX to +FB shunt in 4-wire S1-1 ON

configuration
S1-2 OFF

S1-3 OFF

S1-4 OFF

-EX to -FBR shunt in 8-wire S1-1 OFF

configuration
S1-2 OFF

S1-3 OFF

S1-4 ON

-EX to +FBR shunt in 8-wire S1-1 OFF

configuration
S1-2 OFF

S1-3 ON

S1-4 OFF

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 95

Digital Universal Conditioner (DUC BC) Switches

Bridge balance Switch S1-5 changes the offset of the bridge balance circuit. If the zero offset is
too large when the sensor bridge is balanced, you should enable this feature (it
adds a 100 kΩ resistor to the input of the conditioner preamp).

Disable Enabl
S1-5 OFF S1-5 ON
Default

Excitation sense Switches S1-6 and S1-7 select the local (on board) or remote (through a cable)
excitation sensor connection.

• The local selection is used with 4-wire transducer connections.

• The remote selection is used with 8-wire transducer connections.

• Switch S1-7 configures the + excitation signal.

• Switch S1-6 configures the – excitation signal.

• Both switches need to be set for the same configuration.

Remote Local
S1-6 OFF S1-6 ON
S1-7 OFF S1-7 ON
Default

Single ended Jumper W8 connects -EX to ground for situations requiring single- ended
excitation excitation.

–EX = –EX –EX = GND

Default
W8 W8

96 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Full-Range Digital Universal Conditioner (FRDUC)

Full-Range Digital Universal Conditioner (FRDUC) Jumpers

The following jumpers are for the Model 493.25 Full-Range Digital Universal
Conditioner. The jumpers are labeled W instead of X; the W jumpers are solder
pads. The following jumper descriptions are from the 493.xx Module Setup
configuration drawing (PN 049-336-301).

Active guard Jumper W1 enables or disables an active guard for the sensor cable. A passive
guard drive is the default.

Enable Disable
(Short to Ground) (Cap to Ground)
W1 W1
Default

4- or 8-wire Jumpers W2 and W3 establish the correct shunt calibration connections for 4-
sensor cable wire and 8-wire sensor cables. The length of the sensor cable determines which
type of cable is used. Short cables are typically 4-wire cables while long cables
are typically 8-wire cables.

• Jumper W2 selects a 4- or 8-wire transducer for positive feedback.

• Jumper W3 selects a 4- or 8-wire transducer for negative feedback.

• The setting of jumper W8 (single ended excitation enable) may affect your
choices for these jumpers (W2 and W3).
Note +/– excitation (–excitation is standard).

3 2 1
Default
–EX to –FB shunt W2 -EX to +FB shunt W2
in 4-wire config in 4-wire config
W3 W3

–EX to –FBR shunt W2 -EX to +FBR shunt W2

in 8-wire config in 8-wire config
W3 W3

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 97

Full-Range Digital Universal Conditioner (FRDUC)

Excitation sense Jumpers W5 and W7 select the local (on board) or remote (through a cable)
excitation sensor connection.

• The local selection is used with 4-wire transducer connections.

• The remote selection is used with 8-wire transducer connections.

• Jumper W7 configures the + excitation signal.

• Jumper W5 configures the – excitation signal.

• Both jumpers should be set for the same configuration.

W7
W5 W5W
W5
W7 W7W
Local Remote

±Shunt cal The shunt calibration resistor can be installed on the Full Range Digital
Universal Conditioner module, or, in the transducer ID module. R33 assigns a
positive or negative excitation to the shunt calibration resistor if installed on the
Full Range Digital Universal Conditioner module (not the transducer ID
module).

R33
Default (No Resistor)
+EX Shunt

-EX Shunt

Single ended Jumper W8 connects -EX to ground for situations requiring single- ended
excitation excitation.

–EX = –EX –EX = GND

Default
W8 W8

98 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Full-Range Digital Universal Conditioner (FRDUC)

Bridge balance R32 changes the offset of the bridge balance circuit. If the zero offset is too large
when the sensor bridge is balanced, you should add an appropriately sized
resistor.

R32
Default (No Resistor)
Positive Offset

Negative Offset

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 99

Sensor Cables

Sensor Cables
A typical system is provided with a standard set of sensor cables as specified on
the System Cable/Jumper Plug 493 Package Selection drawing (PN 700-000-
656). Refer to this drawing for the most current part numbers. Standard sensor
cables do not have ID modules.

Sensor cables with an ID module built into them are available as an option.
Sensor cables with ID modules use a system cable to bridge the sensor cable to
the appropriate connector on the rear panel of the chassis.

Sensor Cable Specifications

• 15 contact type D male EMI connector

• Backshell–EMI metallized plastic

• Cable type–For all applications including CE EMC Compliance, use MTS

cable material PN 050-530-101 (two 22 AWG twisted pairs with inner and
outer braided shield for the excitation and feedback signals, plus a twisted
quad for the ID signals, and a single wire for the shunt calibration signal).

• If purchased as an option, each sensor includes one cable with a transducer

ID module and a system extension cable. A system cable is required
between the transducer ID cable and the controller’s chassis.

100 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Sensor Cable Part Numbers

Sensor Cable Part Numbers

Sensor cables without See the System Cable/Jumper Plug 493 Package Selection drawing (PN 700-000-
ID Module 656) for the most current sensor cable part numbers.

Sensor Cables and Connectors

CABLE DESCRIPTION CABLE CONNECTOR
ADT 120º 056-234-8XX 493.40 J4–J7
300º 056-253-1XX 493.40 J4–J7

Extensometer 633 capacitive 051-649-5XX 493.40 J4–J7

Force Transducer w/PT connector 046-440-2XX 493.40 J4–J7

with MS connector 046-440-6XX 493.40 J4–J7
with PC 056-252-9XX 493.40 J4–J7

LVDT 046-440-3XX 493.40 J4–J7

ΔP control 047-927-6XX 493.40 J4–J7

Pressure Control (Sensotec) 056-253-0XX 493.40 J4–J7

Strain with Amphenol connector 056-233-6XX 493.40 J4–J7

with PT connector 050-120-0XX 493.40 J4–J7

Temposonics 049-153-2XX 493.40 J4–J7

Temposonics II (low power conditioner) 056-253-2XX 493.40 J4–J7
Temposonics III 056-316-7XX 493.40 J4–J7

RVDT with MS connector 051-202-8XX 493.40 J4–J7

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 101

Sensor Cable Part Numbers

Sensor cables with ID See the System Cable/Jumper Plug 493 Package Selection drawing (PN 700-000-
Module 656) for the most sensor cable current part numbers.

Each sensor includes a cable with an ID module built into it. Use a system cable
to bridge the sensor cable to the rear panel of the controller chassis.

Sensor Cables and Connectors (ID Module)

CABLE DESCRIPTION ID MODULE W/CABLE SYSTEM CABLE* MODULE
CONNECTOR
ADT 120º 052-543-5XX 056-125-8XX 493.40 J4–J7
300º 052-443-6XX 056-125-9XX 493.40 J4–J7

Extensometer 633 capacitive 052-543-4XX 052-544-3XX 493.40 J4–J7

Force Transducer w/PT connector 052-542-5XX 052-544-2XX 493.40 J4–J7

with PC connector 052-542-6XX 052-544-2XX 493.40 J4–J7
with MS connector 052-542-7XX 052-544-2XX 493.40 J4–J7

LVDT 052-543-1XX 052-544-2XX 493.40 J4–J7

ΔP control 052-543-2XX 052-544-2XX 493.40 J4–J7

Pressure Control (Sensotec) 052-543-3XX 052-544-2XX 493.40 J4–J7

Strain with Amphenol connector 052-542-9XX 052-544-2XX 493.40 J4–J7

with PT connector 052-543-0XX 052-544-2XX 493.40 J4–J7

Temposonics 052-543-7XX 056-126-0XX 493.40 J4–J7

Temposonics II (low power conditioner) 052-543-8XX 052-544-7XX 493.40 J4–J7

RVDT with MS connector 052-750-8XX 052-544-2XX 493.40 J4–J7

* -XX specifies cable length. –01 through –09 represent 10–50 ft. in 5 ft. increments. Higher numbers
represent custom cable lengths.

102 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Shunt Calibration/Bridge Completion Resistor

Shunt Calibration/Bridge Completion Resistor Installation

On a typical system, shunt calibration and bridge completion resistor installation
is completed on the I/O Carrier module.

If you have purchased optional sensor cables with transducer ID modules, shunt
calibration and bridge resistors are installed on these modules.

I/O Carrier Module

Shunt calibration The I/O Carrier module has a shunt calibration connector on its front panel that
connector allows up to four shunt resistors (1 per slot) to be plugged in. The SHUNT CAL
connector is labeled to indicate which slot the shunt calibration resistor is tied to.

Each shunt calibration resistor is soldered to a 2-pin holder (MTS PN 011-433-

826). This holder plugs into the front panel connector shown below. Refer to the
493.40/41 Carrier I/O Shunt Calibration Kit (MTS PN 100-028-185) for more
detailed information on kit components and installation.

Bridge completion Each of the four I/O option card slots on the I/O Carrier module provides support
circuits for up to three bridge completion resistors as well as a shunt calibration resistor.
The bridge completion resistors can be installed into sockets on the I/O Carrier
printed wiring board. The shunt calibration resistor sockets are accessible from
the I/O Carrier front panel.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 103

I/O Carrier Module

The following figures show three typical bridge configurations for a DC

conditioner installed on an I/O Carrier module.

104 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 I/O Carrier Module

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 105

Transducer Identification Modules

Transducer Identification Modules

Transducer ID modules (located at the end of the sensor cable) are optional
components that can store sensor calibration information just like a sensor
calibration file. Since the calibration information stays with the sensors,
transducer ID modules make it easier to change sensors.

Calibration information can be stored in the transducer ID EEPROM or in a

sensor calibration file. When you load a station that does not have a sensor file
assigned to one or more of its signals, by default, the system software looks for
calibration information in the transducer ID.

The molded ID module has a removable cover and includes provisions for:

• A shunt calibration resistor

• Up to three bridge completion resistors

• A transducer ID circuit card

The circuit card has the bridge completion and shunt calibration resistors on one
side, and the transducer ID circuit on the other.

• R6, R7, and R8 are the bridge completion resistors.

• R9 is the shunt calibration resistor.

W1
l

1 R6
2 R7
3 R8
SC R9
W2

106 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Transducer Identification Modules

The following is the schematic diagram of the bridge balance and bridge
completion circuit.

Sensor ID Module
-FB

+EX
Rcomp Pre-amp
(R6) Rcomp (R7) -FB

-FBR +FB +FB

Vin

Rg Rcomp (R8)
Vout
-EX

Note For information about assigning sensors and saving data with
Transducer ID Modules, see the MTS 793 Control Software manual.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 107

Valve Connections

Valve Connections
The following types of valve connections are supported:

• Single or dual Series 252 Servovalve(s) can be controlled with a Model

493.14 Valve Driver mezzanine card.

• A Series 256 Servovalve can be controlled with a Model 493.15

3 Stage Valve Driver mezzanine card.

• A Series 257 Servovalve can be controlled with a Model 493.15

3 Stage Valve Driver mezzanine card and a Model 448.16C Power Driver
chassis.

• For single and dual valve configuration wiring information, see the
servovalve product manual (included with the System Documentation CD).

CAUTION

Improper operation can damage valve driver cards.

Damage can occur if you connect a high-level signal to a valve driver card
when the chassis power is off.

Do not apply a high-level signal to a valve driver card when the chassis power is
off. Disconnect power from any externally powered devices before you switch the
chassis power off.

Cable specification • 15-contact type D male EMI connector

• Backshell–EMI metallized plastic

• Cable type–4 conductor w/foil shield and drain (PN 010-093-580 or

equivalent) with the drain wire connected to metallized plastic backshell at
the chassis.

• For Series 256 and 257 Servovalves, the valve LVDT uses the same type of
connectors as the actuator LVDT.

• Servovalve/valve LVDT Y cable required for Series 256 or 257 servovalves

(PN 039-710-5XX).

108 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Valve Connections

Series 252 Servovalve The Series 252 Servovalve is a 2-stage servovalve. The Model 493.14 Valve
connections Driver supports single or dual valve configurations. The following figure shows
the connections at the valve driver and the connections between the valve and the
valve driver. To connect the valve to the I/O Carrier modulesee “Cable Part
Numbers” on page 85.

From J4 - J7 To
I/O Carrier Servovalve
Controller
1
Test
2 Command Valve Command
Control
3 Mode Driver
4
5
6 Actuator LVDT
7 Feedback

8
9 + Valve Command
10
11 - Valve Command
12 + Valve 2 Command
13 - Valve 2 Command
14
15

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 109

Valve Connections

Series 256 Servovalve The Series 256 Servovalve is a 3-stage servovalve. The Model 493.15 Valve
connections Driver supports the inner loop signals. The following figure shows the
connections between the valve driver and the valve. To connect the valve to the I/
O Carrier module, see “Cable Part Numbers” on page 85.

To/From J4 - J7 To/From Valve LVDT

I/O Carrier Servovalve Controller
Feedback Inner Loop
1 + Excitation
2 - Excitation
Test Valve Command
3
Command Control Driver
4 + Feedback Mode
5 - Feedback
6 Signal Ground
7
Actuator LVDT Outer Loop
Feedback
8
9 + Valve Command
10
11 - Valve Command
12
13
14

110 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Valve Connections

Series 257 Valve The Series 257 Servovalve is a 3-stage servovalve that requires a power driver.
connections The Model 493.15 Valve Driver supports the inner loop signals. The following
figure shows the connections between the valve driver and the valve. To connect
the valve to the I/O Carrier module, see “Cable Part Numbers” on page 85.

To/From J4 - J7 To/From
I/O Carrier Servovalve

1 + Excitation
2 - Excitation
3
4 + Feedback
5 - Feedback
6 Signal Ground
7
8
9 + Valve Command
10
11 - Valve Command
12
13
14
15

Controller Valve LVDT Inner Loop

Feedback

Test Valve Command 448.16

Command Driver Power
Control
Mode Driver
LVT
(stability)
Loop
Actuator LVDT
Feedback Outer Loop

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 111

Multiple Universal Driver Connections

Multiple Universal Driver Connections

For special applications, the Model 493.79 Multiple Universal Driver (MUD)
board provides up to six drivers that can be used to drive standard 252
servovalves. Inputs to this board originate from a Model 493.46 D/A board on a
Model 493.40 I/O Carrier Module.

A Y-cable (PN 100-006-173) connects the I/O Carrier module (15 pin, D-Type)
to J9/J10 on a MUD board (RJ45).

493.40
I/O Carrier

Front Rear

493.10 Chassis

Front/Rear Cable Conduit

112 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Multiple Universal Driver Connections

Output connections Each valve driver output is an RJ50 connection that contains two valve drive
output lines and a cable loss detection loop.

Cable loss detection The cable loss detection wire loops out to the servovalve and back to the driver
output allowing MUD board logic to detect a cable break or a cable disconnect at
the MUD board output. A cable loss will not be detected if the cable is
disconnected at the servovalve.

J3 - J8 To
Servovalve

1
2 + Valve Command
3 - Valve Command
4 + Cable Loss
5 - Cable Loss
6
7
8
9
10

Note Different customer actuator sign conventions might require alterations to

the cable polarity. Contact MTS for more information.

CAUTION

Improper operation can damage valve driver cards.

Damage can occur if you connect a high-level signal to a valve driver card
when the chassis power is off.

Do not apply a high-level signal to a valve driver card when the chassis power is
off. Disconnect power from any externally powered devices before you switch the
chassis power off.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 113

Analog I/O Connections

Analog I/O Connections

The Model 493.45 A/D and Model 493.46 D/A mezzanine cards are installed in
the Model 493.40 I/O Carrier front panel module. A connection from the front
panel mezzanine card to a rear panel BNC transition module allows easy access
to the analog channels.

Note The external analog source can be a stand-alone function generator,

another controller, or a computer controlled analog output.

493.40
I/O Carrier
External Analog Source 493.75
Analog In
493.76
Analog Out Analog Monitor

Select Waveform Breakpt

+100% FS 5 - 05%
Normal Full Scale
410.81 Invert
0

Function +100% FS
Generator
Control Mode Output Mode Output to 0 Ramp Time 1 (sec) Ramp Time 2 (sec)
FS FS
Output Finish
Local Trigger
Main Sync Single Cycle Manual 0 0
Local Ret to t t
Remote Local Cycle Start & Stop Zero Bkpt Hold Hold Time (sec)
FS
t 0
Frequency (Hz)

Front Rear

493.10 Chassis

Front/Rear Cable Conduit

114 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Analog I/O Connections

Analog inputs The analog-to-digital mezzanine cards accommodate up to six analog input
signals. Each A/D input signal must be within ±10 volts.

To From
A/D J4 - J7 A/D

1 +
Input 1
2 -
3 Analog
Ground
4 +
Input 2
5 -
6 Analog
Ground
7 +
Input 3
8 -
9 +
Input 4
10 -
+
11 +
- Input 5
12 -
13 +
Input 6
14 -
15

• Use pin 3 or 6 to prevent problems with floating grounds between devices.

• Analog inputs can be connected at the BNC connectors of a Model 493.75

Analog In transition module and the outputs from this module are connected
to the Model 493.40 I/O Carrier module.

• Analog inputs can be connected at the BNC connectors of a Model 493.77

Filtered Analog Input transition module and the outputs from this module
are connected to the Model 493.40 I/O Carrier module.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 115

Analog I/O Connections

Model 493.77 Filter The following filter modules are available for board mounting at the BNC
Modules connectors of a Model 493.77 Filtered Analog Input transition module:

Filter Module Specifications

ASSEMBLY NUMBER HZ TYPE
047-774-401 50 Bessel

047-774-402 100 Bessel

047-774-403 200 Bessel

047-774-404 500 Bessel

047-774-405 1000 Bessel

047-774-406 2000 Bessel

047-774-407 5000 Bessel

047-774-408 120 Bessel

047-774-409 300 Bessel

116 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Analog I/O Connections

D/A Connections Digital-to-analog mezzanine cards support up to six program or readout signals
to external devices. Each D/A signal is an analog output within ±10 volts.

From To
D/A J4 - J7 External
Device

1 +
Output 1
2 -
3
4 +
Output 2
5 -
6
7 +
Output 3
8 -
9 +
Output 4
10 -
11 + Output 5
12 -
13 +
Output 6
14 -
15

• Each readout signal is from a 16 bit digital to analog converter.

• Each output is a ±10 V analog output.

• The Model 493.46 D/A Mezzanine Card provides analog signals to the
Model 493.76 Analog Out transition module. Analog outputs are available
at the BNC connectors of a Model 493.76 Analog Out transition module for
external devices (DVM, oscilloscope).

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 117

Analog I/O Connections

Cable specification The cable specifications apply to both the analog inputs and analog outputs.

The cable from the front panel of the I/O Carrier module has the following
specification:

• 15-contact type D male EMI connector.

• Backshell–EMI metallized plastic.

• Cable type–up to 6 shielded twisted pairs, each with the drain wire
connected to the signal source.

The cable to the Ch 1 - Ch 6 connectors on the rear panel have the following
specifications:

• BNC connector UG88/U

• Cable–RG-58 coaxial

• Use of a smaller coaxial cable and a RG-174 BNC connector with an

appropriate cable end is permissible.

118 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Accelerometer Connections

Accelerometer Connections
An accelerometer requires the Model 493.48 Acceleration mezzanine card
(installed in a Model 493.40 I/O Carrier module) and the Model 493.78
Accelerometer Transition Board.

• Each Model 493.48 Acceleration mezzanine card supports up to three

accelerometers.

• The transition board accommodates two types of accelerometers: Low

impedance Voltage Mode (LIVM) type accelerometers and High Level
Signal Conditioned type accelerometers.

