MTS Series 793 Utility Software 100-147-132 L be Certain
Revision November 2011 © 2011 MTS Systems Corporation. All rights reserved. MTS, FlexTest, RPC, Temposonics, and TestWare are registered trademarks of MTS Systems Corporation; MPT, Station Builder, Station Manager, and Profile Editor 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.
Contents Technical Support..................................................................................vii How to Get Technical Support...........................................................................................vii Before You Contact MTS..................................................................................................viii If You Contact MTS by Phone.............................................................................................
About Actuator Movement When the Servovalve is Clamped...........................................15 Where to Find Valve Balance Procedures...........................................................................16 HWI Hardware Settings About Hwi File Editor Default Settings..............................................................................20 Edit Hwi Default Settings...................................................................................................20 Apply Hwi Default Settings.
Model 494.16 VD/DUC HWI Settings...................................................................55 Model 494.21 Multi-Range DUC with Acceleration Compensation Card HWI Settings.57 How to Enable Acceleration Compensation on the Model 494.21 Card................58 How to Add a DI/O Load Washer to a Model 494.21 Card....................................59 How to Add a Serial Load Washer to a Model 494.21 Card..................................59 Model 494.25/494.26 DUC HWI Settings............................
Controller Management Tool Controller Options Description...........................................................................................92 Controller Attributes tab.........................................................................................93 User Files tab (FlexTest SE only)...........................................................................96 License Keys tab (FlexTest SE only)......................................................................
Technical Support How to Get Technical Support Start with your manuals The manuals supplied by MTS provide most of the information you need to use and maintain your equipment. If your equipment includes 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.
Before You Contact MTS MTS can help you more efficiently if you have the following information available when you contact us for support. Know your site number and system number The site number contains your company number and identifies your equipment type (such as material testing or simulation). The number is typically written on a label on your equipment before the system leaves MTS. If you do not know your MTS site number, contact your sales engineer.
Know relevant software information For software application problems, have the following information available: • The software application’s name, version number, build number, and (if available) software patch number. This information can typically be found in the About selection in the Help menu.
• If you are not familiar with all aspects of the equipment operation, have an experienced user nearby to assist you. Write down relevant information In case Technical Support must call you: • Verify the notification number. • Record the name of the person who helped you. • Write down any specific instructions. After you call MTS logs and tracks all calls to ensure that you receive assistance for your problem or request.
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.
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.
Hypertext links The electronic document has many hypertext links displayed in a blue font. All blue words in the body text, along with all contents entries and index page numbers, are hypertext links. When you click a hypertext link, the application jumps to the corresponding topic.
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HWI-File-Editor Overview Topics: • • • • • • • About .hwi files........................................................................................................................2 About the Hwi File Editor Application......................................................................................2 Starting Hwi File Editor ..........................................................................................................2 Hwi File Editor Controls............................................
HWI-File-Editor Overview About .hwi files Hwi files are text files that define the internal components—or resources—available to MTS Series 793 Controllers. Resource examples include conditioners, valve drivers, and digital inputs. The text description of a resource in an .hwi file includes proximity information, such as the location of the slot in the chassis in which the resource is installed, and the rear-panel connectors through which it may be accessed.
HWI-File-Editor Overview Editing existing .hwi files with the Hwi File Editor When you open an existing .hwi file with the Hwi File Editor, the Hwi File Editor minimizes the chance of introducing syntax errors when making changes. Creating new .hwi files with the Hwi File Editor When you create a new .hwi file with the Hwi File Editor, the Hwi File Editor’s built-in logic streamlines the process of adding new resources. For instance, when you add or remove analog resources from an .
HWI-File-Editor Overview Number callout in graphic - Item Description The backup filename will contain a date and time stamp in the filename. For example: FTIIM_YYYY-MM-DD_HH-MM-SS.HWI. View: Use to show or hide the Toolbar and Status Bar. Options: Use to rename resources or reconfigure processors. Rename Resources: Selecting this option automatically renames resources to eliminate name conflicts. You should only select this option before you create a configuration using Station Builder.
HWI-File-Editor Overview Number callout in graphic - Item Description Help: Selecting the Electronic Documentation option displays the Hwi File Editor manual in the portable document file (PDF) format. Selecting the About Hwi File Editor displays a window identifying the Hwi File Editor’s release version and build number. 2 - Toolbar Provides quick access to common commands and windows. 3 - Tree view pane Shows icons of selected controller components in an expandable hierarchical display.
HWI-File-Editor Overview Number callout in graphic - Item Description Miscellaneous tab Use the drop-down lists in the Miscellaneous tab to add various external devices to the .hwi file. The devices listed here are not automatically added by the Hardware Detect option. 5 - Hwi text pane The selections you make in the tabbed pages of the controller definition pane are automatically reflected as text in this pane.
HWI-File-Editor Overview When using multiple .hwi files with the same controller, make sure that your .hwi files all have identical hardware resources. Saving Multiple .hwi Files in a Controller Directory You can create multiple .hwi files that contain different hardware settings and save them in the same controller directory. This allows you to create custom .hwi settings for different tests. 1. Shut down any test and quit all Series 793 applications.
HWI-File-Editor Overview If you click No, the file is saved in the controller directory but the controller.793settings file is not modified. Note: You can now use the Project Manager application to switch between the multiple .hwi files that you saved in the controller directory. Selecting .hwi Files in a Controller Directory You can use the Project Manager application to select different .hwi files for use with a controller. 1. Shut down any test and quit all Series 793 applications.
Create and Edit an HWI File Topics: • • • • • Create a New File.................................................................................................................10 Hardware Resources............................................................................................................10 Configure Hardware Resource Settings...............................................................................12 About Actuator Movement When the Servovalve is Clamped...............................
Create and Edit an HWI File Create a New File Create New hwi File for Single Box System Only qualified personnel should create or edit .hwi files. WARNING: An incorrect .hwi file can result in improper system response and unexpected actuator movements. Unexpected actuator movements may result in personal injury or damage to equipment. Before operating your system, ensure the .hwi file you are using is valid for your situation. 1. From the File menu, click New. 2.
Create and Edit an HWI File The Detect Hardware feature will not detect a Model 498.70 board, Model 497 chassis tab, or any hardware added through the Miscellaneous tab (such as temperature controllers, RSCs, and handsets). You must manually add those hardware resources for any system that uses those hardware types. Use Detect Hardware Feature 1. Open either a new or existing .hwi file. 2. From the Options menu, click Detect Hardware.
Create and Edit an HWI File 2. Click the Board tab, and select the VME board for each board slot used in the system. Manually Add Mezzanine Card to .hwi File The Hwi File Editor application includes a tree structure and drop-down lists that allow you to manually add hardware resources. 1. Select the Model 49x.40 I/O Carrier or Model 493.50 ADDAII board in the tree view pane. Empty I/O Carrier and ADDA II boards are not supported. At least one mezzanine card must be specified. 2.
Create and Edit an HWI File Bridge Type Settings Model 494.xx DUCs include settings that define the bridge type (full, half, quarter). Shunt Settings Model 494.xx DUCs include settings that define where the shunt calibration resistor is applied. Analog Input Filter Settings Mezzanine cards that include analog inputs (DUCs, A/D Converter, Encoder, and conditioners) includes filter settings that you may want to change for custom applications.
Create and Edit an HWI File Number callout in graphic - Item Description 3 - Controller Controller chassis 4 - HPU with HSM This setting is available for the HPU transition and system boards (494.41, 494.42, 494.44, 493.42). TRUE–indicates the system’s HPU supplies one or more HSMs. FALSE–used for HPU only systems (makes HPU selection available in Station Builder). 5 - Connect to HPU This setting is available for various HSM transition boards.
Create and Edit an HWI File If you manually added the hardware resources to the .hwi file, you must make sure that the address setting in the .hwi file matches the physical address switch settings on the 493.40 I/O Carrier board, 494.40 I/O Carrier Board, and the ADDA II board. About Actuator Movement When the Servovalve is Clamped If an unbalanced servovalve (two-stage or three-stage) is clamped by Series 793 software, it may act unpredictably.
Create and Edit an HWI File The inner loop (like the outer loop), has gain and rate controls that can be adjusted to optimize performance. The inner-loop is tuned at system installation, and requires periodic fine tuning when the outer-loop becomes sluggish. Number callout in graphic 1 Item Feedback 2 Outer Loop 3 Inner Loop 4 Hydraulic Service Manifold (HSM) 5 Hydraulic Power Supply 6 Control Signal 7 493.
Create and Edit an HWI File For three-stage servovalves, the mechanical valve balance procedure involves the procedure for the pilot spool (which is the same as the procedure for two-stage servovalves), and a procedure to adjust the LVDT mechanical null for the third-stage spool. These procedures are included in the Series 256 Servovalve Product Manual (PN 011-209-602), which is typically included in the system documentation set.