493.40
I/O Carrier

J3 Service

Shunt Cal

J4 I/O
493.78
Accel.
Transition

493.21B Universal Ch 1A In

Conditioner Accelerometer
Ch 2A In
J5 I/O

Accelerometer LIVM
493.21B Universal Ch 3A In

Conditioner
Accelerometer
J6 I/O
Ch 1B In

493.21B Universal
Conditioner Accelerometer
J7 I/O

Ch 2B In

493.48 Acceleration
Conditioner High Level
Accelerometer Signal Conditioned

m Ch 3B In

493.40
Accelerometer
I/O Carrier

J3 Service

J11 B Out

Shunt Cal

J4 I/O J12 B Out

493.21B Universal
Conditioner

J5 I/O m
493.21B Universal
Conditioner

J6 I/O

493.21B Universal
Conditioner

J7 I/O

493.48 Acceleration
Conditioner

I/O Carrier jumper Before installing a Model 493.48 Acceleration Conditioner mezzanine card in a
settings Model 493.40 I/O Carrier module, specific jumpers must be set. Jumper settings
depend on the number and configuration of your system accelerometers.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 119

Accelerometer Connections

In the example shown below, the Acceleration Conditioner supports three

accelerometers. The indicated three jumpers must be set on the I/O Carrier
module.

X101 Analog Bus#1

X102 Analog Bus#2
Analog Bus#3
DUC X103
Analog Bus#4
X104
X105 Analog Bus#5

X201
X202
X203
DUC X204
X205

X301
X302
DUC X303
X304
X305

Accelerometer Ch 1 Accel Out X401

Accel Ch 2 Accel Out X402
Accel Daughter Ch 3 Accel Out X403
Accelerometer
Transitio Card
X404
X405
Accelerometer
Set these jumpers

120 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Encoder Connections

Encoder Connections

I/O Carrier module For an ADDA configuration using an I/O Carrier module, each encoder requires
configuration installation of a Model 493.47 Encoder Interface mezzanine card on the Model
493.40 I/O Carrier board. The I/O Carrier connector is based on the location of
the mezzanine card installed on the board of the I/O Carrier module.

493.40
I/O Carrier

J3 Service

Shunt Cal

J4 I/O

J5 I/O

J6 I/O

J7 I/O

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 121

Encoder Connections

Optional ADDA II For the optional ADDA II configuration, each encoder requires installation of a
configuration Model 493.59 Universal Encoder mezzanine card on the Model 493.50 ADDA II
module.

The Model 493.80 Encoder Transition module provides up to four channels of

encoder interface between the Model 493.50 ADDA II module and various
incremental, Temposonics, or other digital or serial transducers.

Daughter
Board 1

Daughter
Board 2

Front Rear

493.10 Chassis

Daughter
Board 3

Daughter
Board 4

Front/Rear Cable Conduit

122 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Remote Setpoint Adjust Connections

Remote Setpoint Adjust Connections

A Remote Setpoint Adjust (RSA) control is an optional, stand-alone hardware
device that uses an incremental or absolute encoder to control actuator setpoints.

Each RSA control pod requires installation of a Model 493.47 Encoder Interface
mezzanine card on the Model 493.40 I/O Carrier board. The I/O Carrier
connector is based on the location of the mezzanine card installed on the board of
the I/O Carrier module.

For more information, see “Setting Up the Remote Setpoint Adjust” in the MTS
793 Control Software manual.

Remote Setpoint Pod

493.40
I/O Carrier

J3 Service

Shunt Cal

J4 I/O

J5 I/O

J6 I/O

100-051-058

J7 I/O

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 123

ADDA II Connections

ADDA II Connections
Each optional Model 493.50 ADDA II module supports up to four mezzanine
cards. Each installed mezzanine card is assigned a specific ADDA II module
front panel connector (J11–J18).

A hardware interface file (.hwi) defines each type of module (and their associated
mezzanine cards) and maps each module location for the system software. The
hwi file and the physical locations for each type of module and associated
mezzanine cards must match. Also, the ADDA II module address setting (on the
module) must match the .hwi file address. For more information on the .hwi file,
see the MTS 793 Utility Software manual.

The following A/D or D/A mezzanine cards can be installed:

– Model 493.55 A/D

– Model 493.56 D/A

– Model 493.57 DSPAD

– Model 493.59 Universal Encoder

124 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 ADDA II Connections

ADDA II Module I/O The Model 493.55 A/D, Model 493.57 DSPAD, and Model 493.56 D/A
connections mezzanine cards are installed in the Model 493.50 ADD II module assembly. A
connection from the front panel connector to a rear panel BNC transition module
allows easy access to the analog channels.

Note The external analog source can be a stand-alone function generator,

another controller, or a computer controlled analog output.

External Analog Source

Analog Monitor
Select Waveform Breakpt
+100% FS 5 - 05%
Normal Full Scale
410.81 Invert
0

Function +100% FS
Generator
Control Mode Output Mode Output to 0 Ramp Time 1 (sec) Ramp Time 2 (sec)
FS FS
Output Finish
Local Trigger
Main Sync Single Cycle Manual 0 0
Local Ret to t t
Remote Local Cycle Start & Stop Zero Bkpt Hold Hold Time (sec)
FS
t 0
Frequency (Hz)

Daughter
Board 1

Daughter
Board 2

Front Rear

493.10 Chassis

Daughter
Board 3

Daughter
Board 4

Front/Rear Cable Conduit

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 125

ADDA II Connections

Analog inputs The analog-to-digital mezzanine cards accommodate up to eight analog input
signals. Each A/D input signal must be within ±10 volts.

• Analog inputs can be connected at the BNC connectors of a Model 493.81

Analog In transition module and the outputs from this module are connected
to the Model 493.50 ADDA II module.

• Analog inputs can be connected at the BNC connectors of a Model 493.83

Filtered Analog Input transition module and the outputs from this module
are connected to the Model 493.50 ADDA II module.

To From
A/D 493.81 Analog In
Module
1 +
Input 1
2 -
3 +
Input 2
J 11 , J 1 3 4 -
J15, J17 5 +
Input 3
6 -
7 +
Input 4
8 -

1 +
Input 5
2 -
3 +
Input 6
J12, J14 4 -
J16, J18 5 +
Input 7
6 -
7 +
Input 8
8 -

126 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 ADDA II Connections

D/A connections Digital-to-analog mezzanine cards support up to eight program or readout signals
to external devices. Each D/A signal is an analog output within ±10 volts.

• Each readout signal is from a 16 bit digital to analog converter.

• Each output is a ±10 V analog output.

• The Model 493.56 D/A Mezzanine Card provides analog signals to the
Model 493.82 Analog Out transition module. Analog outputs are available
at the BNC connectors of a Model 493.82 Analog Out transition module for
external devices (DVM, oscilloscope).

.
To
From External
D/A Device
1 -
Output 8
2 +
3 -
Output 7
J 11 , J 1 3 4 +
J15, J17 5 -
Output 6
6 +
7 -
Output 5
8 +

9 -
Output 4
10 +
11 -
Output 3
J12, J14 12 +
J16, J18 13 -
14 + Output 2
15 -
Output 1
16 +

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 127

ADDA II Connections

ADDA II Universal Each encoder requires a Model 493.59 Universal Encoder mezzanine card
Encoder connections installed on the Model 493.50 ADDA II module.

Up to four encoders can be connected to the Model 493.80 ADDA II Encoder

Transition module when the Model 493.50 ADDA II module is fully populated
with Universal Encoder cards.

To/From
Encoder Transition
Module
1 Return Gnd
2 Index Ser Clk Input 4
3 B/Interrogate
J 11 , J 1 3 4 A/Serial Dat a
J15, J17 5
Return Gnd
6
Index Ser Clk Input 3
7 B/Interrogate
8 A/Serial Dat a

9 Return Gnd
10 Index Ser Clk Input 2
11 B/Interrogate

J12, J14 1 2 A/Serial Dat a

J16, J18 1 3 Return Gnd
1 4 Index Ser Clk Input 1
1 5 B/Interrogate
1 6 A/Serial Dat a

128 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Emergency Stop Connections

Emergency Stop Connections

Connectors J23 E-STOP Out and J24 E-STOP In are located on the Model
493.73 HPU transition board. The Emergency Stop switch and signal are part of
a controller-wide interlock system.

Emergency Connector J23 E-STOP Out provides an output to external devices when an
stop output emergency stop signal is generated. The inactive status is shown in the figure.

From J23 To
Chassis External
Devices
1

2 Emergency
Stop
3

Emergency Connector J24 E-STOP In accommodates an external emergency stop switch.

stop input As shown, several connectors maintain the continuity of the emergency stop
interlock.

External J24
E-Stop

13 +24 V

8 E-Stop
Relay
7 E-Stop
Signal
5

Cable specifications J23 E-STOP Out is a 9 pin type D male connector

• 9-contact type D female EMI connector

• Cable—24 AWG, 10 conductor with overall foil shield, (Carol C0745 or

equivalent) with drain wire connected to metallized plastic backshell to the
chassis.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 129

Emergency Stop Connections

J24 E-STOP In is a 15 pin type D female connector.

• 15-contact type D male EMI connector.

• Backshell–EMI metallized plastic.

• Cable–24 AWG 4 connector with overall foil shield, (Belden 9534 or

equivalent) with drain wire connected to metallized plastic backshell at the
chassis and to ground at the emergency stop station.

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 PN 039-713-201 or jumper pins: 5
and 7; 8 and 13.

130 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 J25 Hydraulic Power Unit Connection

J25 Hydraulic Power Unit Connection

Connector J25 HPS on the Model 493.73 HPU transition board controls the
hydraulic power unit (HPU).

• The module produces 24 V logic signals to control the HPU.

• The Model 493.07 HPU Converter Box allows any MTS HPU to be
connected to the chassis with the following exceptions:

– 506.52-.92 HPUs (24 volt, PLC compatible)

– All Series 505 HPUs

The converter box is used with other configurations. For more information
see “Hydraulic Configurations” on page 243.

CAUTION

Control voltages for hydraulic power units vary between models.

The HPU interface between the Model 493.73 HPU transition board and an
HPU is 24 volt logic signals. Connecting J25 to a non-compliant HPU can
damage the module.

DO NOT connect 24 V DC relay circuitry or 115 V AC circuitry to the HPU

connector J25.

Service LED The Service LED turns on when electrical power is applied and it turns off when
the chassis makes contact with the personal computer and processor has
successfully booted.

Cable specification J25 HPS is a 15 pin type D male connector.

• 15-contact type D female EMI connector.

• Cable—24 AWG, 10 conductor with overall foil shield, (Carol C0745 or

equivalent) with drain wire connected to metallized plastic backshell to the
chassis.

Jumper plug required If connector J25 HPS 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.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 131

J25 Hydraulic Power Unit Connection

J25 Diagram
To/From J25 To/From
Chassis HPU
HPS On
Sense 9

10

Over Temp
11
Low Level
12
HPS 24 Vdc +24
1
vdc
CRM

Start Start
2 1CR Relay
Lo
3
Motor
Relay

High Hi Pressure
4 SOL
Solenoid

To J24 pin 13 5 +24 Vdc

E-stop HPS Interlock
To J29 pin 8 6 CRM
Relay

Controller 24 Vdc 7
HPS Defeat Voltage
(not connected in HPS)
8

132 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 J25 Hydraulic Power Unit Connection

System I/O Connector J54 Sys I/O provides three digital inputs and one digital output. The
inputs are connected to the high and low inputs of an opto-isolator. The output is
from the collector (+) and emitter (-). For circuit drawings, see the “Digital I/O
Connections” on page 141.

To/From To/From
HPU J54 External
Devices

+24 V 1
2 +
Input 1
3 -
4
+24 V 5
6 +
Input 2
7 -
8
+24 V 9
10 +
Input 3
11 -
12
13
14 +
Output 1
15 -

Cable specification J54 Sys I/O is a 15-contact type D female connector.

• 15-contact type D male EMI connector.

• Backshell–EMI metallized plastic.

• Cable–24 AWG 4 connector with overall foil shield, (Belden 9534 or

equivalent) with drain wire connected to metallized plastic backshell at the
chassis and to ground at the emergency stop station.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 133

Station Connections

Station Connections
Each Model 493.74 HSM transition board controls up to two stations. A standard
chassis configuration supports up to four stations. Each station has the following
connections

• J28 Hydraulic service manifold (HSM)

• J29 Load unit

• J43 Interlock

• J44 Remote run/stop

• J49 Auxiliary power

As a system option, the Model 493.10 Chassis can be configured to support six or
eight stations. See “Optional Station Configurations” on page 255.

J28 Hydraulic Service Manifold Connector

Connector J28 HSM controls the pressure of a hydraulic service manifold. The
controller software can configure the connector for solenoid or proportional
control of a 24 volt hydraulic service manifold.

From Chassis J28 To HSM

lo
+24 V 1 Low Pressure
Solenoid
2 DC Common
- Proportional Solenoid or
3 Shield Proportional
hi Valve
4 High Pressure

+ Proportional

Cable specification • P28 is a 4-contact CPC male connector (AMP Incorporated).

• Cable for on/off HSMs–18 AWG/2 conductor with overall foil shield (Carol
C2534 or equivalent) with drain wire connected to pin 3 at the chassis.

• Cable for high/low HSMs–18 AWG/4 conductor with overall foil shield
(Carol C2543 or equivalent) with drain wire connected to pin 3 at the
chassis.

134 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 J28 Hydraulic Service Manifold Connector

Proportional output The proportional output is configured with the controller software.

• The output signal can be ramped from 20 mA (minimum) to 700 mA

(maximum) which corresponds with 50 psi (0.4 MPa) and 3000 psi (21
MPa). By default, low pressure is factory set at 500 psi and high pressure is
set at 3000 psi.

• The ramp rate from zero to high pressure can be set to two or four seconds.
The ramp rate from high pressure to zero can be set to zero, two or four
seconds.

• The ramp rate is constant (set to the two or four second rate), The amount of
time to reach low pressure depends on the low pressure setting.

.hwi file settings The following items can be specified in the .hwi file. For more information, see
the MTS 793 Utility Software manual.

• HSM ramp rate from zero to high pressure (HSM RATE):

SLOW = zero to high pressure in approximately 4 seconds

FAST = zero to high pressure in approximately 2 seconds

• HSM high pressure to zero mode (HSM OFF MODE):

STEP = HSM steps from high pressure to zero (default)

RAMP = HSM ramps from high pressure to zero
Important Unless there is a special need, HSM OFF MODE should not be set
to RAMP. For your safety, keep this setting at STEP.

• HSM low pressure setting as a percentage of full-scale (LOW PERCENT)

• HSM high pressure setting as a percentage of full-scale (HIGH

PERCENT)

• HSM type can be set to PROPORTIONAL, SOLENOID, or

ON_OFF_SOLENOID.

If you select ON_OFF_SOLENOID only 2 HSM control buttons (OFF/

ON) will appear on the Station Manager Station Controls panel. For the
other selections, 3 HSM control buttons will appear (OFF/LOW/HIGH).

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 135

J29 Load Unit

J29 Load Unit

Connector J29 Load Unit connects to the load unit lift/lock panel.

Pins 1, 2, 3, and 4 can be +24 V DC 1

configured for contacts (with X*
jumpers X* and X†) or a logic 4 Cross
Head
signal (without jumpers X* and 3 Lock
X†). X†
2
OR Station
X* = Jumper X2 for Channel A +24 V DC 13 Stop
Jumper X1 for Channel B CRM Relay
in HPS 8
Emergency
X† = Jumper X4 for Channel A Stop
Jumper X3 for Channel B E-Stop 7

5
Pins 5, 7, 8, and 13 maintain
9 Shield
the continuity of the
emergency stop interlock. +24 V HSM hi 12
Crosshead
Cross Head Unlock Solenoid
14
DC Common

Cable specification • P29 is a 15-contact, type D, male, EMI connector.

• Cable for load frames with crosshead locks built after 1985, 18 AWG, 8
conductor with overall foil shield Alpha 5388C or equivalent with drain
wire connected to pin 9 at both ends of the cable.

• Cable for all load frames without crosshead locks–22 AWG, 6 conductor
with overall foil shield Alpha 5386C or equivalent with drain wire
connected to pin 9 at both ends of the cable (pin 9 may be pin E at the load
frame).

Jumper plug If connector J29 is not used, you must install a jumper plug to maintain the
integrity of the interlocks. Use jumper plug 100-007-947 or jumper pins: 3 and 4;
5 and 7; 8 and 13.

Station stop The Emergency Stop connection can also be configured as a station stop. When
this is done, be sure that you have other Emergency Stop boxes near by. Pressing
Station Stop will shut down the hydraulics to an individual station without
shutting down power to the hydraulic power unit.

Note A Model 493.73 HPU Transition Board must be installed for the
Emergency Stop connection to be enabled.

136 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 J43 Interlock

J43 Interlock
Connector J43 Interlock accommodates two general purpose inputs to be
connected to the interlock chain.

• Input 1 is dedicated as a station interlock.

• Input 2 is dedicated as a program interlock.

• Both inputs are optically isolated.

• If just one contact is used, the other must be jumped.

Both inputs can accept relay To J43 From

Chassis External Device
contacts or a logic signal.
Both configurations are +24 V 1
shown.
2
Each input can be have Input 1
Station
relay
contacts
either configuration. Interlock 3

+24 V 5

Input 2 6 logic
Program driver
Interlock 7 0V

Cable specification • 9-contact type D male EMI connector.

• Backshell–EMI metallized plastic.

• Cable–shielded twisted pairs (24 AWG minimum) with drain wire(s)

connected to the metallized backshell at the chassis.

Power characteristics Channel inputs can be 3 volts (minimum) and 26 volts (maximum) from an
external voltage source.

Jumper plug If connector J43 is not used, you must install a jumper plug to maintain the
integrity of the interlocks. Use jumper plug PN 100-007-948 or jumper pins 1
and 2; 3 and 4; 5 and 6; 7 and 8.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 137

J44 Run/Stop

J44 Run/Stop
Run/Stop status Connector J44 Run/Stop provides the run/stop status of the controller to external
devices.

• Two form C contacts provide the run/stop status.

• The contacts are rated 1.0 A at 30 V (AC or DC).

From J44 To
Chassis External Devices

2 Run/Stop 0

4 +
Interlock Status
Output
5 -

7 Run/Stop 1

Interlock status Connector J44 Run/Stop also provides opto-isolator outputs that indicate the
interlock status of each station to an external device. These interlock status
outputs are normally on and will turn off when an interlock occurs. For detailed
circuit drawings, see “Digital outputs” on page 143.

138 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 J44 Run/Stop

Output specifications The specifications for the interlock status opto-isolator outputs are as follows:

• Output Format: open collector, open emitter transistor

• Maximum Voltage: 26 V DC

• Minimum Guaranteed Output Current Drive: 20 mA (30 mA typical) @ 1.0

V max

Jumper X5 Jumper setting X5 selects the source for interlock status output. The following
jumper settings select the indicated interlock source:

• X5 Jumpered = HSM Board Interlocks Only

• X5 Not Jumpered = Station and HPU Interlocks

Jumpers W8/W9 Jumper settings W8/W9 determine the output polarity of the opto-isolators.

Cable specification • 9-contact type D female EMI connector

• Backshell–EMI metallized plastic

• Cable–shielded twisted pairs (24 AWG minimum) with drain wire(s)

connected to the metallized backshell at the chassis.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 139

J49 Auxiliary Power

J49 Auxiliary Power

Connector J49 Aux Pwr provides +5 V DC, ±15 V DC, and 24 V DC from the
chassis internal power supply to drive external high level conditioners, proximity
switches, solenoids, and so forth.

• The outputs are fused at 0.75 A to protect the power supply from an external
short.

• The fuses can be reset by shutting off power and waiting a few minutes (the
fuses automatically reset when cooled) then reapplying power.

From J49 To
Chassis External Devices

F7
+15 Vdc 1

Analog 2
Ground
7
F4
-15 V DC 3
F9
+24 V DC 9

24V 8
Common
F7
+5 V DC 5

5V 4
Ground

Cable specification • 9-contact type D male EMI connector

• Backshell–EMI metallized plastic

• Cable–shielded twisted pairs (22 AWG minimum) with drain wire(s)

connected to the metallized backshell at the chassis.

140 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Digital I/O Connections

Digital I/O Connections

The Model 493.72 Digital I/O transition module has two connectors; one
provides connections for sixteen digital inputs and the other provides connections
for sixteen digital outputs.