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HWI Hardware Settings Topics: • • • • • • • • • • • • • • • • • • • • About Hwi File Editor Default Settings..................................................................................20 Edit Hwi Default Settings......................................................................................................20 Apply Hwi Default Settings....................................................................................................21 Export HWI Defaults........................................
HWI Hardware Settings About Hwi File Editor Default Settings The Hwi Defaults feature allows you to change the default HWI settings for most VME- and transition-bus hardware. When Show HWI Defaults is selected, Hwi Default settings appear in an editable resource tree that appears above the Controller resources. To change Hwi Default values, edit the hardware properties pages in the HWI Defaults tree.
HWI Hardware Settings 2. Change the default HWI Settings in the HWI Defaults tree. You can also use the Import HWI Defaults function to change the default settings based on a previously exported HWI Defaults file. Note: When you import a previously created Hwi Default file, the Hwi Editor application will use those default values for any subsequent .hwi files that you create. 3. Once the default settings are changed, you can apply the settings to the controller resources.
HWI Hardware Settings • Right-click the I/O Carrier icon and click Apply HWI Defaults. HWI defaults are applied to the hardware resources in the I/O carrier. • Right-click a hardware resource in the Controller tree and click Apply HWI Defaults. The HWI default settings are only applied to that hardware resource. In this example, the default HWI values will only be applied to the selected 494.26 hardware resource.
HWI Hardware Settings In this example, the default values for the 494.16 VD/DUC will be applied to all instances of the 494.16 in the Controller tree. Use one of the following methods to apply Hwi defaults to new hardware that you add to an Hwi file: • On the Options menu, click Detect Hardware. Any hardware detected will use the default Hwi settings. • Manually add hardware to the Controller tree. Any new hardware that is added will use the default Hwi settings.
HWI Hardware Settings Import HWI Defaults Previously exported Hwi Defaults files can be imported. After HwiDefaults are imported, the Hwi Editor application will use those default values for any subsequent Hwi files that you create. Note: Hwi Default files use a “.hwidef” file extension. Use one of the following methods to import a previously exported Hwi Defaults file. • On the File menu, click Import HWI Defaults. OR • Right-click the HWI Defaults icon and click Import HWI Defaults.
HWI Hardware Settings VME Board FlexTest FlexTest IIM GT, (498.xx) Teststar IIM (493.10) Model 493.40 I/O Carrier X Aero ST FlexTest FlexTest FlexTest (493.20) SE 40 60/100/200 (493.02) (494.04) (494.06/.10/.20) X X Model 494.40 I/O Carrier Model 493.50 ADDA II X X X Model 49x.43 Multi-Box I/O X X X Model 498.71 GRES II X Model 498.71 GRES III X Model 498.65 ADDA X Model 498.70 Digital I/O X X Model 493.42 System Board X X Model 494.41 System Board X Model 494.
HWI Hardware Settings Two processor boards By default, the core in Processor [1] performs the SUP and optional THP functions, while the core in Processor [2] performs the DSP function. Note: If necessary, use the Reconfigure Processors option window to reconfigure the core functions for existing two-processor systems. Three processor boards The core in Processor [1] performs the SUP function (and THP if the Hybrid Simulation option is installed), and the core in Processor [2] performs the DSP function.
HWI Hardware Settings Existing Settings: Some existing systems may require the “SUP on 1 and shared DSP/THP on 2” OR “Shared SUP/DSP on 1 and THP on 2” settings. Important: If an existing HWI file uses one of the other settings, do not change the setting. Processor Hwi Settings Item Description Processor circuit board Address: Describes the proximity of the circuit board within the icon Processor properties chassis.
HWI Hardware Settings Item Description SIM = Hybrid Simulation (option) Processor Number: Not applicable Interrupt Level: Not applicable SIM Function icon (optional) The hybrid simulation (SIM) function for internal models is an option that requires a license key. Once the license key is installed, you must add the SIM function to the appropriate processor core. To configure a processor to run the Hybrid Simulation (SIM) option: 1. Right-click the processor Core icon and click Add Simulation Function.
HWI Hardware Settings Item Description (SIM) function to a processor and define the number of input/output ports. Note: Hybrid Simulation is set up by MTS personnel only. This is described in an internal MTS document. Model 493.50 ADDA II Board Settings This board is compatible with Aero ST, FlexTest GT, FlexTest IIm, and TestStar IIm controllers. Item Description 493.50 ADDAII circuit board icon When the optional Model 493.50 ADDA II board is being used, the .
HWI Hardware Settings Item Description Slot: Specifies which slot the circuit board occupies in the chassis. Clock Type: Master/Dependent. For Master Clocks System Rate: 1024, 2048, 4096 and 6144 Hz (binary). Note: The System Rate must be an integer multiple of the Medium System Rate. Medium System Rate: Must be an integer multiple of the Low System Rate. Note: The Low System Rate is always set at 25.6. The Medium System Rate is typically 256.
HWI Hardware Settings Item Description Medium System Rate: Must be an integer multiple of the Low System Rate. The Low System Rate is always set at 25.6. The Medium System Rate is typically 256. Digital Input/Output icons Name: Describes this resource as it will appear in Station Builder resource lists when opened against an .hwi file. Changing this name may invalidate existing station configurations. Channel: Not applicable. Model 49x.
HWI Hardware Settings The Model 493.40 board is compatible with Aero ST, FlexTest GT, FlexTest SE, and TestStar IIm controllers. The Model 494.40 board is compatible with FlexTest 40/60/100/200 controllers. Note: When a 494.40 I/O carrier board is plugged in to a chassis, but the .hwi file does not include the I/O board, the system load will generate a hardware interlock that you cannot clear. Paddleboard considerations for the Model 494.40 I/O Carrier To avoid system-load errors, the Model 494.
HWI Hardware Settings Item Description calibrate the transducer/AC conditioner pair in the new clock mode and run your tests in the same clock mode. System Rate: 512 (single-box Aero systems), 1024, 2048, 4096 and 6144 Hz (binary). Note: The System Rate must be an integer multiple of the Medium System Rate. Medium System Rate: Must be an integer multiple of the Low System Rate. Note: The Low System Rate is always set at 25.6. The Medium System Rate is typically 256. 49x.
HWI Hardware Settings Item Description Changing this name may invalidate existing station configurations. Analog Output icons Name: Describes this resource as it will appear in Station Builder resource lists when opened against an .hwi file. Connector: Both Analog Outputs are available on the “DA Output” connector (located on the front of the 494.04 chassis). Changing this name may invalidate existing station configurations. Hydraulic Interface icon (HPU) Connector: J25.
HWI Hardware Settings Item Description panel. For the other types, three HSM control buttons will appear (Off/Low/High). If you select Proportional, you configure the proportional output 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 750 psi (5.25 MPa) and high pressure is set at 3000 psi (21 MPa). Low Percent: 25.
HWI Hardware Settings Model 494.42 Single-Station System Board Settings The Model 494.42 board is used with FlexTest 40 controllers. Item Description 494.42 System Board circuit board icon The System Board defines digital and analog inputs and outputs, and hydraulic power unit (HPU) and hydraulic service manifold (HSM) functionality. Properties tab Slot: 4. Slot 4 in the FT-40 chassis is reserved for the system board. System Rate: 1024, 2048, 4096 and 6144 Hz (binary).
HWI Hardware Settings Item Description Type: Off-high–only two HPU control buttons (Off/High) will appear on the Station Manager Station Controls panel. Off-low-high–three HPU control buttons (Off/Low/High) will appear on the Station Manager Station Controls panel. First On: True: Indicates that the first HSM turned on activates the HPU. False: Setting First On and Last Off to False allows the HPU to turn on independent of HSM power.
HWI Hardware Settings Item Description 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 750 psi (5.25 MPa) and high pressure is set at 3000 psi (21 MPa). Connect to HPU: True: Indicates the HSM requires the HPU to be started (either manually or as “first on”) prior to being started. False: Indicates the HSM can be activated without an HPU activation. Low Percent: 25.
HWI Hardware Settings Model 494.44 Two-Station System Board Settings The Model 494.44 board is used with FlexTest 40 controllers. Item Description 494.44 System Board circuit board icon The System Board defines digital and analog inputs and outputs, and hydraulic power unit (HPU) and hydraulic service manifold (HSM) functionality. Properties tab Slot: 4. Slot 4 in the FT-40 chassis is reserved for the system board. System Rate: 1024, 2048, 4096 and 6144 Hz (binary).
HWI Hardware Settings Item Description Off/high: two HPU control buttons (Off/High) will appear on the Station Manager Station Controls panel. First On: False: Setting First On and Last Off to False allows the HPU to operate independent of HSM controls. True: Setting First On and Last Off to True allows HSM Low selection to activate HPU High without pressing the HPU buttons. (The first HSM turned on activates the HPU.) Last Off: True: Causes the last HSM turned off to turn off the HPU.