From J3 To From J4 To
External Device 493.72 Digital Input 493.72 Digital Output External Device

1 + + 1
Channel 1 Input - Channel 1 Output
20 - 20
2 + + 2
Channel 2 Input Channel 2 Output
21 - - 21
3 + + 3
Channel 3 Input Channel 3 Output
22 - - 22
4 + + 4
Channel 4 Input Channel 4 Output
23 - - 23
5 + + 5
Channel 5 Input Channel 5 Output
24 - - 24
6 + + 6
Channel 6 Input Channel 6 Output
25 - - 25
7 + + 7
Channel 7 Input Channel 7 Output
26 - - 26
8 + + 8
Channel 8 Input Channel 8 Output
27 - - 27
9 + + 9
Channel 9 Input Channel 9 Output
28 - - 28
10 + + 10
Channel 10 Input Channel 10 Output
29 - - 29
11 + + 11
Channel 11 Input Channel 11 Output
30 - - 30
12 + + 12
Channel 12 Input Channel 12 Output
31 - - 31
13 + + 13
Channel 13 Input Channel 13 Output
32 - - 32
14 + + 14
Channel 14 Input Channel 14 Output
33 - - 33
15 + + 15
Channel 15 Input Channel 15 Output
34 - - 34
16 + + 16
Channel 16 Input Channel 16 Output
35 - - 35
18 +12 V DC +12 V DC 18
19 19
36 36
37 37

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 141

Digital I/O Connections

Digital inputs The J3 In connector accommodates up to sixteen digital signals from external
devices. You can use digital input signals to trigger test events with your
controller applications.

• All of the inputs are optically isolated and support relay contacts or logic
inputs (see the following figure).

• Channel inputs can be 3 volts (minimum) and 26 volts (maximum) from an

external voltage source.

• Jumpers select the debounce time for each group of four inputs.

Jumper X2 configures inputs 1–4. Jumper X3 configures inputs 5–8. Jumper

X4 configures inputs 9–12. Jumper X5 configures inputs 13–16.

– Not using a jumper sets the debounce to 20 msec.

– Jumper pins 1 and 4 to set the debounce to 10 msec.

– Jumper pins 2 and 3 to set the debounce to 1 msec.

– Jumper pins 1 and 4, and 2 and 3 to set the debounce to 0.1 msec.

Digital I/O 493.72 Digital I/O

Access Panel J3 Transition Module
External Device
18 +12 Opto-
+CH1 Coupler
1
External Switch
or -CH1
20
Relay Contact
36

Digital I/O 493.72 Digital I/O

Access Panel J3 Transition Module
External Device
18 +12 Opto-
+CH1 Coupler
1
-CH1
20

36

142 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Digital I/O Connections

Digital outputs Connector J4 Out provides sixteen general purpose digital outputs that can send
digital logic signals to external switches or logic devices.

• Minimum output current drive is 6 mA. Maximum output current drive is 20

mA.
Note The maximum output current can vary from unit to unit. The minimum
guaranteed output current is 6 mA and the maximum output current is 20
mA. You can connect the digital outputs in parallel to increase the current
drive. When connected in parallel, the station must be configured so that
all paralleled outputs are driven from the same event.

• The output is rated for a maximum of 30 V DC.

• Fused 12 V DC is available at pins 18 and 19.

Install a current-limiting resistor that is appropriate for the external device.

• If an output is not used, a jumper is not needed to complete a circuit.

• The outputs are optically isolated.

• The outputs are triggered by the system controller.

493.72 Digital I/O Digital I/O

Transition Board J4 Access Panel External Device

+12 Ext Voltage

Opto- 18
Coupler +CH2
2
-CH2
21

36

Cable specification The cabling information shown assumes a single cable destination (with an
overall shield). In other applications, the cable may have more than one
destination. For these applications an overall shield is not practical and non-EMI
connectors and back shells are permissible.

• 37-contact type D male EMI connector

• Back shell–EMI metallized plastic

• Cable–shielded twisted pairs as required (24 AWG minimum) with drain

wire(s) connected to the metallized backshell at the chassis.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 143

Digital I/O Connections

Digital I/O The digital inputs and outputs can be cabled to an optional digital I/O access box.
access panel The box is a convenient way to wire digital sources and destination to the Model
493.72 Digital I/O transition module.

493.72
Digital I/O

+12V

J3 IN

Connectors J10 and J20 on the

side of the module and on top
of the module are the same.
The top connectors are used
when the module is configured
for use in a console.

J4 OUT

144 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Workstation Connection

Workstation Connection
The workstation computer is connected to the Model 498.96 Processor module
installed in the VMEbus of the chassis. It is an Ethernet 10/100 Base-T
connection. The workstation computer must have a dedicated Ethernet
compatible connector.

498.98-2
Power PC

BFL
ABT

CPU
RST
PMC

Note If your processor has more than one Ethernet 10/100

Base T connection, use the connection labeled LAN
1.
m

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 145

Workstation Connection

CAUTION

The symbol shown here indicates that you must not connect
telecommunications equipment to the equipment showing this symbol.

Several modules have connectors that look similar to a phone connector. Special
cables are required. Installing telecommunications equipment cables can cause
equipment damage to the electrical components of the chassis or to your
telecommunications system.

146 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Remote Station Controller Connection

Remote Station Controller Connection

The optional Remote Station Controller (RSC) module requires a Model 498.71B
GRES III VMEbus module and a Model 493.71 Serial Interface transition
module to be installed in the chassis. The RSC can be connected to any of the
four J50 connectors of the serial interface. An interlock is permanently assigned
to each J50 connector (e.g., J50A= Interlock 1). Connecting an RSC
automatically assigns the RSC pod to the interlock.

The .hwi file defines which connector is used for each station. For more
information, see “Hwi file additions” on page 148.

The RSC control panel is available in two configurations; one provides an E-Stop
and HPS control for single station configurations, and the other provides a
Station Stop with no HPS control for multi-station configurations.

498.71B 493.71
GRES III Serial
Interface

+12V J50A

CLOCK OUT

Use Jumper Plug 055-634-101

EVENT OUT
in these connectors.
EVENT IN
J50B

J3 IN
Remote Station Control

J4 OUT

J50C

J5 DEBUG

F1 F2 F3 F4 Status

Interlock HSM HPS Test Manual Control

Enable /
J6 STATION J50D Reset High High Run Disable

Emergency Stop

Low Low Hold

Off Off Stop

J7 SERIAL
J7 SERIAL

049-876-501

m m
055-634-2xx (E-Stop)
or 055-634-3xx (Station Stop)

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 147

Remote Station Controller Connection

Hwi file additions In order to use one or more RSCs with your Model 493.10 Chassis, two sections
must be added to your .hwi file—an RSC section and a GRES III section.

Note Remote Station Controllers are not available with the optional 6 or 8-
station system configurations

Note If you specified RSC support when you ordered your test system, these
sections will be added to your .hwi file at the factory. For information on
editing your .hwi file to accommodate RSCs, see the MTS 793 Utility
Software manual.

148 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Service Connections

Service Connections
The Model 493.10 Chassis can have several service connectors. There are two
types of connectors:

• The chassis connection monitors the power supply.

• The connection on the I/O Carrier module monitors the output of each
mezzanine card.

Chassis service The J39 Power Monitor connector is located on the rear panel of the chassis. It
functions as test points for a service technician. It allows you to check all of the
power supply voltages along with the status of the overtemperature sensor and
the power fail circuit.

+5 Volts 2

+12 Volts 3

-12 Volts 4

+15 Volts 5

-15 Volts 6

+24 Volts 7

Ground 8

2.5 Volts Reference 9

Ground 11

Temperature 14

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 149

Service Connections

I/O Carrier service The J3 Service connector on the Model 493.40 I/O Carrier module provides the
monitor output from each of the four I/O option cards installed. It is an 8-pin RJ-
45 connector.

From To
Daughter J3 External
Boards Device

1 Slot 1 Monitor
2 Slot 1 Ground
3 Slot 2 Monitor
4 Slot 2 Ground
5 Slot 3 Monitor
6 Slot 3 Ground
7 Slot 4 Monitor
8 Slot 4 Ground

Important The signals at the J3 Service connector are provided for service
and troubleshooting only. These signals are defined by the I/O
option mezzanine cards that are installed on a respective Model
493.40 I/O Carrier module. Some of these signals may be
uncalibrated. Before use, take appropriate steps to determine the
characteristics of these signals.

150 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Cabling and Programming Series 407 Controllers

Cabling and Programming Series 407 Controllers

This section describes:

• Cabling and programming the FlexTest GT Controller to analog program

and feedback signals from a Series 407 Controller.

• Connecting FlexTest GT Controllers to interlock signals from a Series 407

Controller.

• Setting up a Series 407 Controller to send and receive signals from FlexTest
GT Controllers.
Important When used as a programmer, FlexTest GT Controllers do not have
automated mode switching capabilities. Control mode selection on
these controllers do not effect the control mode of the controller to
which they are sending test commands.

How to Provide Program to a Series 407 Controller

1. Cable the Series Series 793 and Model 407 Controllers together.

Cable the analog inputs and outputs between the Model 493.10 chassis and a
Model 407 Controller as follows:
Note Analog I/O connectors are located on the rear panel of the chassis.

A. Connect a Model 493.76 Analog Out BNC connector to the program

(analog) input on the 407 Controller. Connections for single or multiple
Model 407 Controllers are shown.

B. If you intend to monitor sensor feedback for data acquisition or control

feedback, connect the external controller’s conditioner output to a
Model 493.77 Filtered Analog Input BNC connector. For conditioner
output locations on various MTS devices, see “Miscellaneous
Conditioner Output Connections” on page 167.

C. Make interlock connections as appropriate. See “Connecting Interlock

Signals to 407 Controllers” on page 156.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 151

How to Provide Program to a Series 407 Controller

WARNING

Do not interrupt Model 493.10 Chassis power when you are programming
another controller. A power interrupt may cause the external controller to
react to a zero command and move the actuator unexpectedly.

Ensure that power cannot be removed accidently while a test is in progress.

For more detailed information about analog I/O connections, see “Analog I/
O Connections” on page 114.

Single 407 Controller Connections

Transition modules on the 493.77 Filtered
rear panel of the Model
493.76
Analog Out
PN 044-632-0XX 493.77
Filtered In
Analog Input
493.10 chassis are used for
Ch 1 Ch 1

This module includes

analog inputs and outputs. Ch 2 Ch 2
six BNC connectors
that provide filtered
Ch 3 Ch 3

analog inputs to a
493.76 Analog Out Ch 4 Ch 4 Model 493.45 A/D
mezzanine card.
This module includes six Ch 5 Ch 5

BNC connectors that Six analog inputs are

provide analog outputs from Ch 6 Ch 6
available with each A/D
a Model 493.46 D/A mezzanine card
mezzanine card. installed on the Model
493.40 I/O Carrier
Six analog outputs are
module.
available with each D/A
mezzanine card installed on J11
(Ch 1-4)
J11
(Ch 1-4)

the Model 493.40 I/O 407 Controller

Carrier module. J12 J12
(Ch 5-6) (Ch 5-6)

m m

152 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 How to Provide Program to a Series 407 Controller

Multiple 407 Controller Connections

Conditioner Conditioner
Monitor Monitor

493.76 Filtered
493.76 Analog Out Program In Analog Input
493.76
Analog Out
407 493.77
Filtered In

Ch 1
Ch 1

Ch 2
Ch 2

Ch 3
Ch 3

Conditioner Conditioner
Ch 4 Monitor Monitor Ch 4

Ch 5

Program In Ch 5

Ch 6
407 Ch 6

Conditioner Conditioner
J11
(Ch 1-4) J11
(Ch 1-4)

Monitor Monitor
J12
(Ch 5-6) J12

407
(Ch 5-6)
Program In

m
m

2. On the Series 793 Controller, create a station configuration file.

Use the Station Builder application to define controller resources to provide

program to the Model 407 Controller. When you create this type of station
configuration, you typically select an analog output for the channel output
resource, and Program Only or Program with Feedback for the channel type.

If you create a Program with Feedback channel, you typically select analog
inputs for the control mode input resources. This allows you to receive 407
control mode feedback. You also select unit type and dimension.
Note Because of wiring considerations between 793 and 407 Controllers, you
must assign an HSM in the station configuration file even if an HSM does
not control power to the external controller.

3. On the 793 Controller, adjust the program signals.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 153

How to Provide Program to a Series 407 Controller

Use the Station Manager application to adjust the full scale, polarity, gain,
and offset for the external controller channel (Display menu > Station
Setup).

If your station configuration includes sensor feedback, you can also adjust
the full scale, gain, polarity, and offset of the incoming sensor signals, as
well as limits.

4. On the 793 Controller, set up the program.

Define a program with the Function Generator, Basic TestWare, or

MultiPurpose TestWare applications.
Note It is good practice to use tapered wave shapes to apply the program
command to the external controller slowly.

The Basic TestWare application allows you to create simple test programs
that do not require complex signal management or mode switches for station
configuration files. To create more sophisticated test programs use the
optional MultiPurpose TestWare application.

5. On the 407 Controller, select the External program source.

On the Function Generator menu, select Waveform, then scroll through

the selections to select External.
Note The operational sequence in the following step may not be intuitive. This
sequence is necessary because of how the 793 and 407 Controllers are
cabled together. The following step assumes that at power up, hydraulics
are off, the 793 Controller has a hydraulic and a program interlock active,
and the 407 Controller has a hydraulic interlock active.

6. Apply the program.

To apply the program from the 793 Controller to 407 Controller:

A. On the Station Manager application’s Station Controls panel, click

Reset to clear the Hydraulic interlock.

B. On the Station Manager application’s Station Controls panel, click

HPU Power Low and then HPU Power High to turn on the HPU.

C. On the Station Manager application’s Station Controls panel, click

HSM Power Low and then HSM Power High to turn on the HSM.

154 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 How to Provide Program to a Series 407 Controller

D. On the 407 Controller, clear the hydraulic Interlock:

– Press the Alt Function button.

–Press the Reset button (“9” on the key pad). The Interlock indicator
on the front panel should extinguish.

E. On the 407 Controller, apply hydraulic pressure with the Hydraulic

Pressure buttons.

F. On the 407 Controller, press Run. This step readies the 407 Controller
to receive program from the 793 Controller.

G. On the Station Manager application’s Station Controls panel, click

Reset to clear the Program interlock.

H. On the Station Manager application’s Station Controls panel, click the

(Program Run). This step sends program from the 793 Controller
to the 407 Controller.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 155

Connecting Interlock Signals to 407 Controllers

Connecting Interlock Signals to 407 Controllers

The Model 793 Controller monitors digital I/O interlock signals through the
Model 493.74 HSM transition module’s J43A and J43B connectors. Use these
connectors when connecting to Model 407 Controllers.

Model 493.74 HSM transition module connectors are as shown in the figure that
follows.

Interlock cabling to Model 407 Controllers depends on your system’s

configuration. There are three possible configurations:

• Single station—one Model 407 Controller runs a single test program.

• Multiple stations—two or more independent Model 407 Controllers each

run different test programs.

• Master-dependent station—one master Model 407 Controller daisy-chained

with other dependent Model 407 Controllers together run a single test
program.

Single 407 Controller The following figure shows how to cable interlocks for a single station Model
interlock connections 407 Controller to the Model 493.10 Chassis (via its Model 493.74 HSM
transition module). Use the specified interlock cable (PN 056-455-0xx) to make
these connections.

Digital
I/O Connector
Hydraulic
Interlock,
ActiveLow To
407
Run/Stop, Controller
ActiveHigh

To
493.74
HSM
Transition Jumper

Jumper

Jumper

Interlock Cable PN 056-455-0XX

156 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Connecting Interlock Signals to 407 Controllers

How to jumper the The following figure shows how to cable the hydraulic terminal on a single
hydraulic terminal on a station Model 407 Controller.
single station Model 407
Controller
407 Controller

Hyd
No Connection In

Hyd
Out Jumper Plug PN
049-635-901
Intlk

No Connection In

Intlk
Out Jumper Plug PN
049-635-901

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 157

Connecting Interlock Signals to 407 Controllers

Multiple 407 Controller The following figure shows how to cable interlocks for multiple Model 407
interlock connections Controllers to the Model 493.10 Chassis (via its Model 493.74 HSM transition
module). Use the specified interlock cable (PN 056-455-0xx) to make these
connections for each Model 407 Controller station.

Digital
I/O Connector
Hydraulic
Interlock,
ActiveLow To
407
Run/Stop, Controller
ActiveHigh (Station 1)

To
493.74
HSM
Transition Jumper

Jumper

Jumper

Interlock Cable PN 056-455-0XX

Digital
I/O Connector
Hydraulic
Interlock,
ActiveLow To
407
Run/Stop, Controller
ActiveHigh (Station 2)

To
493.74
HSM
Transition Jumper

Jumper

Jumper

Interlock Cable PN 056-455-0XX

158 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Connecting Interlock Signals to 407 Controllers

How to connect The following figure shows how to cable hydraulic terminals on multiple station
hydraulic terminals on Model 407 Controllers, where each Model 407 Controller can run an independent
test program. Repeat this scheme for each additional Model 407 Controller.
multiple station 407
Controllers
407 Controller

Hyd
No Connection In

Hyd
Out Jumper Plug PN
049-635-901
Intlk

No Connection In

Intlk
Out Jumper Plug PN
049-635-901

407 Controller

Hyd
No Connection In

Hyd
Out Jumper Plug PN
049-635-901
Intlk

No Connection In

Intlk
Out Jumper Plug PN
049-635-901

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 159

Connecting Interlock Signals to 407 Controllers

Interlock connections The following figure shows how to cable interlocks when a master Model 407
for master/dependent Controller is daisy-chained with three other dependent Model 407 Controllers to
407 Controllers run a single test program on a FlexTest GT Controller (via its Model 493.74 HSM
transition module). Use the specified four-channel master/dependent interlock
cable (PN 056-448-9XX) to make these connections for each Model 407
Controller station.

Digital
I/O Connector
Hydraulic
Interlock
Active Low To
407 Controller
Run/Stop Master
Active High

To
493.74
HSM Jumper
Transition
Hydraulic
Jumper Interlock To
Active Low 407 Controller
Run/Stop Dependent
Active High

Jumper

Hydraulic
Interlock
Active Low To
407 Controller
Run/Stop Dependent
Active High

Hydraulic
Interlock
Active Low To
407 Controller
Run/Stop Dependent
Active High

Master/Dependent Interlock Cable

(PN 056-448-9XX)

160 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Connecting Interlock Signals to 407 Controllers

How to connect The following figure shows how to cable hydraulic terminals on three Model 407
hydraulic terminals on Controllers in a master-dependent daisy-chain. Note that the last dependent
controller in any daisy-chain must have jumper plugs installed in its Hyd Out
master-dependent 407 and Intlk In terminals.
Controllers

Master 407 Controller

Hyd
Dependant 407 Controller
No Connection In

Hyd
Last Dependant
Hyd
Out In 407 Controller

Hyd Hyd
Intlk
Out In
No Connection In

Intlk Hyd
Intlk
Out In
Out Jumper Plug PN
049-635-901
Intlk Intlk
Out In

Intlk
Out Jumper Plug PN
049-635-901

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 161

Sending and Receiving Signals to a Model 407

Sending and Receiving Signals to a Model 407 Controller

After cabling the Model 407 Controller, you must configure it to receive and send
signals from the FlexTest GT Controller. The tables below list typical menu
settings. Refer to the Model 407 Controller Product Information Manual for
more information.

407 Configuration Menu

PARAMETER SETTING
Eng Units —
EOC Act —
CYC Src PROGRAM
SetPt R 150%/s (or highest)
Span R 300%/s (or highest)
Hyd Cnfg —
Intlk Cnfg MASTER*
P/V Sens —
Span Cnfg 1X
CMD Sel EXT IN
Prog Out —

* Always designate one 407 in a station as a MASTER. If there are

other 407s in the same station, daisy-chain their interlocks and
designate them as DEPENDENT.

407 Function Generator Menu

PARAMETER SETTING
Wvform EXTERN
Freq —
Setpnt —
Span —
Preset —

162 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Sending and Receiving Signals to a Model 407

407 Amplitude Control Menu

PARAMETER SETTING
Ampl Cntrl OFF
Fdback —
Mean —
Ampl —
AMC Gain —

407 Digital I/O Menu

PARAMETER SETTING
Din1 Definition Program in RUN
Din1 RUN/STOP
Din1Pol ACT HI
Din2 Definition Hydraulic Interlock
Din2 Interlock
Din2Pol ACT LOW
Dout1 Definition Hydraulics ON*
Dout1 HYD OFF
Dout1Pol ACT LOW
Din2 Definition —
Dout2 —
Dout2Pol —

* Or Run/Stop (ACT HI), Interlock (ACT LOW), None (ACT HI).

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 163

Connecting Interlock Signals to 458 Controllers

Connecting Interlock Signals to 458 Controllers

FlexTest GT Controllers monitor digital I/O interlock signals through the Model
493.74 HSM transition module.

Jumper

Jumper
To
493.74
HSM To
Transition 458.XX
Controller

Jumper

Run/Stop Program Interlock Cable

(PN 056-455-2xx)

Jumper

To
To 458.XX
493.74 Controller
HSM
Transition

Hydraulic Enable Interlock

Cable (PN 056-455-1XX)

164 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Eurotherm Temperature Controller Connection

Eurotherm Temperature Controller Connection

When equipped with a Model 498.71B GRES III plug-in module, your controller
can program and control one or more Series 2200/2400 Eurotherm Temperature
Controllers via the J50 serial connectors on a Model 493.71 Serial Interface
transition module.

In order to use this configuration, a special temperature controller resource must

be added to your .hwi file.

J50 connectors The temperature controller can be connected to any of the four J50 connectors on
the serial interface.

Temperature controller For more information on adding the Eurotherm hwi file resource, see the MTS
hardware resource 793 Utility Software manual.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 165

Eurotherm Temperature Controller Connection

Program the Use the Station Builder application to configure a Eurotherm temperature
temperature controller controller.

.
498.71B 493.71
GRES III Serial
Interface

+12V J50A

CLOCK OUT Use Jumper Plug 055-634-101

EVENT OUT
in these connectors.

EVENT IN
J50B

J3 IN

J4 OUT

J50C

J5 DEBUG

J6 STATION J50D

Eurotherm
Temperature
J7 SERIAL
Controller
J7 SERIAL

049-876-501

m m
056-172-0xx (for Model 652/653 Temperature Chambers)
056-128-0xx (for Model 651 Temperature Chambers)

166 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Miscellaneous Conditioner Output Connections

Miscellaneous Conditioner Output Connections

The following table shows connector assignments for various MTS products you
can use with your the Model 493.10 Chassis.

Conditioning Sensors with Other MTS Products

MTS PRODUCT SENSOR OUTPUT
Model 408.81 Testing Panel/ Sensor output is available at the rear-panel connector J201
Model 408.82 DC Conditioner or J202.
Model 409.81C Temperature Controller Temperature output (via an analog signal) is available at
rear-panel connector J1.
Model 448.82/85 Test Controller with Sensor output is available at rear-panel connector J335.
Model 448.21/22 AC and DC Conditioners
Ensure sensor conditioners are set as follows:
X1: 2&3
X2: 2&3
Model 458.10/20 MicroConsole with Model Sensor output is available at the MicroConsole rear-panel
458.11/12/13/14 AC and DC Controllers connector Jx03. Connector Jx03 represents the module
location (J100–J600).
MicroConsole jumper Jx00 should be set to 1&2 (standard
setting).

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 167

Cabling for External Command Inputs

Cabling for External Command Inputs

Cabled properly, Model 793 Controllers can receive programming from an
external controller.

How to Enable and Run External Command Inputs

1. Cable the controllers.

Cable the external programmer analog out connector to a Model 493.75

Analog In module BNC connector.

External Analog Source

Select Waveform Breakpt

+100% FS 5 - 05%
Normal Full Scale
410.81 Invert
0

Function +100% FS
Generator
Control Mode Output Mode Output to 0 Ramp Time 1 (sec) Ramp Time 2 (sec)
FS FS
Output Finish
Local Trigger
Main Sync Single Cycle Manual 0 0
Local Ret to t t
Remote Local Cycle Start & Stop Zero Bkpt Hold Hold Time (sec)
FS
t 0
Frequency (Hz)

From
I/O Carrier
Module

2. Allocate external command resources in Station Builder.

Using Station Builder, allocate controller resources to receive programming

from an external controller.

3. Adjust the command signal with Station Manager.

4. Start the External Command.

168 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Cabling and Using External Readout Devices

Cabling and Using External Readout Devices

Cabled appropriately, your controller can send station signals to external readout
devices such as oscilloscopes and digital-volt-meters. You define which signal is
sent to the readout device using the Station Setup window’s Readout panel.

For more information, see “Working with Readout Devices” in the MTS 793
Control Software manual.

Station signal diagram The block diagram identifies the station signals you can monitor.

Compensated
Command Command Output

Valve Driver Signals

from Other Modes of
PIDF Controller this Channel
F
I

Command Output Valve Driver

Test P FLF Signal
Scalar D/A
Command Compensator - - -
D S (convert control
Mode signal to counts )
Switch

Closed
Absolute Error Loop
Generator

(Dela P/Load Cell Feedback) Stabilization

Feedback
Input Signal Conditioning Signal

Inner/Outer
Error Detector
(LVDT Feedback) Active
Feedback
Input Signal Conditioning Signal

Absolute Error Error Sensor Signal Stabilization

Station signal Except for time and auxiliary data signals, station signals listed in your software
descriptions windows include the name of their associated control channel. For example, if
your channel is labeled Ch. 1, the available station signals would be Ch.1
Output, Ch. 1 Command, and so forth.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 169

Cabling and Using External Readout Devices

The following table provides a description of the various station signals.

Station Signals
SIGNAL DESCRIPTION
Time Displays the time reference signal derived from the internal clock that
increments continually. This signal exists to support data acquisition by test
program applications, such as Basic TestWare and MultiPurpose TestWare. It is
not practical to monitor the time signal with an external readout device.
Rollover Time Displays the time reference signal derived from the internal clock that resets
every hour. Like the time signal, this signal exists to support data acquisition
by test program applications. It is not practical to monitor the hourly rollover
time with external readout devices.
Output Displays the test control signal sent to the valve driver in volts.
Command Displays the program command signal in engineering units.
Comp. Cmd Displays the value of the compensated command signal in engineering units.
This signal is only valid when using PVP, PVC, AIC, APC, or ALC
compensators.
Count Displays the number of segments played out so far in the selected control
channel. When using a Station Manager meter, this signal is only available for
the Timed meter.
Error Displays the error signal in engineering units. The error is the difference
between the command signal and the sensor feedback signal.
Abs. Error Displays the absolute value of the error signal in engineering units.

170 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 How to Send Signals to External Readout Devices

How to Send Signals to External Readout Devices

1. Cable your controller to the readout device.

Cable your FlexTest IIm analog output connector to the readout device.
Analog I/O connectors are located on the rear of the test processor chassis.
Connect an external readout device analog input to a BNC connector on a
Model 493.76 Analog Out module.

493.76
Analog Out Analog Monitor

From
I/O Carrier
Module

2. Create a readout channel with Station Builder.

3. Adjust the readout signal in Station Manager.

Use Station Manager to adjust the readout signal.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 171

Multi-Box I/O Module

Multi-Box I/O Module

The optional Model 493.43 Multi-Box I/O module allows multiple controllers to
share a master hardware synchronization clock and pass station interlock state
information between each other. In addition, this front panel module also
provides user station interlock inputs and outputs.

Module features • 4 optically isolated station interlock inputs (J8)

• 4 station interlock outputs with relay contacts (J9)

• Box In (J51) and Box Out (J52) to connect multiple MTS controller boxes to
share station interlock status and the master synchronization clock.

• 32 Mb FLASH disk on board

• Box address switch (software readable) allows you to set a unique address
for each controller in a multi-box chain.

J8 Interlock IN
Connector J8 Interlock IN provides four station interlock inputs that can be
connected to external interlock chains.

• Inputs 1 through 4 are dedicated as a station interlock.

• All inputs are optically isolated.

Electrical Refer to the following table for input electrical specifications:

specifications

PARAMETER SPECIFICATION

Input type Contact (Open = Interlock)

Logic (0 = Interlock)

Input debounce time 12-16 msec

Input resistance 2.7 kΩ

Minimum input off voltage 0.8 V (Interlock)

Maximum input voltage 26 V

Minimum input on voltage 3 V @ 1 mA (No Interlock)

172 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 J9 Interlock OUT

Cable specifications • Connector: 25-contact, type D, male, EMI

• Backshell: EMI, metalized plastic

• Twisted pairs with overall braided shield. Braided shield is terminated to

conductive backshell at the chassis.

Jumper plug Use MTS jumper plug PN 100-079-233.

J9 Interlock OUT
Connector J9 Interlock OUT provides four station interlock outputs that can be
connected to a multiple MTS controller box interlock chain.

From J9 To
Chassis External Devices

1 +
Interlock Status
Output 1
6 -

2 +
Interlock Status
Output 2
7 -

3 +
Interlock Status
8 Output 3
-

4 +
Interlock Status
9 Output 4
-

Electrical Normally, Open = Interlock, 1 A maximum @ 30 V DC/AC maximum

specifications

Cable specification • Connector: 9-contact, type D, male, EMI

• Backshell: EMI metalized plastic

• Twisted pairs with overall braided shield. Braided shield is terminated to

conductive backshell at the chassis.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 173

J51 Box In

J51 Box In
The J51 Box In connector provides an interface for connecting multiple MTS
controller boxes together to allow sharing of station interlock status and a master
synchronization clock.

J51
Box In

+clk in 1
/intlk in 1 2
/intlk in 2 3
signal return 4
/intlk in 3 5
/intlk in 4 6
signal return 7
master/dependent in 8
-clk in 9
/intlk return out 1 10
/intlk return out 2 11
12
/intlk return out 3 13
/intlk return out 4 14
15

Master/dependent The master/dependent input setting (connector pin 8) determines whether a

input controller box is master or dependent in the multibox chain. If this pin is
jumpered to ground the controller is dependent, if not it is the master. Upon a
CPU or interlock reset, software checks the state of this pin, and configures the
controller box accordingly.

Cable specification Use MTS cable PN 056-534-1xx.

174 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 J52 Box Out

J52 Box Out

The J52 Box Out connector provides an interface for connecting multiple MTS
controller boxes together to allow sharing of station interlock status and a master
synchronization clock.

J52 Box Out

+clk in 1
/intlk out 1 2
/intlk out 2 3
4
/intlk out 3 5
/intlk out 4 6
7
test 8
-clk out 9
/intlk return in 1 10
/intlk return in 2 11
signal return 12
/intlk return in 3 13
/intlk return in 4 14
signal return 15

Last controller jumper The last controller box in a chain must have a jumper plug (MTS PN 100-079-
126) on its J52 Box Out connector. This jumper allows the return of the
composite station interlock signal for all controllers in the chain to monitor.

Note If there is only one controller, a jumper is still required on its Box Out
connector.

Cable specification Use MTS cable PN 056-534-1xx.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest GT Controller Connections 175

J52 Box Out

176 FlexTest GT Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

Chapter 4
FlexTest IIm Controller Connections
Note For information on connecting power cables, see “Connecting the
Console and Chassis Power” on page 61.

Note For information about CE compliance, see “CE EMC Compliant Cabling”
on page 83.

Contents Workstation Connection 178

Sensor and Valve Connections 179
ADDA Module Connections 183
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
Programming Eurotherm Temperature Controllers 209
Cabling for External Command Inputs 210
Cabling for External Command Inputs 210
Cable Part Numbers 216

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 177
Workstation Connection

Workstation Connection
Connect the computer’s network interface card to the 10/100 BaseT connector on
the front panel of the processor installed in slot 1.

Processor
24x1
Processor

PN 051-996-803

DEBUG
BEI

ABT CPU

PMC
RST

10/100 BASET
m

178 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 Sensor and Valve Connections

Sensor and Valve Connections

The Model 497.01 Analog Chassis connectors J101 through J1601 are 15-pin D-
type connectors located on the chassis rear panel. They connect either a valve
driver to a servovalve or a conditioner to a transducer. Connectors J102 through
J1602 provide a second connection for dual conditioners, dual valve drivers, or
three-stage valve drivers.

To/From J101 - J1601 To/From

AC/DC Conditioner Transducer or
or Valve Driver Servovalve
1 + Excitation
2 - Excitation
3 Guard
4 + Feedback
5 - Feedback
6 Serial Ground (future)
No Connection 7 Shield Drain
8 Serial Clock (future)
9 + Valve Command
10 + Excitation Sense
11 - Valve Command
12 + Feedback Return (+ Valve 2)
13 - Feedback Return (- Valve 2)
14 Serial Data (future)
15 - Excitation Sense
Shield to Backshell

Cable specification Cable (sensor)—Two twisted shielded pairs with an overall braided shield (MTS
material 003-724-401). Cable outer shield drain wire to pin 7 (optional) and cable
outer braid folded back under the EMI backshell clamp.

Cable (valve)—18 AWG, 4-conductor shielded (Belden 9418 or equivalent).

Cable outer shield drain wire to pin 7 (optional) and to the EMI backshell.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 179
Sensor and Valve Connections

AC sensor connection
AC Sensor
(LVDT)

+FB
-FB
Inner
Guard
+EX
-EX

DC sensor connection
4-wire connections are the
Outer Drain
most common. An 8-wire Shield 7
Braid
connection is typically used
Inner
for long cables. Guard 3

The additional wires for an -FB 5 DC Sensor

8-wire connection are -FBR 13
shown with dashed lines.

+FB 4
+FBR 12

-EX 2
-EXS 15

+EX 1
+EXS 10

180 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 Sensor and Valve Connections

Single-valve
connection
+ Valve
9 A
Command 1

– Valve
11 D
Command 1

Dual-valve connection
P2

Shown for valves phased the D

same hydraulically. For valves
phased opposite hydraulically,
reverse A and D on P2.

+ Valve P0 P1
Command 1 9 A

– Valve 11 D
Command 1

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 181
Sensor and Valve Connections

Sample control The following figure illustrates sample connections to a sensor and a servovalve.
channel

Valve Driver DC Conditioner AC Conditioner

Signals Signals Signals

J1401 J1301 J601 J501 J201 J101

Force

Force
(load
sensor)
Valve

Valve

LVDT

LVDT (displacement sensor)

Model 497.01 Analog Chassis Rear Panel

182 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 ADDA Module Connections

ADDA Module Connections

In order to process A/D and D/A signal conversion, you must connect your
Model 497.01 Analog Chassis to your Model 498.65 ADDA plug-in module. The
following graphic illustrates the connections for a Model 497.01 Analog Chassis
containing four AC conditioners, dual DC conditioners, and valve drivers.

Valve DC AC
Drive Conditioner Conditioner
Signals Signals Signals
J28 J27 J24 J23 J22 J21
497.01
Analog
Chassis

The analog inputs and

outputs use the top
four connectors

498.65 498 498

ADDA
ANALOG Filter
OUT Input

0
A
9
D
1
2 3
7 8

4
R
CH 1 CH 1
6

S
FAIL
050-053-401
RESET
CH 2 CH 2

J11
1
1

CH 3 CH 3

J12
1
2

CH 4 CH 4

048-202-102 J13
1
3

J1
1 CH 5 CH 5
4

E
X CH 6 CH 6
T

047-808-502
050-053-401 CH 7 CH 7

J
1
5
CH 8 CH 8

J
1
6
J11 J11
(CH 1-4) (CH 1-4)

J J11 J11
1
7 J17
J12 J12
J (CH 5-8) (CH 5-8)

J18
1
8

047-808-502
m

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 183
ADDA II Connections

ADDA II Connections
Each optional Model 493.50 ADDA II module supports up to four mezzanine
cards. Each installed mezzanine card is assigned a specific ADDA II module
front panel connector (J11–J18).

A hardware interface file (.hwi) defines each type of module (and their associated
mezzanine cards) and maps each module location for the system software. The
hwi file and the physical locations for each type of module and associated
mezzanine cards must match. Also, the ADDA II module address setting (on the
module) must match the .hwi file address.

The following mezzanine cards can be installed:

– Model 493.55 A/D

– Model 493.56 D/A

– Model 493.57 DSPAD

– Model 493.59 Universal Encoder

ADDA II Module I/O The Model 493.55 A/D, Model 493.57 DSPAD, and Model 493.56 D/A
Connections mezzanine cards can be installed in the Model 493.50 ADD II module assembly
as needed. A connection from the front panel connector to a rear panel BNC
transition module allows easy access to the analog channels.

184 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 ADDA II Connections

Note The external analog source can be a stand-alone function generator,

another controller, or a computer controlled analog output.

External Analog Source

Select Waveform Breakpt
+100% FS 5 - 05%
Normal Full Scale
410.81 Invert
0

Function +100% FS
Generator
Control Mode Output Mode Output to 0 Ramp Time 1 (sec) Ramp Time 2 (sec)
FS FS
Output Local Finish Trigger
Main Sync Single Cycle Manual 0 0
Local Ret to t t
Remote Local Cycle Start & Stop Zero Bkpt Hold Hold Time (sec)
FS
t 0
Frequency (Hz)

Analog Monitor

Daughter
Board 1

Daughter
Board 2

Daughter
Board 3

Daughter
Board 4

ADDA II Module I/O Connections

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 185
ADDA II Connections

Analog inputs The analog-to-digital mezzanine cards accommodate up to eight analog input
signals. Each A/D input signal must be within ±10 volts.

• Analog inputs can be connected at the BNC connectors of a Model 493.81

Analog In transition module and the outputs from this module are connected
to the Model 493.50 ADDA II module. This configuration is typically used
for DSPAD mezzanine cards that provide on-board digital filtering.

• Analog inputs can be connected at the BNC connectors of a Model 493.83

Filtered Analog Input transition module and the outputs from this module
are connected to the Model 493.50 ADDA II module. This configuration is
typically used for A/D mezzanine cards that requires filtering.

To From
A/D 493.81 Analog In
Module
1 +
Input 1
2 -
3 +
Input 2
J 11 , J 1 3 4 -
J15, J17 5 +
Input 3
6 -
7 +
Input 4
8 -

1 +
Input 5
2 -
3 +
Input 6
J12, J14 4 -
J16, J18 5 +
Input 7
6 -
7 +
Input 8
8 -

186 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 ADDA II Connections

D/A connections Digital-to-analog mezzanine cards support up to eight program or readout signals
to external devices. Each D/A signal is an analog output within ±10 volts.

• Each readout signal is from a 16 bit digital to analog converter.

• Each output is a ±10 V analog output.

• The Model 493.56 D/A mezzanine card provides analog signals to the
Model 493.82 Analog Out transition module. Analog outputs are available
at the BNC connectors of a Model 493.82 Analog Out transition module for
external devices (DVM, oscilloscope).

To
From
External
D/A
Device
1 -
Output 8
2 +
3 -
Output 7
J 11 , J 1 3 4 +
J15, J17 5 -
Output 6
6 +
7 -
Output 5
8 +

9 -
Output 4
10 +
11 -
Output 3
J12, J14 12 +
J16, J18 13 -
14 + Output 2
15 -
Output 1
16 +

ADDA II Universal Each encoder requires a Model 493.59 Universal Encoder mezzanine card
Encoder connections installed on the Model 493.50 ADDA II module.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 187
ADDA II Connections

Up to sixteen encoders can be connected to the Model 493.80 ADDA II Encoder

Transition module when the Model 493.50 ADDA II module is fully populated
with Universal Encoder cards.

To/From
Encoder Transition
Module
1 Return Gnd
2 Index Ser Clk Input 4
3 B/Interrogate
J 11 , J 1 3 4 A/Serial Dat a
J15, J17 5
Return Gnd
6
Index Ser Clk Input 3
7 B/Interrogate
8 A/Serial Dat a

9 Return Gnd
10 Index Ser Clk Input 2
11 B/Interrogate

J12, J14 1 2 A/Serial Dat a

J16, J18 1 3 Return Gnd
1 4 Index Ser Clk Input 1
1 5 B/Interrogate
1 6 A/Serial Dat a

188 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 Hydraulic Connections

Hydraulic Connections
You must connect your external hydraulic equipment to the Model 497.05
Hydraulic Control Panel. The FlexTest IIm hardware supports control of up to
four hydraulic stations simultaneously.

J25

Hydraulic Power Unit

J28C J28B
POTS

J28D J28A
GNINRAW

.egat
yrujni erelov suodrazaH
ves esuac
naC
.htaed ro
dna rew
secruos re op niam ffo nruT
wop e
.lenap gnilpitlum lla
nepo erofe
b

HSM

HSM

HSM

HSM

FlexTest IIm Hydraulic Connections

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 189
HPU Connections

HPU Connections

Connector J25 To/From J25 To/From

497.05 HPU
controls the hydraulic
power unit. 2 Interlock 1

3 Interlock 2

4 HPS Ground

5 Hyd Interlock Reset HPU

7 Interlock Common

9 HPU Power

10

12

11 HPU Start

14 Interlock 3

15 HPU High

16 + Defeat

17 HPU Common

18 Voltage (Common)

+24 V 19 HPU Defeat

Cable specification • P25 is a 24-contact CPC female connector (AMP Incorporated)

• Cable—18 AWG, 14 conductor rated for 300 V

• Compatible with MTS 24 V DC or 115 V AC control cables

• Cable assembly numbers PN 039-708-7XX (24 V DC), 039-708-8XX (115

V AC)

• Uses special MTS cable material (PN 044-297-301)

Jumper plug If an HPU is not connected to the digital controller, a jumper plug is required to
maintain the integrity of the interlocks. Use jumper plug 039-719-901 or jumper
pins: 2 and 3; 3 and 7; 9 and 19; 10 and 12; 11 and 16; 17 and 18.

190 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 HSM Connections

HSM Connections
The outputs provide 24 V DC to turn on the HSM solenoids.

From J28 To HSM Connector J28 controls the

Hydraulic I/O Solenoids low-pressure and high-
pressure solenoids of a
1 Low Pressure hydraulic service manifold.
2 DC Common

4 High Pressure

Cable specification • P28 is a 4-contact CPC male connector (AMP Incorporated).

• Cable—18 AWG/2 connector type SJOOW-A for on/off HSMs 18 AWG/3

connector type SJOOW-A for high/low HSMs

• Cable assembly numbers:

– 290.XX HSM, on/off, 24 V DC, PN 039-705-3XX 18/2 SJO

– 290.XX/294.XX HSM, high/low, 24 V DC, PN 039-705-5XX 18/3

SJO

– 298.11 HSM, on/off, 24 V DC, PN 039-708-1XX 18/2 SJO

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 191
Interlock Connections

Interlock Connections

Remote Interlock
497.05 Hydraulic J52 (Jumper Plug,
Inputs (3 for each
hydraulic channel) Control Panel (046-350-701)

J8 J51

J52

J26

E-Stop

047-807-8xx

497.01 Analog Chassis 046-350-602

J51
051-074-601

J52
051-074-501
498.71B 498
24X1 24X1 GLOBAL 498.65 System 498
Processor Processor RESOURCES ADDA Digital DIGITAL I/O
III I/O TRANSITION
MODULE
+5V +12V
DEBUG

DEBUG

J3A J3B
Sta 1 Sta 2 +5V +12V
Intlk Intlk

BEI BEI

J2 Paddle Board
J3 IN
ABT CPU ABT CPU

PMC PMC
RST RST

049-792-301
10/100 BASET

10/100 BASET

J3C J3D
Sta 3 Sta 4
Intlk Intlk

to 498
J4 J5
J4
497
Hyd
J5
497
Intlk

backplane
050-774-501
J6 (same slot J4 OUT

as 498.71)
J6
J6
I/O
J7
I/O

to J2 (rear) to J2 (rear)

MOTOROLA
mm m m
049-792-201
The System Digital I/O and Digital I/O transition modules along with the paddle
board are located on the rear panel of the Series 498.XX Test Processor.

192 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 Interlock Jumper Plugs

Interlock Jumper Plugs

Several jumper plugs must be installed to maintain the integrity of the interlock
chain. Each jumper plug represents a place where you can add a custom
connection to the interlock chain.

Model 497.05 Any interlocks connected to the hydraulic control panel will generate a hydraulic
Hydraulic Control interlock which shuts down the hydraulic power supply. This type of interlock
Panel shuts down all test stations.

• Connector J52 requires a jumper plug to close the interlock chain.

• If J26 is not connected, it needs a jumper plug.

• Connectors J15A–J17C (Remote Interlock Inputs) each require a jumper

plug unless it is being used. Jumper both pins of each connector.

Series 498 System Any interlock connected to the Series 498 System Digital I/O transition module
Digital I/O can generate a station interlock to disable pressure (the HSM) to that station.

The Series 498 System Digital I/O transition module supports:

• Four stations of Hydraulics On digital inputs

• Four stations of Hydraulics Hi digital inputs

• Four stations of Hydraulics Enables

• Four stations of Remote Stop/Run outputs

• Four stations of program interlocks

• Four stations of auxiliary interlocks

• Four stations of 497 interlock inputs

• Four stations of 497 interlock outputs

• Four stations of auxiliary interlock inputs

• Four stations of auxiliary interlock outputs

• Two spare digital inputs

• Two spare digital outputs

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 193
Interlock Jumper Plugs

The interlock connectors require jumpers under the following conditions:

• If you do not use the external hydraulic/program interlocks on any of the D-

15S connectors (J3A Sta 1, J3B Sta 2, J3C Sta 3, and J3D Sta 4). Use an
external jumper plug (PN 052-750-501) on each connector not used.

• If you use the system digital I/O as a stand-alone unit. That is, if you do not
connect the System Digital I/O Module to a 497.xx Chassis, you must use an
external jumper plug (PN 050-774-701) on the J5 497 Intlk connector.

This shows how to connect an external switch or set of relay contacts to one of
the station interlocks:

J3A-J3D
+12 VDC
External Device
x1—x4 Opto-
Coupler
1
External Switch
or 9
Relay Contact
x9—x11
7

194 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 Serial Communications

Serial Communications
Each chassis communicates with each other through a serial communications
cable.

Model 497.05
J41 J42
Hydraulic Control
Panel

046-350-902

Model 497.01
Analog Chassis J41
J42

Debug
498.71B
24X1 24X1 GLOBAL 498.65

056-027-101
Processor Processor RESOURCES ADDA
III
DEBUG

DEBUG

BEI BEI

ABT CPU ABT CPU

PMC PMC
RST RST
10/100 BASET

10/100 BASET

Model 498.22
Test Processor

MOTOROLA
mm

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 195
Digital I/O Connections

Digital I/O Connections

Digital I/O hardware enables two-way communication between your test and
external logic devices.

This transition module provides user 498

DIGITAL I/O 498
This transition module
digital I/O the built-in digital I/O reserves system DIO.
TRANSITION System
MODULE Digital
I/O

+5V +12V

access panel (FTIIm) +5V +12V

J3A
Sta 1
J3B
Sta 2
Intlk Intlk

J3 IN

046-442-302 --
For the connectors on this
J3C J3D

J3
Sta 3 Sta 4

Connects to back of
Intlk Intlk

built-in module module see “Interlock

(FTIIm) Connections” on page 192
J4 J5
497 497
Hyd Intlk

J4 OUT

J6 J7

A digital output
I/O I/O

J4 Model 498.22
produces a logic Chassis Backplane
signal to an external
circuit.

71
498.
BAL
GLOURCES
DIGITAL I/O ACCESS PANEL RES
O

DIGITAL IN1-16 FAIL

N
RU
DIGITAL OUT1-16
T
OR
AB

Digital Input Digital Output SE

T
RE
Channels Channels
1-2 9 - 10 1-2 9 - 10 J4 J4
NE
T

J3

LE
NSO
CO
J5

3-4 11 - 12 3-4 11 - 12

A digital input can 049-792-201 J4

NET

be a mechanical 5-6 13 - 14 5-6 13 - 14

Connects to J2
switch or a logic on back of
signal. module.
L
RIA

Paddle
SE
J7

7-8 15 - 16 7-8 15 - 16 Board

196 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 Digital I/O Connections

Digital inputs • Digital inputs can be wired to allow the input from a switch contact, a relay
contact, or a logic signal.
• All digital inputs are optically isolated at the Series 498 Digital I/O
transition module.
• For example, an action defined in the can be selected, in the Station Setup
window’s Digital Input panel, as an Action.

• The digital inputs are used by the Digital Input process in the MultiPurpose
TestWare application. They can also be monitored from the Station Manager
application.
• You can use the Event-Action Editor window to define an action that occurs
in response to a digital input event. The defined action can then be selected
in the Station Setup window’s Digital Input panel.

• Sixteen jumpers located on the Series 498 Digital I/O transition module allow
each input to be configured for a relay contact or logic signal.
• Each digital input connector on the built-in Digital I/O Access panel (FlexTest
IIm) supports two channels.
• Each digital input supports a differential TTL to +30 V DC signal or a
switch or relay contact switching the on-board 12 V supply.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 197
Digital I/O Connections

This shows how to

Digital I/O 498 Digital I/O
connect an external Access Panel Transition Module
switch or a set of relay
+12 VDC
contacts to channel 1 of J1 - 2
the digital inputs. 3
Opto-
External Device +CH1 X1 Coupler
6
1 2
-CH1
2
External Switch
or 1 +12 VDC
Relay Contact
7 12 volt common

This shows how to Digital I/O 498 Digital I/O

connect an external logic Access Panel Transition Module
signal to channel 4 of the External Device
+12 VDC
digital inputs. J3 - 4
Opto-
X4 3
Coupler
+CH4
9
1 2
-CH4
4

5 +12 VDC

8 12 volt common

198 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 Digital I/O Connections

Digital outputs • Digital outputs provide an optically isolated open collector/open emitter
output.

• The digital outputs are controlled by the Digital Output process in the
MultiPurpose TestWare application. They can also be controlled manually
in the Station Manager application.

• Each digital output connector located on the Digital I/O Access Panel
supports two channels.

• Each digital output is an open collector/open emitter rated at 30 V DC max

at 50 mA max.

This figure shows how to

connect to an external 498 Digital I/O Digital I/O
Transition Module Access Panel External Device
circuit using an external
power supply. Ext Voltage
J3 - 4
Opto-
Coupler +CH4
9
-CH4
4
common

Connector pinouts The pin connections for the digital inputs and digital outputs are the same. Each
“D” style connector supports two channels.

For example, the pins

associated with channels 1 +12 V DC 1
and 2 are outlined. 6 + Odd Channel #

The 12 volt supply is 1

–Odd Channel # 2
reserved for the digital 12 volt common
7
inputs and should not be
used to power external 3
devices (it is rated for 8 12 volt common
maximum 250 mA current). –Even Channel # 4
2
9 + Even Channel #
+12 V DC 5

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 199
Encoder/Temposonics Connections

Encoder/Temposonics Connections
Encoders and Temposonics sensors are connected to the FlexTest IIm controller
in a similar way. Each type of sensor requires a different jumper configuration on
the Model 498.65 Transition Module and a different mezzanine card for the
498.65 ADDA Module.

Model 498.65
ADDA Module
ADDA Encoder The FlexTest IIm
Encoder

Transition controller supports both

498.65
ADDA
+/-Ex +5V
Module linear (shown) and
rotational encoders.
0
A J1
9
D
1
2 3
7 8

4
R
6

S
FAIL

RESET

J
1
1 J2

J
1
2

J
1
3
J3

J
1
4

E
X
T
J4

J
1
5

OR J11
J
1
6

J J12
1
7
Temposonics III A Temposonics
J
Transition Module sensor is usually
1
8
mounted inside
an actuator.

200 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 Encoder/Temposonics Connections

Jumper configurations The Series 498 transition module can be configured for a Temposonics sensor, a
5 V DC encoder, a 12 V DC encoder, a 24 V DC encoder. The following is a list
of the configuration drawings:

• 049-035-301 Absolute Encoder

• 049-035-401 +5 Volt Encoder

• 049-035-501 +12 Volt Encoder

• 049-035-601 +24 Volt Encoder

• 049-035-701 Temposonics II

• 053-070-201 Temposonics III

ADDA mezzanine The ADDA module requires special mezzanine cards to support encoders and
cards Temposonics sensors.

Mezzanine cards for encoders and Temposonics sensors support four input
channels.

Mezzanine cards for multiturn encoders (Heidenhain 417/425) and Temposonics

III position sensors support two channels.)

• The encoder mezzanine card counts pulses from the encoder to determine
the displacement of an actuator.

• The Temposonics mezzanine card interprets the pulses from the

Temposonics sensor to determine the displacement of an actuator.

Optional ADDA II For the optional ADDA II configuration (using the Model 493.50 ADDA II
configuration module), each encoder requires installation of a Model 493.59 Universal Encoder
mezzanine card on the Model 493.50 ADDA II module.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 201
Encoder/Temposonics Connections

The Model 493.80 Encoder Transition module provides up to four channels of

encoder interface between the Model 493.50 ADDA II module and various
incremental, Temposonics, or other digital and serial data transducers.

Daughter
Board 1

Daughter
Board 2

Daughter
Board 3

Daughter
Board 4

ADDA II Configuration

202 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 Remote Station Controller (RSC) Connections

Remote Station Controller (RSC) Connections

When equipped with a GRES III plug-in module and a corresponding Series
498 RS-485 transition module, your FlexTest IIm controller can
accommodate up to four remote station controllers (one RSC for each
station).

Each RSC connects to a J50 serial connector on the Series 498 RS-485
transition module. The hwi file defines which connector is used for each
station.

498 RS-485 Transition Module

498
RS-485

055-634-3XX Cable the RSC to the proper J50 serial

TRANSITION
MODULE

+12V +5V

J50A
connector (usually J50A) using cable PN
Remote Station Controller 055-634-3XX.

J50B
Remote Station Control

J50C

F1 F2 F3 F4 Status Use Jumper Plug 055-634-101

Interlock

Reset
HSM

High
HPS

High
Test

Run
Manual Control

Enable /
Disable*
in these connectors.
Emergency Stop
J50D

Low Low Hold

Off Off Stop

J7 SERIAL

.hwi file additions In order to use one or more RSCs with your FlexTest controller, two sections
must be added to your .hwi file—an RSC section and a GRES III section.

Note If you specified RSC support when you ordered your test system,
these sections will be added to your hwi file at the factory.

Note For information on editing your .hwi file to accommodate RSCs, see
the Hwi File Editor manual.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 203
Cabling and Programming External Controllers

Cabling and Programming External Controllers

Cabled properly, you can use your FlexTest controller to send test commands to
another controller. For detailed setup information, see “How to Program an
External Controller” on page 204.

When programming Series 2200 and 2400 Eurotherm temperature controllers,

the FlexTest IIm controller supports a special serial connection and software
setup. For more information, see “Programming Eurotherm Temperature
Controllers” on page 209.

How to Program an External Controller

To send programming to an external controller, you must:

1. “Cable the controllers.” on page 204.

2. “Create your configuration file with Station Builder.” on page 207.

3. “Adjust the signals with Station Manager.” on page 207.

4. “Set up your program.” on page 208.

Cable the controllers.

Standard Configuration For a standard configuration (using the Model 498.65 ADDA module), cable the
analog inputs and outputs between your FlexTest controller and the external
controller. Analog I/O connectors are located on the rear of the test processor
chassis.

1. Connect a Series 498 Analog Out connector to the external controller

program (analog) input.

204 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 How to Program an External Controller

2. If you will monitor sensor feedback for data acquisition or control feedback,
connect the external conditioner output to a Series 498 Input Filter
connector.

For conditioner output locations on various MTS devices, see “Sample

conditioner output connections” on page 207.

Transition modules on the back

of the Series 498 test processor
498 498
ANALOG INPUT
OUT FILTER

chassis are used for analog CH 1 CH 1

inputs and outputs.

CH 2 CH 2

CH 3 CH 3

498 Analog Out CH 4 498 Input Filter CH 4

This module includes 8 BNC This module includes 8 BNC

connectors that provide analog CH 5 connectors that provide CH 5

outputs from the 498.65 ADDA filtered analog inputs to the

module. 498.65 ADDA module.
CH 6 CH 6

Four analog outputs are CH 7

Four analog inputs are CH 7

available with the standard CH 8

available with the standard CH 8

ADDA module. The other four ADDA module. The other

outputs require a second J11
(CH 1-4) four inputs require a second J11
(CH 1-4)

ADDA module. ADDA module.

J12 J12
(CH 5-8) (CH 5-8)

WARNING

Do not interrupt FlexTest controller power when you are programming

another controller. A power interrupt may cause the external controller to
react to a zero command and move the actuator unexpectedly.

Ensure power cannot be removed accidently while a test is in progress.

Optional ADDA II For the optional ADDA II configuration (using the Model 493.50 ADDA II
configuration module), cable the analog inputs and outputs between the FlexTest controller and
the external controller as follows:

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 205
How to Program an External Controller

Note Analog I/O connectors are located on the rear panel of the Series 498
test processor chassis.

1. Connect a 493.82 Analog Out BNC connector to the external controller

program (analog) input.

2. If you will monitor sensor feedback for data acquisition or control feedback,
connect the external conditioner output to a 493.83 Filtered Analog Input
BNC connector.

For conditioner output locations on various MTS devices, see “Sample

conditioner output connections” on page 207.

Transition modules on the rear panel of the

Series 498 test processor chassis are used for
analog inputs and outputs.

493.82 Analog Out 493.83 Filtered Analog Input

This module includes 8 BNC This module includes 8 BNC
connectors that provide analog connectors that provide filtered
outputs from a Model 493.56 D/A analog inputs to the Model
mezzanine card. 493.55 A/D mezzanine cards.
Eight analog outputs are available Eight analog inputs are
with each D/A mezzanine card available with the each A/D
installed on the Model 493.50 mezzanine card installed on
ADDA II module. the Model 493.50 ADDA II
module.

Transition Module Connections

206 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 How to Program an External Controller

Sample conditioner This table shows connector assignments for various MTS products you can use
output connections with your FlexTest IIm controller.

Conditioning Sensors with Other MTS Products

MTS PRODUCT SENSOR OUTPUT
Model 408.81 Testing Panel/ Sensor output is available at the rear-panel connector J201
Model 408.82 DC Conditioner or J202.
Model 409.81C Temperature Controller Temperature output (via an analog signal) is available at
rear-panel connector J1.
Model 448.82/85 Test Controller with Sensor output is available at rear-panel connector J335.
Model 448.21/22 AC and DC Conditioners
Ensure sensor conditioners are set as follows:
X1: 2&3
X2: 2&3
Model 458.10/20 MicroConsole® with Sensor output is available at the MicroConsole rear-panel
Model 458.11/12/13/14 AC and DC connector Jx03. Connector Jx03 represents the module
Controllers location (J100–J600).
MicroConsole jumper Jx00 should be set to 1&2 (standard
setting).

Task 1 Create your configuration file with Station Builder.

Using Station Builder, define controller resources to provide programming to an
external controller.

For more information, see “How to Create Your Station Configuration File” and
“Creating Program Channels” in the MTS 793 Control Software manual.

Task 2 Adjust the signals with Station Manager.

Adjust program signal Adjust the outgoing program signal for the required external controller channel.

For more information, see “How to Adjust Program Output Signals” in the MTS
793 Control Software manual.

Adjust feedback If you will monitor sensor feedback for data acquisition or control feedback,
signals adjust the incoming feedback signals.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 207
How to Program an External Controller

For mroe information, see “How to Configure an Externally Conditioned

Feedback Signal” in the MTS 793 Control Software manual.

Task 3 Set up your program.

Define a program with the Function Generator, Basic TestWare, or Multipurpose
TestWare applications.

Using Function Refer to “How to Program with the Function Generator” in the MTS 793 Control
Generator Software manual.

Using Basic TestWare The Basic TestWare application allows you to create simple test programs that do
not require complex signal management or mode switches for station
configuration files.

Refer to “Defining the Test Command” in the MTS 793 Control Software manual.

Note It is good practice to use tapered wave shapes to apply the program
command to the external controller slowly.

Using MultiPurpose To create more sophisticated test programs, use the optional MultiPurpose
TestWare TestWare application.

For more information, see the MTS 793 Application Software manual.

208 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 Programming Eurotherm Temperature Controllers

Programming Eurotherm Temperature Controllers

When equipped with a GRES III plug-in module, your FlexTest IIm controller
can program and control one or more Series 2200/2400 Eurotherm Temperature
Controllers via the J50 serial connectors on the Series 498 RS-485 transition
module.

498 RS-485 Transition Module

498
RS-485

Cable the Eurotherm temperature

TRANSITION
MODULE

+12V +5V

PN 055-634-3XX J50A
controller to the proper J50 serial
connector using cable PN 055-634-3XX.

J50B

Eurotherm
Temperature J50C

Controller

J50D

J7 SERIAL

J50 connector The J50 connectors provide two-way communication between the FlexTest
controller and the Eurotherm temperature controller.

Temperature controller For more information on adding the Eurotherm hwi file resource, see the Hwi
hardware resource File Editor manual.

Program Eurotherm Use the Station Builder application to configure a Eurotherm temperature
Temperature controller.
Controller
For more information, see “How to Program a Eurotherm Temperature
Controller” in the MTS 793 Control Software manual.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 209
Cabling for External Command Inputs

Cabling for External Command Inputs

Cabled properly, your FlexTest controller can receive programming from an
external controller.

How to Enable and Run External Command Inputs

To enable an external command source, perform the following:

1. “Cable the controllers.” on page 211.

2. “Allocate external command resources in Station Builder.” on page 211.

3. “Adjust the command signal with Station Manager.” on page 212.

4. “Start the External Command.” on page 212.

210 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 How to Enable and Run External Command Inputs

Task 1 Cable the controllers.

Cable the external programmer analog out connector to a Series 498 Input Filter
connector. Analog I/O connectors are located on the rear of the test processor
chassis.

Note If you cable the hardware before you create a station configuration file,
note the connector you use on the FlexTest IIm rear console.

498
INPUT
FILTER

CH 1

CH 2

CH 3

498 Input Filter CH 4

This module includes 8 BNC

connectors that provide filtered CH 5

analog inputs to the 498.65

ADDA module.
CH 6

Four analog inputs are available CH 7

with the standard ADDA module. CH 8

The other four inputs require a

second ADDA module. J11
(CH 1-4)

J12
(CH 5-8)

Task 2 Allocate external command resources in Station

Builder.
Using the Station Builder application, allocate controller resources to receive
programming from an external controller.

For more information, see “Enabling External Command Inputs” in the MTS 793
Control Software manual.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 211
How to Enable and Run External Command Inputs

Task 3 Adjust the command signal with Station Manager.

For more information, see “How to Enable and Run External Command Inputs”
in the MTS 793 Control Software manual.

Task 4 Start the External Command.

For more information, see “How to Enable and Run External Command Inputs”
in the MTS 793 Control Software manual.

212 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 Cabling and Using External Readout Devices

Cabling and Using External Readout Devices

Cabled appropriately, your FlexTest controller can send station signals to external
readout devices such as oscilloscopes and digital-volt-meters. You define which
signal is sent to the readout device with the Adjust Readouts window.

For a diagram and description of signals available to the station, refer to “Station
signal descriptions” on page 169.

How to Send Signals to External Readout Devices

To send station signals to an external readout device, you must:

1. “Cable your controller to the readout device.” on page 214.

2. “Create a readout channel with Station Builder.” on page 215.

3. “Adjust the readout signal in Station Manager.” on page 215.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 213
How to Send Signals to External Readout Devices

Task 1 Cable your controller to the readout device.

Cable your FlexTest IIm analog output connector to the readout device. Analog I/
O connectors are located on the rear of the test processor chassis.

Connect a Series 498 Analog Out connector to the external readout device analog
input.

498 Analog Out

498

This module includes 8 BNC

ANALOG
OUT

connectors that provide analog CH 1

outputs from the 498.65 ADDA

CH 2

module.
Four analog outputs are available CH 3

with the standard ADDA module. CH 4

The other four outputs require a

second ADDA module.
CH 5

CH 6

CH 7

CH 8

J11
(CH 1-4)

J12
(CH 5-8)

214 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
 How to Send Signals to External Readout Devices

Task 2 Create a readout channel with Station Builder.

For more information, see “How to Create a Readout” in the MTS 793 Control
Software manual.

Task 3 Adjust the readout signal in Station Manager.

Use the Station Manager application to adjust the readout signal.

For a detailed description of readout signal configuration and adjustment, see

“How to Configure a Signal for External Readout” in the MTS 793 Control
Software manual.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest IIm Controller Connections 215
Cable Part Numbers

Cable Part Numbers

Refer to the following table for cable part numbers used to connect test hardware
to the Model 497.01 Analog Chassis rear-panel connectors.
DESCRIPTION CABLE PART NUMBER
Load cell, 661.xx w/MS connector 046-440-6XX

Load cell, 661.xx w/PT connector 046-440-2XX

Strain w/PT connector 050-120-0XX

LVDT 046-440-3XX

ADT–120º 048-341-1XX

Remote E-stop/X-head Interlock-load frame 054-145-4XX

Servovalve, 252.xx single 046-440-1XX

Servovalve, 252.xx dual 046-440-4XX (in-phase); 046-440-5XX (out-of-

phase)

Jumper plug 2nd servovalve eliminator 039-705-901

Servovalve, 256.xx w/valve 046-440-1XX

Servovalve, 256.xx w/valve LVDT 046-440-8XX

ΔP stability 047-927-6XX

ΔP stability–dual cells 048-049-6XX

System ground–console MTD FlexTest 005-402-3XX

HSM on-off 039-705-3XX (24 V DC); 039-719-1XX (115 V AC)*

HSM high-low 292.xx/298.xx 039-705-5XX (24 V DC); 039-719-2XX (115 V AC)*

HSM on-off 292.xx/298.xx 039-708-1XX (24 V DC)*

413.07 Hydraulic interface to 298.12 prop HSM 042-664-5XX (24 V DC)

497.05 Control Panel to 413.07 042-075-701 (24 V DC)*

HPS (HSM power not included) 039-708-7XX (24 V DC); 039-708-8XX (115 V AC)*

Y adapter at HPS 005-407-801 (24 V DC); 005-401-801 (115 V AC)

* For CE configurations, there are CE versions of these cables. Refer to the System Cable Package
Selection-FlexTest drawing (PN 047-922-501) for these cable numbers.

216 FlexTest IIm Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware
Chapter 5
FlexTest SE Controller Connections
This section describes the connections to the MTS 493.02 Chassis.

Note For information on connecting power cables, see “Connecting Electrical

Power” on page 53.

Note For information about CE compliance, see “CE EMC Compliant Cabling”
on page 83.

Contents 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 FlexTest SE Controller Connections 217

Stand-alone Cabling Overview

Stand-alone Cabling Overview

218 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Automated Cabling Overview

Automated Cabling Overview

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections 219

Multiple Controller Connections

Multiple Controller Connections

About multiple Some characteristics of a multiple controller network are as follows:

controller networks
• Each controller in the network provides control for one station with up to
two channels.

• A hub connects each controller in the network to the supervising PC.

• A single network may have a maximum of four stations (regardless of the

number of controllers cabled to the hub).

• When used in a network, controllers must be registered for automation and

operate in the automation mode.

• Each controller in the network must have a unique ID and name.

For more information about setting up multiple controller networks for FlexTest
SE Controllers, see Appendix D, Using Multiple Automated Controllers in the
FlexTest SE User’s Manual.

E-stop J29
Dig Out J55
Box Out J52
Analog out

Intlk J43
Power
FLOW
AIR

mm
J49 Aux Pwr
Analog In

J51 Box In

J54 Dig In
SYSTEM
493.42

J28 HSM
J25 Hpu
I/O

SHUNT CAL
CARRIER
493.40
I/O

J4 I/O

J5 I/O

J6 I/O

J7 I/O
J3

1
2
3
4
S
E
V

E
I

100–240 VAC
50–60 Hz, 12–6A

MOTOROLA
RUN 6TS BFL
MVME
2100

ABT RST

TYPE E PC-MIP DEBUG

TYPE E PC-MIP PCI MEZZANNE CARD

HUB

011-437-8xx 011-437-8xx

011-437-8xx
E-stop J29
Dig Out J55
Box Out J52
Analog out

Intlk J43

Power
FLOW
AIR

mm
J49 Aux Pwr
Analog In

J51 Box In

J54 Dig In
SYSTEM
493.42

J28 HSM
J25 Hpu
I/O

2SHUNT CAL
CARRIER
493.40
I/O

J4 I/O

J5 I/O

J6 I/O

J7 I/O
J3

3
4
S
E
V

E
I

100–240 VAC
50–60 Hz, 12–6A
MOTOROLA

RUN 6TS BFL

MVME
2100

ABT RST

TYPE E PC-MIP DEBUG

TYPE E PC-MIP PCI MEZZANNE CARD

Typical multiple controller cabling

Master-dependent Connect two or more FlexTest SE Controllers in a master-dependent

FlexTest SE configuration as shown below.
Controllers

220 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Multiple Controller Connections

Note The indicated cables on each controller must be connected before the
controllers are turned on.

E-stop J29
Dig Out J55
Box Out J52
Analog out

Intlk J43
Power

FLOW
AIR

mm
J49 Aux Pwr
Analog In

J51 Box In

J54 Dig In
SYSTEM
493.42

J28 HSM
J25 Hpu
I/O
Master

2SHUNT CAL
CARRIER
493.40
I/O

J4 I/O

J5 I/O

J6 I/O

J7 I/O
J3

3
4
S
E

E
I
100–240 VAC
50–60 Hz, 12–6A

MOTOROLA
RUN 6TS BFL

MVME
2100
ABT RST

TYPE E PC-MIP DEBUG

TYPE E PC-MIP PCI MEZZANNE CARD

056-316-0xx

E-stop J29
Dig Out J55
Box Out J52
Analog out

Intlk J43
Power
FLOW
AIR

mm
J49 Aux Pwr
Analog In

J51 Box In

J54 Dig In
SYSTEM
493.42

J28 HSM
J25 Hpu
I/O

Dependent 1
SHUNT CAL
CARRIER
493.40
I/O

J4 I/O

J5 I/O

J6 I/O

J7 I/O
J3

1
2
3
4
S
E

E
I

100–240 VAC
50–60 Hz, 12–6A

MOTOROLA
RUN 6TS BFL
MVME
2100

ABT RST

TYPE E PC-MIP DEBUG

TYPE E PC-MIP PCI MEZZANNE CARD

Box Out 056-316-0xx

Jumper Plug
100-057-246
E-stop J29
Dig Out J55
Box Out J52
Analog out

Intlk J43

Power
FLOW
AIR

mm
J49 Aux Pwr
Analog In

J51 Box In

J54 Dig In
SYSTEM
493.42

J28 HSM
J25 Hpu
I/O

Dependent 2
SHUNT CAL
CARRIER
493.40
I/O

J4 I/O

J5 I/O

J6 I/O

J7 I/O
J3

1
2
3
4
S
E

E
I

100–240 VAC
50–60 Hz, 12–6A
MOTOROLA

RUN 6TS BFL

MVME
2100

ABT RST

TYPE E PC-MIP DEBUG

TYPE E PC-MIP PCI MEZZANNE CARD

Use the J51 Box In and J52 Box Out connectors on the 493.42 System I/O
module in the controller’s rear panel to connect one controller to another.

The master controller will have an open Box In connector, and a cable attached to
the Box Out connector. A middle-run dependent controller will have cables
attached to both the Box In and Box Out connectors. The end-of-run dependent
will have a cable attached to the Box In connector, and a jumper plug attached to
its Box Out connector.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections 221

Multiple Controller Connections

Interlock function Power must be applied to all controllers in the chain for proper interlock
operation. If power is not applied to any one of the controllers, you will not be
able to clear an interlock condition in any of the controllers.

Also, if a cable becomes disconnected from a dependent controller’s Box In

connector, or if a cable is inadvertently connected to the Box In connector on the
master controller, an interlock is set which cannot be reset until all controllers are
restarted.

222 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Cable Part Numbers

Cable Part Numbers

System cables The following is a list of the most common cables, see the System Cable/Jumper
Plug 493 Package Selection drawing (MTS PN 700-000-656) for the most
current and additional cable part numbers.

Model 493.02 Chassis Cables

CABLE DESCRIPTION PART NUMBER* MODULE JUMPER PLUG†
CONNECTOR
Servovalve 252.xx single 039-708-3XX 493.40 J4–J7 N/A

Servovalve 252.xx dual 039-708-4XX 493.40 J4–J7 N/A

Servovalve 256.xx 3-stage N/A

Valve 055-439-6XX 493.40 J4–J7
Valve LVDT 039-708-6XX 493.40 J4–J7
Calibration Cable Package 100-026--213 493.40 J3

Y Adapter—Servovalve/Valve LVDT 039-710-501 493.40 J4–J7 N/A

(required for 256.xx or 257.xx servovalves)

Workstation Link (Ethernet cable) 051-996-8XX 10/100‡ N/A

System ground (table top) 005-402-3XX N/A

System ground (rack mount) 039-709-2XX gnd lug

Hydraulic Power Unit (HPU) (see “Hydraulic 039-713-7XX 493.42 J25 039-713-301
Configurations” on page 243 for more
information)

Hydraulic Service Manifold (HSM) 039-701-5XX 493.42 J28 N/A

Emergency Stop (E-STOP) 493.42 J29 100-007-947

Interlock (Intlk) Per System 493.42 J43 100-057-245

Auxiliary Power (Aux Pwr) Per System 493.42 J48 N/A

Box In 056-316-0xx 493.42 J51 N/A

Box Out 056-316-0xx 493.42 J52 100-057-246

Digital Input (Dig In) Per System 493.42 J54 N/A

Digital Output (Dig Out) Per System 493.42 J55 N/A

Analog In (Anlg In) Per System 493.42 N/A

Analog Out (Anlg Out) Per System 493.42 N/A

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections 223

Cable Part Numbers

* -XX specifies cable length. –01 through –09 represent 10–50 ft. in 5 ft. increments. Higher numbers
represent custom cable lengths.
† Jumper plugs are required if a cable is not installed.
‡ The connector is the 10/100 BaseT connector on the power PC module.

Sensor cables See “Sensor Cables” on page 100 for a detailed list of sensor cables and part
numbers.

For the most current part numbers, see the System Cable/Jumper Plug 493
Package Selection drawing (PN 700-000-656).

224 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Model 493.40 I/O Carrier Connections

Model 493.40 I/O Carrier Connections

For more information, see “Model 493.40 I/O Carrier Connections” on page 87.

Automated option Automated FlexTest SE Controllers are designed to be used with a PC, MTS 793
software, and various types of support files, including a hardware interface file
(.hwi) file. The .hwi file defines each type of electronic module in the chassis
(and associated mezzanine cards), and maps each module location for the MTS
793 software. The .hwi file and the physical locations for each type of module
and associated mezzanine cards must match. Also, the I/O Carrier module
address setting (on the module) must match the .hwi file address.

Adding I/O Carrier For automated controllers, a second I/O Carrier module can be added to support a
second channel or to expand sensor conditioning. Its addition can also be used to
support more A/D and D/A channels.

Note If you are upgrading your system, a faster processor may be required.
Contact MTS for information on system upgrade requirements.

To add a second I/O Carrier module:

1. Install the required mezzanine cards in the I/O Carrier module.

2. Install a second Model 493.40 I/O Carrier module in slot 3 of the controller
chassis.
E-stop J29
Dig Out J55
Box Out J52
Analog out

Intlk J43

Power
J28 HSM
FLOW
AIR

m m
J49 Aux Pwr
Analog In

J51 Box In

J54 Dig In
SYSTEM
493.42

J25 Hpu
I/O

SHUNT CAL
CARRIER
493.40
I/O

J4 I/O

J5 I/O

J6 I/O

J7 I/O
J3

1
2
3
4
S
E
V

E
I

100–240 VAC
50–60 Hz, 12–6A
MOTOROLA

RUN 6TS BFL

MVME
2100

ABT RST

TYPE E PC-MIP DEBUG

TYPE E PC-MIP PCI MEZZANNE CARD
m
SHUNT CAL
CARRIER
493.40
I/O

J4 I/O

J5 I/O

J6 I/O

J7 I/O
J3

1
2
3
4
S
E

E
I

3. Change your .hwi file to reflect the added I/O Carrier module and its
mezzanine cards.

4. Use the Station Builder application to allocate resources for the additional
hardware.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections 225

Sensor Connections

Sensor Connections
See “Sensor Connections” on page 88.

See “Sensor Cables” on page 100.

See “Shunt Calibration/Bridge Completion Resistor Installation” on page 103.

See “Transducer Identification Modules” on page 106.

Valve Connections
See “Valve Connections” on page 108.

See “Series 252 Servovalve connections” on page 109.

See “Series 256 Servovalve connections” on page 110.

See “Series 257 Valve connections” on page 111.

Analog I/O Connections

The Model 493.45 A/D and Model 493.46 D/A mezzanine cards are installed in
the Model 493.40 I/O Carrier front panel module.

Note The external analog source can be a stand-alone function generator,

another controller, or a computer controlled analog output.

226 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Analog I/O Connections

A/D connections The analog-to-digital mezzanine cards accommodate up to six analog input
signals.

• Each A/D input signal must be within ±10 volts.

To From
A/D J4 - J7 A/D

1 +
Input 1
2 -
3 Analog
Ground
4 +
Input 2
5 -
6 Analog
Ground
7 +
Input 3
8 -
9 +
Input 4
10 -
+
11 +
Input 5
-
12 -
13 +
Input 6
14 -
15

• Use pin 3 or 6 to prevent problems with floating grounds between devices.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections 227

Encoder Connections

D/A connections Digital-to-analog mezzanine cards support up to six program or readout signals
to external devices.

• Each D/A signal is an analog output within ±10 volts.

From To
D/A J4 - J7 External
Device

1 +
Output 1
2 -
3
4 +
Output 2
5 -
6
7 +
Output 3
8 -
9 +
Output 4
10 -
11 + Output 5
12 -
13 +
Output 6
14 -
15

• Each readout signal is from a 16 bit digital to analog converter.

• Each output is a ±10 V analog output.

Cable specification The cable specifications apply to both the analog inputs and analog outputs.

The cable from the front panel of the I/O Carrier module has the following
specification:

• 15 contact type D male EMI connector.

• Backshell–EMI metallized plastic.

• Cable type–up to 6 shielded twisted pairs, each with the drain wire
connected to the signal source.

Encoder Connections
See “Encoder Connections” on page 121.

228 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Workstation Connection

Workstation Connection
The workstation computer is connected to the processor module installed in the
VMEbus of the chassis. It is an Ethernet 10/100 Base-T connection. The
workstation computer must have an Ethernet compatible connector.

RUN 6TS BFL

ABT RST

TYPE E PC-MIP DEBUG

TYPE E PC-MIP PCI MEZZANNE CARD

CAUTION

The symbol shown here indicates that you must not connect
telecommunications equipment to the equipment showing this symbol.

Several modules have connectors that look similar to a phone connector. Special
cables are required. Installing telecommunications equipment cables can cause
equipment damage to the electrical components of the chassis or to your
telecommunications system.

Service Connection
See “I/O Carrier service” on page 150.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections 229

Model 493.42 System I/O Connections

Model 493.42 System I/O Connections

The Model 493.42 System I/O module is a dual-wide VME-based slave board
used in the Model 493.02 Chassis.

• Provides box-in and box-out, analog and digital I/O, E-Stop, and HSM and
HPU control.

• Contains three general purpose digital input channels and three general
purpose digital output channels.

• Interfaces the controller with a hydraulic power unit.

• Interfaces the controller with a hydraulic service manifold and other

devices.

• Provides one BNC channel for analog output signals. The output signals are
within ±10 V DC.

• Provides one BNC channel of analog input. The input signals must be
within ±10 V DC.

J25 Hydraulic Power Unit Connection

Connector J25 HPU controls the hydraulic power unit (HPU).

• The connector provides 24 V logic signals to control the HPU.

• The connector may be connected directly to MTS Series 505 HPUs, other
MTS HPUs via the Model 493.07 HPU Converter Box, and
24 V PLC compliant HPUs.
Note For more information, see “Hydraulic Configurations” on page 243.

CAUTION

Control voltages for hydraulic power units vary between models.

The HPU interface between the Model 493.42 System I/O board and an HPU
is 24 volt logic signals. Connecting J25 to a non-compliant HPU can damage
the module.

DO NOT connect 24 V DC relay circuitry or 115 V AC circuitry to connector J25 on

the Model 493.42 System I/O board.

230 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 J28 Hydraulic Service Manifold Connector

Cable specification The J25 HPU and J51 Box In connectors are 15 pin type D male connectors.

• 15 contact type D female EMI connector.

• Cable—24 AWG, 10 conductor with braided shield with drain wire

connected to metallized plastic 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, 6-9.

For an electrical diagram of J25, see page 132.

J28 Hydraulic Service Manifold Connector

See “J28 Hydraulic Service Manifold Connector” on page 134.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections 231

J29 Emergency Stop Connections

J29 Emergency Stop Connections

Connector J29 E-STOP provides an output to external devices when an
emergency stop signal is generated. This connector may also be used with an
external E-stop.

J29 Connector Pin Assignments

PIN NAME FUNCTION
1 xhead 24V Fused +24V

2 xhead intlk com 24V common

3 Program interlock low Low side of opto-isolator, jumpered to common

(xhead interlock low)

4 Program interlock high High side of opto-coupler, pulled up to 24V (opto on = intlk)
(xhead interlock high)

5 Local E stop Local E stop loop (connected to pin 7)

6 N/C No connection

7 Local E stop Local E stop loop (connected to pin 5)

8 HPU E stop E stop loop from HPU (connect to pin 13)

9 N/C No connection

10 N/C No connection

11 N/C No connection

12 xhead power +24 V crosshead unlock power output (from HSM high relay
contact)

13 HPU E stop E stop loop from HPU (connect to pin 8)

14 xhead power return 24 V common for crosshead unlock power output

15 N/C

Cable specification • 15 contact type D male EMI connector.

• Backshell–EMI metallized plastic.

• Cable–24 AWG 4 connector with braided shield, with the braid connected to
a metallized plastic backshell at the chassis and to ground at the emergency
stop station.

232 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 J43 Interlock

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 PN 100-007-947B or jumper pins: 3-
4, 5-7, 8-13.

J43 Interlock
Connector J43 Interlock contains one optically isolated interlock input and one
relay contact interlock output.

Note The intlk out relay (Pin 6) is normally energized when no interlocks are
active. So even though Pin 6 is a NO (normally open) relay contact, it is
actually normally closed when no interlocks are active. Similarly, the intlk
out relay (Pin 8) is normally closed when no interlocks are active, so
even though Pin 8 is a NC (normally closed) relay, it is actually normally
open when no interlocks are active.

.
J43 Connector Pin Assignments
PIN NAME FUNCTION
1 intlk in 24V 24 V through 6.6K resistor

2 intlk in high High side of opto-isolator (opto off = intlk)

3 intlk in low Low side of opto-isolator

4 intlk in comm 24 V common

5 N/C No connection

6 intlk out NO Normally open relay contact

7 intlk out COM Common relay contact

8 intlk out NC Normally closed relay contact

9 N/C No connection

Cable specification • 9 contact type D male EMI connector.

• Backshell–EMI metallized plastic.

• Cable–shielded twisted pairs (24 AWG minimum) with drain wire(s)

connected to the metallized backshell at the chassis.

Power characteristics Channel inputs can be 3 volts (minimum) and 26 volts (maximum) from an
external voltage source.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections 233

J49 Auxiliary Power

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 PN 100-057-245, or jumper pins: 1-2,
3-4.

J49 Auxiliary Power

See “J49 Auxiliary Power” on page 140.

CJ51 Box In
Connector J51 Box In allows the Model 493.02 chassis to receive clock,
hydraulic, and interlock signals from another Model 493.02 chassis.

J51 Connector Pin Assignments

PIN NAME FUNCTION
1 +clk in +External clock input

2 hyd high in Hydraulic high input

3 reset in Interlock reset request input

4 signal return Signal return for optically isolated inputs

5 /intlk in Hydraulic interlock input

6 hyd low in Hydraulic low input

7 signal return Signal return for optically isolated inputs

8 master/slave in Master -/Slave select input

9 - clk in - External clock input

10 hyd hi return out Hydraulic high return output

11 reset return out Interlock reset return output

12 ground Signal ground

13 /intlk return out Hydraulic interlock return output

14 hyd low return out Hydraulic low return output

15 ground Signal ground

234 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 J52 Box Out

J52 Box Out

Connector J52 Box Out allows the Model 493.02 Chassis to send clock,
hydraulic, and interlock signals to another Model 493.02 Chassis.

J52 Connector Pin Assignments

PIN NAME FUNCTION
1 +clk in +External clock output

2 hyd high out Hydraulic high output

3 reset out Interlock reset request output

4 ground Signal ground

5 /intlk out Hydraulic interlock output

6 hyd low out Hydraulic low output

7 ground Signal ground

8 N/C No connection

9 - clk out - External clock output

10 hyd hi return in Hydraulic high return input

11 reset return in Interlock reset return input

12 signal return Signal return for optically isolated inputs

13 /intlk return in Hydraulic interlock return input

14 hyd low return in Hydraulic low return input

15 signal return Signal return for optically isolated inputs

Jumper plug required If connector J52 Box Out is not used, you must install a jumper plug to maintain
the integrity of the interlocks. Use jumper plug PN 100-057-246 or jumper pins:
2-10, 3-11, 4-12, 5-13, 6-14, 7-15.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections 235

J54 Digital Inputs

J54 Digital Inputs

Connector J54 Dig In accommodates up to three digital signals from external
devices. You can use digital input signals to trigger test events with your
controller applications.

• All of the inputs are optically isolated.

• Channel inputs can be 3 volts (minimum) and 26 volts (maximum) from an

external voltage source.

To J54 From
FTSE Controller External Device

+24 V 1

2 Switch or dry contact.

Input 1
3

4
Input 2
5

6
Input 3
7

8 Low side of Opto Inputs

must be jumpered to
9 ground. Use 22 AWG
Jumper Wire.

Cable specification The cabling information shown assumes a single cable destination (with an
overall shield). In other applications, the cable may have more than one
destination. For these applications an overall shield is not practical and non-EMI
connectors and back shells are permissible.

• 9 pin contact type D male EMI connector

• Back shell–EMI metallized plastic

• Cable–shielded twisted pairs as required (24 AWG minimum) with drain

wire(s) connected to the metallized backshell at the chassis.

236 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 J55 Digital Outputs

J55 Digital Outputs

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

• The digital output relays are rated for a maximum of 1 Amp max, 30 V DC/
AC max.

• The outputs are optically isolated.

From J55 To
FT SE Controller External Device

1
Relay Contact Channel 1 Output
2

3
Relay Contact Channel 2 Output
4

6
Relay Contact Channel 3 Output
7

+24 V 8

Cable specification The cabling information shown assumes a single cable destination (with an
overall shield). In other applications, the cable may have more than one
destination. For these applications an overall shield is not practical and non-EMI
connectors and back shells are permissible.

• 9 pin contact type D male EMI connector

• Back shell–EMI metallized plastic

• Cable–shielded twisted pairs as required (24 AWG minimum) with drain

wire(s) connected to the metallized backshell at the chassis.

Run/Stop setup If required, digital output 1 (pins 1 and 2) can be set up as a Run/Stop connector.
Use the following procedures to set up this Run/Stop connector:

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections 237

J55 Digital Outputs

Stand-alone mode

1. Press Setup on the console front panel menu.

2. Scroll down the Setup menu to Digital Output 1.

3. Press the button next to Digital Output 1.

4. Press the button next to Assignment until the state Run/Stop is shown.

5. Press Polarity to select Normal or Inverted.

Automation mode

1. Ensure that digital outputs have been added using Station Builder.

2. In the Station Manager window’s Display menu, select Station Setup.

3. In the Station Setup window’s navigation pane, double-click Digital

Inputs/Outputs and then click Outputs.

4. On the Digital Outputs window, use Assignment for Digital Output 1 to

assign Run/Stop.

5. Use Polarity to select the required polarity (Normal or Inverted) for

Digital Output 1.

238 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Eurotherm Temperature Controller Connection

Eurotherm Temperature Controller Connection

Automated FlexTest SE Controllers can program and control a single Eurotherm
temperature controller.

Note Stand-alone FlexTest SE Controllers are not equipped for use with
temperature controllers.

To use a temperature controller with a FlexTest SE Controller:

1. Configure the FlexTest SE Controller’s Debug Serial Port.

2. Cable the temperature controller to the FlexTest SE Controller.

3. Add a temperature controller resource to the hardware interface file (hwi).

4. Add a temperature control channel to the station configuration file.

Configuring the Debug To use a FlexTest SE Controller with a temperature controller, configure the
Serial Port Debug Serial Port as follows:

1. Access the Model 498.96 Processor circuit card in the Controller’s chassis.

2. Locate switch S3.

3. Set bit 8 to the off (open) position.

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections 239

Eurotherm Temperature Controller Connection

Cabling the Two cables and an RS 232/RS 485 converter are required to connect the FlexTest
temperature controller SE Controller to a temperature controller, as shown.

E-stop J29
Dig Out J55
Box Out J52
Analog out

Intlk J43
Power

FLOW
AIR

mm
J49 Aux Pwr
Analog In

J51 Box In

J54 Dig In
SYSTEM
493.42

J28 HSM
J25 Hpu
I/O

SHUNT CAL
CARRIER
493.40
I/O

J4 I/O

J5 I/O

J6 I/O

J7 I/O
J3

1
2
3
4
S
E

E
I
100–240 VAC
50–60 Hz, 12–6A

MOTOROLA
RUN 6TS BFL

MVME
2100
ABT RST

TYPE E PC-MIP DEBUG

TYPE E PC-MIP PCI MEZZANNE CARD

Debug Serial Port 100-112-652

RS232/RS485 Eurotherm Temperature

Converter Controller
056-719-6xx (651 Chamber)
(100-112-820)
OR

056-719-7xx 409.83
Temperature
Controller

240 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

 Eurotherm Temperature Controller Connection

Debug serial port Two different cables can be used to connect the converter to the temperature
controller:

• For Eurotherm Temperature Controllers used with Series 651 chambers, use
cable assembly PN 056-719-6xx.

• For MTS Model 409.83 Temperature Controllers (equipped with Eurotherm

control modules), use cable assembly PN 056-719-7xx.

RS-485
D-9P D-25P

BLU/WHT 3
TO + 7 HF (-)
RS232/485 TO
WHT/BLU 2 651.XX
COMMUNICATION - 8 HE (+)
CONVERTER CHAMBER
ORN/WHT COMMUNICATION
6 7 HD (COM)
WHT/ORN

N/C N/C

056-719-6XX

RS-485 P6
D-9P D-9P

+ 7 WHT WHT 4 TO
TO HF (-)
409.83
RS232/485
COMMUNICATION - 8
BLK BLK 5 HE (+) TEMPERATURE
CONTROLLER
CONVERTER 2
6 BLK
3
6
056-719-7XX BLK 409.83
7 INTERLOCK

Adding a temperature To use a temperature controller with your FlexTest SE Controller, you must add a
controller resource to temperature controller resource to the Controller’s hardware interface file (.hwi).
the hardware interface This adds a temperature controller resource to the inventory of hardware
file resources available for station configuration files.

To do this, use the MTS Hwi File Editor application (installed with MTS 793
software) to open the controller’s hardware interface file. (The typical path to this
application is: Start > Programs > MTS Systems Software > Service Tools > Hwi
File Editor.)

Models FlexTest® IIm/GT/SE Controller Hardware FlexTest SE Controller Connections 241

Eurotherm Temperature Controller Connection

To add the resource, select the Miscellaneous tab and select 1 for temperature
controllers, then save the file. The application automatically adds the required
information in the proper syntax to the text in the hardware interface file.

Adding a temperature After updating the hardware interface file, you must add a temperature control
control channel to the channel to the Controller’s station configuration file.
station configuration
file To do this, use the Station Builder application to open the station configuration
file, and then add temperature controller input (Temp Control 1-Input) and output
(Temp Control 2-Output) resources to a Program w/Feedback type channel. This
creates a temperature control channel.

For detailed instructions, see “How to Program a Eurotherm Temperature

Controller” in the MTS 793 Control Software manual for more information.

242 FlexTest SE Controller Connections Models FlexTest® IIm/GT/SE Controller Hardware

Appendix A
Hydraulic Configurations
This section describes how to connect the Model 493.10 Chassis (FlexTest GT
Controllers) and the Model 493.02 Chassis (FlexTest SE) to a variety of MTS
hydraulic configurations.

Use the following connectors and cables to connect the Model 493.10/02 Chassis
to your HPU with a Model 493.07 Converter Box:

Note For jumpering information, see Appendix B: Model 493.07 Converter Box
on page 251.

Models 493 Chassis to • 15 contact type D female EMI connector at J25 of the Model 493.73 HPU
493.07 Converter Box Transition module in the rear panel of the Model 493.10 Chassis.
Backshell–EMI metallized plastic.

• 14 contact type CPC male connector at J1 of the Model 493.07 Converter

Box chassis.

• Cable–24 AWG 10 conductor with overall foil shield, (Carol C0745 or

equivalent) with drain wire connected to metallized plastic backshell at the
493.10 chassis, and pin 14 at the Model 493.07 Controller Box chassis.

Model 493.07 Converter • 24 contact type CPC female connector at J25 of the Model 493.07 Converter
Box to HPU Box chassis.

• 14 contact type MS connector at J1 of the HPU.

• Cable—18 AWG 14 conductor with overall foil shield, (Alpha 2248C or

equivalent) with drain wire connected to pin 4 of connector J25 and pin A of
the pump connector.

Hydraulic pump The following diagrams show how to connect the chassis to a hydraulic power
configurations unit.

• Single 493 chassis with a 24 V PLC (programmable logic controller) pump

or 505 pump

• Single 493 chassis with a non-PLC pump

• Multiple 493 chassis with a non-PLC pump

• Compatible controllers controlling a pump

Models FlexTest® IIm/GT/SE Controller Hardware Hydraulic Configurations 243

 Single Model 493.02
chassis with a 24 V PLC
pump (506.52-.92) or
505 pump

493.02 039-713-7XX
Chassis HPU
J25
HPS

Note The following three configurations have cables to support both 24 V DC

and 115 V AC control voltages. A Model 493.07 Converter Box is
available for each voltage (not both). Be sure the cables and Converter
Box are rated for the same voltage.

Single Model 493.02

chassis with a non-PLC
pump

039-713-8XX (24 V DC) 039-710-7XX (24 V DC)

039-714-6XX (115 V AC) 493.07 039-710-8XX (115 V AC)
493.02
Chassis Converter Box HPU
J25 J1 J25
HPS HPS HPS

Multiple Model 493.02

chassis’ and 407
Controllers

039-713-8XX (24 V DC)

039-714-6XX (115 V AC) 039-710-7xx (24 V DC)
493.02 039-710-8xx (115 V AC)
Chassis J25
HPS 493.07
Converter Box HPU
J1 J25
493.02 HPS HPS
Chassis J25
HPS
low level Y cable 039-713-501
OR
050-182-2XX
407 Controller 051-995-8XX (CE)
J25
HPS

244 Hydraulic Configurations Models FlexTest® IIm/GT/SE Controller Hardware

 Compatible Controllers

039-710-7XX (24 V DC) High-level Y cable

039-710-8XX (115 V AC) 005-407-801 (24 V DC)
005-401-801 (115 V AC)
039-713-8XX (24 V DC)
039-714-6XX (115 V AC)

493.10 493.07 HPU

Chassis J25 J1 Converter Box J25
HPS HPS HPS

458* or 039-708-7XX (24 V DC)

490.01* 039-708-8XX (115 V AC)
497.05*

* For standard Model 493.07 Converter Box jumper setting only. Alternate settings are required for Model
436.11 and 413.05 controllers. See Appendix B: Model 493.07 Converter Box.

You can mix Models 493.07, 458, 490, and 497.05 Controllers directly on the
same HPU (without the use of an HPU isolation box).

You cannot mix Models 493.07, 458, 490, and/or 497.05 Controllers with 436,
413.05, or 413.8X Controllers unless you use an isolation box.

You can jumper the Model 493.07 Converter box so you can use it directly with
436 and 413.05 Controllers. However, if you do this you must use an isolation
box if you attempt to use the Converter Box with Models 458, 490, and 497.05
Controllers. See Appendix B, “Model 493.07 Converter Box” on page 251.

Models FlexTest® IIm/GT/SE Controller Hardware Hydraulic Configurations 245

Model 493.02 Chassis Multiple Controller

Model 493.02 Chassis Multiple Controller Interconnections

FlexTest SE Controllers support the following hydraulic interconnections for
multiple controller configurations:

• Independent HSM control with no HPU

• Independent HSM control with a shared HPU

• Shared HSM with an HPU

• Shared HSM without HPU

• Independent HSM controlled with a shared HPU using first-on-last-off

For more detailed information about multiple controller configurations,

see“Multiple Controller Connections” on page 220 and the FlexTest SE User
Manual.

Independent HSM (no HPU)

Power Type = HSM Only Power Type = HSM Only

Interlock/Hydraulics
FlexTest SE FlexTest SE
A FG
7 8 9 Rewind Run Hold Stop
A FG
7 8 9 Rewind Run Hold Stop

B B Setup
Setup
Recall 4 5 6 Program
Recall
Status
4 5 6 Program
Status
Hydraulic
Scope 1 2 3
Hydraulic
Interlock
Scope 1 2 3 Interlock

reset Enabled reset

.
Enabled Meters Program

.
Meters Program
+/- 0 Interlock
Tuning
+/- 0 Interlock

Tuning

056-316-0xx
Low High Off Low High
Emergency Stop Config
Off
Emergency Stop Config
enter
enter HPU HPU
Limits Limits
cancel Off Low High
Log
cancel Off Low High
Log HSM
HSM
Monitor 1 Monitor 2
Navigate ? Menu
Monitor 1 Monitor 2
Navigate ? Menu
Power Power

J28 HSM J28 HSM

056-126-4xx 056-126-4xx

HSM 1 HSM 2

For this multiple controller configuration:

• Each controller has an independent hydraulic service manifold (HSM).

• No hydraulic power unit (HPU) is connected.

• Select HSM Only for Power Type on each connected controller.

Path: Config > Edit Hardware > Power Options > Power Type > HSM
Only

246 Hydraulic Configurations Models FlexTest® IIm/GT/SE Controller Hardware

 Independent HSM (shared HPU)

Independent HSM (shared HPU)

Power Type = HPU/HSM Power Type = HPU/HSM

FlexTest SE FlexTest SE
A FG
7 8 9 Rewind Run Hold Stop A FG
7 8 9 Rewind Run Hold Stop

Interlock/Hydraulics
B Setup B Setup
Recall
Status
4 5 6 Program Recall
Status
4 5 6 Program
Hydraulic
2
Hydraulic
Scope 1 2 3 Interlock Scope 1 3 Interlock

reset Enabled reset

.
Enabled Meters Program

.
Meters Program
+/- 0 Interlock
Tuning
+/- 0 Interlock

Tuning

056-316-0xx
Off Low High Off Low High
Emergency Stop Config
enter Emergency Stop Config
enter
HPU HPU
Limits Limits
cancel Off Low High
Log
cancel Off Low High
Log HSM
HSM
Monitor 1 Monitor 2
Navigate ? Menu
Monitor 1 Monitor 2
Navigate ? Menu
Power Power

J28 HSM
J25 HPU

056-126-4xx 039-713-8xx

HSM 1 039-713-5xx HSM 2

HPU
Converter
039-710-7xx

HPU

For this multiple controller configuration:

• Each controller has an independent hydraulic service manifold (HSM).

• An HPU is shared by all connected controllers via Y-cables.

• Select HPU/HSM for Power Type on each connected controller.

Path: Config > Edit Hardware > Power Options > Power Type > HPU/
HSM

Shared HSM (with HPU)

Power Type = HPU/HSM Power Type = Slave HSM

Interlock/Hydraulics
FlexTest SE FlexTest SE
A FG
7 8 9 Rewind Run Hold Stop
A FG
7 8 9 Rewind Run Hold Stop

B B Setup
Setup
Recall 4 5 6 Program
Recall
Status
4 5 6 Program
Status
Hydraulic
Scope 1 2 3
Hydraulic
Interlock
Scope 1 2 3 Interlock

reset Enabled reset

.
Enabled Meters Program

.
Meters Program
+/- 0 Interlock
+/- 0 Interlock

056-316-0xx
Tuning Tuning

Low High Off Low High

Emergency Stop Config
Off
Emergency Stop Config
enter
enter HPU HPU
Limits Limits
cancel Off Low High
Log
cancel Off Low High
Log HSM
HSM
Monitor 1 Monitor 2
Navigate ? Menu
Monitor 1 Monitor 2
Navigate ? Menu
Power Power

J28 HSM
J25 HPU
056-126-4xx

039-713-7xx
HSM HPU

Models FlexTest® IIm/GT/SE Controller Hardware Hydraulic Configurations 247

Shared HSM (no HPU)

For this multiple controller configuration:

• The HSM and HPU are connected to one controller only.

• Select HPU/HSM for Power Type on the controller to which the HSM and
HPU is connected.

Path: Config > Edit Hardware > Power Options > Power Type > HPU/
HSM

• Select Slave HSM for Power Type on controllers connected to the master
controller.

Shared HSM (no HPU)

Power Type = HSM Only Power Type = Slave HSM

Interlock/Hydraulics
FlexTest SE FlexTest SE
A FG
7 8 9 Rewind Run Hold Stop
A FG
7 8 9 Rewind Run Hold Stop

B B Setup
Setup
Recall 4 5 6 Program
Recall
Status
4 5 6 Program
Status
Hydraulic
Scope 1 2 3
Hydraulic
Interlock
Scope 1 2 3 Interlock

reset Enabled reset

.
Enabled Meters Program

.
Meters Program
+/- 0 Interlock
+/- 0 Interlock

056-031-6xx
Tuning Tuning

Low High Off Low High

Emergency Stop Config
Off
Emergency Stop Config
enter
enter HPU HPU
Limits Limits
cancel Off Low High
Log
cancel Off Low High
Log HSM
HSM
Monitor 1 Monitor 2
Navigate ? Menu
Monitor 1 Monitor 2
Navigate ? Menu
Power Power

J28 HSM

056-126-4xx

HSM

For this multiple controller configuration:

• An HSM is connected to one controller only.

• Select HSM Only for Power Type on the controller to which the HSM is
connected.

Path: Config > Edit Hardware > Power Options > Power Type > HSM
Only

• Select Slave HSM for Power Type on controllers connected to the master
controller.

248 Hydraulic Configurations Models FlexTest® IIm/GT/SE Controller Hardware

 Independent HSM with HPU (First On-Last Off)

Independent HSM with HPU (First On-Last Off)

Note This interconnect option is only available for controllers on the same
interlock.

Power Type = Auto. HPU/HSM Power Type = HSM Only

Interlock/Hydraulics
FlexTest SE FlexTest SE
A FG
7 8 9 Rewind Run Hold Stop
A FG
7 8 9 Rewind Run Hold Stop

B B Setup
Setup
Recall 4 5 6 Program
Recall
Status
4 5 6 Program
Status
Hydraulic
Scope 1 2 3
Hydraulic
Interlock
Scope 1 2 3 Interlock

reset Enabled reset

.
Enabled Meters Program

.
Meters Program
+/- 0 Interlock
+/- 0 Interlock

056-316-0xx
Tuning Tuning

Low High Off Low High

Emergency Stop Config
Off
Emergency Stop Config
enter
enter HPU HPU
Limits Limits
cancel Off Low High
Log
cancel Off Low High
Log HSM
HSM
Monitor 1 Monitor 2
Navigate ? Menu
Monitor 1 Monitor 2
Navigate ? Menu
Power Power

J28 HSM
J25 HPU

056-126-4xx

039-713-7xx
HSM 1 HPU HSM 2

For this controller configuration:

• Two or more FlexTest SE Controllers are connected.

• An HSM is connected to each controller only.

• Select Auto. HPU/HSM for Power Type on the controller to which both a
HSM and HPU is connected.

Path: Config > Edit Hardware > Power Options > Power Type > Auto.
HPU/HSM

• Select HSM Only for Power Type on controllers with an independent HSM,
but no HPU.
Note The HPU can be connected to any controller in the interconnected group
of controllers.

Models FlexTest® IIm/GT/SE Controller Hardware Hydraulic Configurations 249

Independent HSM with HPU (First On-Last Off)

250 Hydraulic Configurations Models FlexTest® IIm/GT/SE Controller Hardware

Appendix B
Model 493.07 Converter Box
This section describes how to jumper the Model 493.07 Converter Box to
connect the Model 493.10 chassis and other controller types to a hydraulic power
unit (HPU). The Converter Box converts logic-level signals to and from the
Model 493.10 chassis to relay signals used by the HPU pump.

For pumps that are 24 V PLC compliant, the Converter Box is not needed. This
includes all Series 505 HPUs and 506.52-.92 HPUs.

CAUTION

You must have the Model 493.07 Converter Box designed for the correct
voltage before installation. Connecting a 24 V Converter Box to a 115 V AC
HPU causes improper operation.

Be sure that the voltage marked on the cover of the Converter Box matches the
required voltage for the HPU.

The following figure shows the main components of the 493.07 Converter Box,
including connectors and jumpers.

WARNING

If the converter box remains connected to a 120 volt HPU, voltage will be
present.

Failure to disconnect cables could expose the operator to dangerous

voltages.

Disconnect all cables from the Model 493.07 Converter Box before removing

Jumper configurations As shipped, the HPU interface on the Model 493.07 Converter Box is compatible
with Model 458.10/.20, 490.01, 493.xx, and 497.05 components.

The Model 493.07 Converter Box may be connected to other controllers (as
shown in the following table) using a “Y” cable.

Models FlexTest® IIm/GT/SE Controller Hardware Model 493.07 Converter Box 251
 Note If the Model 493.10 Chassis is the only device connected to the HPU, the
jumper settings do not matter.

COMPATIBLE WITH JUMPERS

Model 458.05/.10/.20/.40 Standard jumper setting:
Model 490.01
Model 497.05 E10–E11install
E12–E13 install
E14–E15 install
E16–E17 install
E10–E13 remove
E14–E17 remove

Model 413.05 Jumper change required:

Model 436.11
Model 407.05 E10–E11 remove
E12–E13 remove
E14–E15 remove
E16–E17 remove
E10–E13 install
E14–E17 install

Note The Model 493.07 Converter Box cannot be used with both groups of
controllers at the same time. If this functionality is needed, use an HPU
isolation box.

252 Model 493.07 Converter Box Models FlexTest® IIm/GT/SE Controller Hardware
Appendix C
Chassis Maintenance
This section describes how to maintain your MTS controller chassis.

Cleaning the chassis Remove any dust from the chassis with Endust for Electronics or equivalent.

Cleaning the air filter Be sure the cooling fan is operational and not clogged. Clean or replace the filter
as required.

The filter is typically located in the top of the chassis, and can be accessed from
the rear.

To clean the air filter:

1. Remove the filter from the chassis.

2. Immerse the filter in a large pan filled with warm water and a mild
detergent, and allow it to soak a few minutes.

3. Gently agitate the filter to loosen debris.

4. Rinse the filter thoroughly with clean water.

Note Do not use compressed air to help dry the filter. Compressed air may
damage the filter element.

5. Allow to drip until completely dry.

Note The air filter has a distinct top and bottom. Ensure that you orient the
filter properly.

6. Replace the filter in the chassis.

Models FlexTest® IIm/GT/SE Controller Hardware Chassis Maintenance 253

254 Chassis Maintenance Models FlexTest® IIm/GT/SE Controller Hardware
 6-Station Configuration

Appendix D
Optional Station Configurations
This section describes how to configure your Model 493.10 Chassis (FlexTest GT
Controllers) to support an optional six or eight stations.

When configuring your system for a six or eight stations you must consider the
following:

• Ensure that the .hwi file is correctly set for the desired multi-station
configuration, especially the interlock and HSM board settings.

• Power to each HSM is limited.

• Cross-head interlocks with solenoid power are not supported.

• Remote Station Control (RSC) is not supported.

• AC input power must be at least 115 V AC.

• Auxiliary power out of J49 on the Model 493.74 HSM Transition board is
not supported.

6-Station Configuration
The 6-station configuration can provide either six or eight channels of control.

A typical 6-channel/6-station configuration requires 12 Digital Universal

Conditioners and 6 two-stage valve drivers.

A typical 8-channel/6-station configuration requires 16 Digital Universal

Conditioners and 8 two-stage valve drivers.

HSM power limits HSM power current is limited to 1.5 A per HSM.

Interlocks For 6-station configurations the .hwi file must contain the line
INTERLOCKS=6. This line must be a discrete entry, not part of any other .hwi
section.

Cross-head interlocks with solenoid power are not supported for 6-station
configurations.

RSC Remote Station Control (RSC) is not supported for 6-station configurations.

Models FlexTest® IIm/GT/SE Controller Hardware Optional Station Configurations 255

8-Station Configuration

8-Station Configuration
The 8-Station configuration can provide eight channels of control.

A typical 8-Channel/8-Station configuration requires 16 Digital Universal

Conditioners and 8 two-stage valve drivers.

HSM power limits HSM power current is limited to 1.5 A per HSM.

Interlocks For 8-station configurations the hwi file must contain the line
INTERLOCKS=8. This line must be a discrete entry, not part of any other hwi
section.

Cross-head interlocks with solenoid power are not supported for 8-station
configurations.

RSC Remote Station Control (RSC) is not supported for 8-station configurations.

A/D analog inputs Only one set of six A/D analog inputs is supported for 8-station configurations.

256 Optional Station Configurations Models FlexTest® IIm/GT/SE Controller Hardware

Index

Numerics ADDA
cabling 183
connections 183
daughter boards 201
252 servovalve,I/O carrier connection 109, 226, 228 analog chassis (497.01) 63
256 servovalve,I/O carrier connection 110 adding to console 69
257 servovalve,I/O carrier module connection 111 chassis slots 63
407 controller,programming to receive, send signals 162 modules 64
493.07 HPU Converter 251 analog I/O
493.10 chassis 39 cable specifications 118, 228
AC grounding 39 I/O carrier connections 226
digital universal conditioner (DUC) jumpers 92, 94, 97 automated configuration 25
functional description 21
grounding 39
power connections 40
specifications 23, 27, 33
493.42 System I/O
B
auxiliary power connection (J43) 234
E-stop connection (J29) 232 back panel 26
HPU connection (J25) 230 Box In (J51) 234
HSM connection (J28) 231 Box Out (J52) 235
Interlock connection (J43) 233 bridge completion
493.42 System I/O module I/O carrier module 103
description 230 ID module 107
493.46 D/A,493.76 Analog Out connection 117, 127, 187
497.01 Analog Chassis
about 63
adding analog chassis 69 C
chassis slots 63
hydraulic control panel connection 62
install transition module 66 cable specifications
plug-in modules 64 analog I/O 118, 228
sensor/valve connections 179 digital I/O 143
transition modules 66 digital inputs 236
497.05 Hydraulic Control Panel digital output 237
about 31, 71 J24 E-stop input 129
HPS/HSM connections 189 J25 HPS (497.05) 190
rear-panel connectors 71 J25 HPU 131, 231
497.36 Communication Module J28 HSM (497.05) 191
jumper/switch settings 70 J28 HSM solenoid 134
498 System Digital I/O J29 E-stop 232
interlock jumpers 193 J29 E-stop input 232
498.22 Test Processor, about 32 J29 load unit 136
J43 interlock 137, 233
J44 run/stop 139
A J49 auxiliary power 140
J54 system I/O 131, 231
servovalve 108, 179
transducer 179
AC conditioners,connections 180
AC power connections 55
accelerometer, I/O carrier connection 119, 229

Models FlexTest® IIm/GT/SE Controller Hardware Index 257

cables conditioner jumpers (DUC)
CE ECM compliant 83 ± shunt cal 98
E-stop 129 4/8 wire sensor cable 93, 95, 97
fabrication 83 active guard 92, 94, 97
HPU connector 131, 231 bridge balance 93, 96, 99
part number list 85, 223 excitation sense 94, 96, 98
sensor 100 single-ended excitation 94, 96, 98
system 223 conditioners
cabling cabling 180
AC sensor connections 180 configurations
ADDA 183 AC power 55
cable numbers 179 configurations, FlexTest IIm Controller 28
console/chassis power 61 connecting
DC sensor connections 180 electrical power 53
digital I/O 196 external readout devices 210
E-stop 232 connection
Eurotherm temperature controller 165, 209, 239 workstation 229
external controllers 168, 204, 211 connections
front panel 227 AC power 55
J4-J7 A/D inputs 115 AC sensors 180
J4-J7 D/A outputs 117, 127, 187 ADDA (analog to digital/digital to analog) 183
J4-J7 transducer 108 chassis ground 53
J4-J7 valve 108 computer 178
HPS 190 console/chassis power 61
HSM 191 DC sensors 180
hydraulic connections 189 digital I/O 196
interlock 192 digital inputs 197
low-frequency ground loops 83 digital outputs 199
readout devices 171, 214 encoders 200
rear panel HPS 190
J101-J1601 servovalve 179 HSM 191
J101-J1601 transducer 179 hydraulic control panel 71
J102-J1602 dual servovalve 179 multiple controllers 220
J23 E-stop output 129 serial communications 195
J24 E-stop input 129 System I/O module 230
J25 HPU 131, 230 Temposonics sensors 200
J28 HSM solenoid 134, 231 console grounding 62
J29 E-stop 232 controller
J29 load unit 136 automated configuration 25
J3 In digital inputs 142 back panel 26
J4 Out digital outputs 143 front panel 24
J43 Interlock 233 handle kit install 58
J43 interlock 137 interlocks 26
J44 run/stop 138 multiple connections 220
J49 auxiliary power 140, 234 stand alone configuration 24
J54 System I/O 131, 231 controller chassis
serial communications 195 DUC jumpers 92, 94, 97
typical system layout 84 controller connection, CTM programmer 151
valve 181 CTM programmer
CE EMC compliance, cabling 83 controller connections 151
chassis
grounding 53, 62
installation options 51
power connections 53, 61 D
power description 55
chassis modules, installing 42
computers,connections 178 daughter boards 51
daughter boards, ADDA module 201
DC conditioners
connections 180

258 Index Models FlexTest® IIm/GT/SE Controller Hardware

digital I/O
connections 196 F
digital I/O access panel 144
digital I/O connections 141
digital I/O transition module force/strain sensor
J3 In connector 142 I/O carrier connection 92
J4 out connector 143 front panel 24
digital inputs function generation 25
cable specification 236
J3 In connector 142
J54 Dig In connector 236
digital inputs, connections 197 G
digital outputs
cable specification 143, 237
J4 out connector 143 grounding
J55 Dig Out connector 237 chassis AC power 39
digital outputs, connections 199 console/chassis 62
low-frequency ground loops 83
grounding chassis 53

E
H
electrical power
connecting 38
grounding 39 HPU 230
emergency stop HPU transition board connection 131
cable specifications 129, 232 system I/O connector 133
E-STOP Out connector 129 HPU connector (J25) 230
E-stop out connector (J29) 232 HPU transition board
HPU transition connectors 129, 232 E-stop cable specifications 129, 232
encoder E-STOP connectors 129, 232
I/O carrier connections 121 E-STOP Out (J23) 129
encoders HPU cable specifications 131, 231
connections 200 HPU connector (J25) 131
daughter boards 201 system I/O connector (J54) 133
jumper configurations 201 HSM
Eurotherm temperature controller proportional output 135
cabling 165, 209, 239 HSM transition board
how to configure 166, 209 J28 HSM connector 134
programming 165, 209, 239 J29 load unit connection 136
external controllers 168, 210 J43 interlock connection 137
adjust command signal 168, 212 J43 interlock connector 137
allocating resources 168, 211 J44 run/stop connection 138
cabling 168, 204, 211 J49 auxiliary power connector 140
conditioner outputs (MTS products) 167 hydraulic control panel (497.05)
programming 204 about 31, 71
external programs (receiving) 210 rear-panel connectors 71
external readout devices 169, 210, 213 hydraulic pressure control 26
adjust readout signals 171, 215 hydraulics
cabling 171, 214 cabling 189
create readout channel 171, 215
sending station signals to 171, 213
station signals available 169, 213 I
I/O carrier daughter boards
connecting 87
description 45, 46, 73

Models FlexTest® IIm/GT/SE Controller Hardware Index 259

I/O carrier module jumpers
252 servovalve connection 109, 226, 228 ± shunt cal 98
256 servovalve connection 110 4/8 wire sensor cable 93, 95, 97
257 servovalve connection 111 498 System Digital I/O 193
accelerometer connection 119, 229 active guard 92, 94, 97
analog I/O cable specifications 118, 228 bridge balance 93, 96, 99
analog I/O connection 114, 226 digital I/O transition module 142
analog I/O connections 226 digital universal conditioner (DUC) 92, 94, 97
analog inputs 115, 227 encoder configuration 201
bridge completion circuits 103 excitation sense 94, 96, 98
connecting force/strain sensor 92 HPU converter 251
connecting LVDT 90 interlock 193
D/A connection 117, 127, 187, 228 J24 E-stop input 130
daughter boards 51, 87 J25 HPS 131
encoder connections 121 J25 HPS (497.05) 190
J3 Service connector 150 J25 HPU 231
servovalve cable specifications 108 J29 E-stop input 233
servovalve connections 108, 226 J29 load unit 136
shunt calibration connector 103 J43 interlock 137, 173, 234
installing J52 Box Out 235
handle kit 58 rear panel 235
plug-in modules 42, 49 single-ended excitation 94, 96, 98
transition panels 47
VMEbus modules 43, 50
interlock
connections 192 L
HSM transition connections 137, 138
jumper plugs 193
interlocks 22, 26 load unit
HSM transition connections 136
low-frequency ground loops
correcting noise problem 83
J LVDT
I/O carrier connection 90

J29 E-stop 232

J49 auxiliary power connector 234
J51 Box In connections 234 M
J52 Box Out connections 235
J54 Digital Input connections 236
J55 Dig Out connection 237 meters
jumper settings connecting external 210
adding analog chassis 69 modules
communication module (497.36) 70 analog chassis (497.01) 64
Multiple Controller networks 220
multiple controllers
connecting 220

P
pinouts
digital input/output connectors 199
plug-in modules
installing 42, 49
plug-in modules (analog chassis)
configuration information 64
install/remove 65

260 Index Models FlexTest® IIm/GT/SE Controller Hardware

power specifications
UPS requirements 78 493.10 chassis 23, 27, 33
power cabling 53, 61 sensor cables 100
power connections UPS 78
493.10 chassis 40 stand alone configuration 24
pressure control 26 standard configurations, FlexTest IIm Controller 28
programming station connections 134
Eurotherm temperature controller 209 station signals
receiving from external controllers 210 available for monitoring 169, 213
sending to external controllers 204 descriptions 169
external readout of 171, 213
system cables
R analog I/O 118, 228
part number list 85, 223
servovalve cables 108
system cables/jumpers 223
readout channel, creating 171, 215 System I/O module connections 230
readout devices, using external 210
readout signal, adjust 171, 215
rear-panel connectors
497.01 analog chassis 67 T
497.05 hydraulic control panel 71
remote station controller
.hwi file 148, 203 temperature controllers, connecting. See transition modules
serial interface connection Temposonics sensors
(J50) 147 connections 200
serial interface connection (J50) 203 daughter boards 201
jumper configurations 201
test processor (498.22)
S about 32
transducer cables
part numbers 101
specifications 100
scope transducer ID module
connecting external 210 assigning a sensor 107
sensor transition bus 21
analog chassis connection 179 transition module connections (analog chassis) 67
assigning with transducer ID 107 transition modules
cables 100 analog chassis (497.01) 66
sensor cables transition panels
4/8 wire jumpers 93, 95, 97 description 48
active guard jumper 92, 94, 97 installing 47
part numbers 101
specifications 100
with ID module 102
without ID module 101 U
serial communications, cabling 195
service connections
J3 Service (I/O carrier) 150 UPS
J39 power monitor 149 493.73 connections,493.73 HPU Interface board
servovalve UPS connections 79
analog chassis connection 179 FlexTest 40, FlexTest SE 77
I/O carrier cable specifications 108 FlexTest 60, 100, 200, GT 76
I/O carrier connection 108, 226 FlexTest SE, 493.42 connections 80
shunt calibration specifications 78
I/O carrier connector 103
shunt resistor connector 103

Models FlexTest® IIm/GT/SE Controller Hardware Index 261

V
valve
dual-valve connection 181
single-valve connection 181
VME bus 21
VMEbus
installing modules 43
VMEbus modules
description 45
descriptions 50
installing 43, 50

W
workstation connection 145, 229

262 Index Models FlexTest® IIm/GT/SE Controller Hardware

m
MTS Systems Corporation
14000 Technology Drive
Eden Prairie, Minnesota 55344-2290 USA
Toll Free Phone: 800-328-2255
(within the U.S. or Canada)
Phone: 952-937-4000
(outside the U.S. or Canada)
Fax: 952-937-4515
E-mail: [email protected]
Internet: www.mts.com

ISO 9001 Certified QMS