HWI Hardware Settings Item Description Time to low pressure from zero pressure = (Low Percent value) x (HSM Rate value). Time to achieve high pressure from low pressure = (High Percent value x HSM Rate value) - (Time to low pressure). Example: If Low Percent value = 25, High Percent value = 100, and HSM Rate = Slow (4 seconds): Time to achieve low pressure = 0.25 x 4 = 1 second. Time to achieve high pressure = (1 x 4) - (1) = 3 seconds. Interlock Interface 1 and 2 Connector: J43,J29.
HWI Hardware Settings Item Description The System Rate must be an integer multiple of the Medium System Rate. Medium System Rate: Must be an integer multiple of the Low System Rate. The Low System Rate is always set at 25.6. The Medium System Rate is typically 256. Low System Rate: 25.6. Miscellaneous tab # of HPU Interfaces: Allows you to add or remove the HPU interface. # of HSM Interfaces: Allows you to add or remove the HSM interface.
HWI Hardware Settings Item Description (Should this be read only?)Type: Solenoid, On/Off Solenoid, Proportional, Remote. If you select Proportional, you configure the proportional output 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 750 psi (5.25 MPa) and high pressure is set at 3000 psi (21 MPa).
HWI Hardware Settings Model 498.65 ADDA Board Settings This card is compatible with FlexTest IIm controllers. Item Description 498.65 ADDA circuit board When the optional Model 498.65 ADDA board is being used, the .hwi icon file describes this board and the A/D, D/A, and various mezzanine cards that are installed on it, as follows: • Model 493.65A-10 8-A/D (8-Channel) • Model 493.65A-11 8-D/A (8-Channel) • Model 493.65A-12 Encoder • Model 493.65A-15 Temposonics • Model 493.
HWI Hardware Settings Item Description Changing this name may invalidate existing station configurations. Connector: Not applicable. Model 498.71 GRES II Board Settings This card is compatible with FlexTest IIm controllers. Item Description 498.71 GRES II circuit board icon The Model 498.71 GRES II board supports both the Remote Station Controller (RSC) and the temperature controller.
HWI Hardware Settings Mezzanine Card Compatibility The following table lists the different mezzanine cards and the type of carrier board where they can be used. Mezzanine Card 493.40 494.40 498.65 I/O I/O ADDA Carrier Carrier Board 493.14 2SVD# X 493.15 3SVD# X 493.21 DUC, 493.21B DUC, 493.25 DUC X 493.45 6-A/D X 493.46 6-output D/A X 493.47 Encoder Card X 493.48 Accelerometer Input X 493.50 ADDA II Board 493.55 8-A/D (8-Channel), 493.57 8-A/D (8-Channel) X 493.
HWI Hardware Settings Model 493.40 I/O Carrier Mezzanine Cards The Model 493.40 board is compatible with FlexTest GT, Aero ST, and TestStar IIm controllers. Model 493.1x Valve Driver Settings The following settings apply to the Model 493.14 Two-Stage Valve Driver and the Model 493.15 Three-Stage Valve Driver. Item Description 493.14 2SVD mezzanine Describes the valve driver mezzanine card. card icon 493.
HWI Hardware Settings Item Description Zero—Clamps the servovalve to zero—if valve balance is used, it will clamp to this value. Positive—Clamps the servovalve to positive 50% spool opening on a 2-stage valve driver, 50% outer-loop command on the 3-stage valve driver. Negative—Clamps the servovalve to negative 50% spool opening on a 2-stage valve driver, 50% outer-loop command on a 3-stage valve driver. 2SVD icon Range: Defines the output (in mA) of the valve driver. The settings are 25 or 50.
HWI Hardware Settings How to Add Accelerometer Compensation to a Model 493.21B/493.25 DUC This procedure only applies to Model 493.21B and 493.25 DUCs. 1. Add a 493.48 Accelerometer Conditioner board to the .hwi file. 2. Right-click the DUC icon and select Add Accelerometer Compensation. A 493.48 Accel Input resource appears as an Auxiliary Input on the DUC Properties tab. 3. If necessary, change the hardware resource name to match the Accel Input where the accelerometer is physically connected.
HWI Hardware Settings a) Click the Serial LoadWasher icon. b) From the Serial Port drop-down list, select the serial port where the loadwasher is connected. c) Verify the scale settings are correct for the loadwasher that you are using. d) If you want to assign custom names to each range, use the Hwi FIle Editor application to change the range names to match the range names that you will use in the Station Manager application.
HWI Hardware Settings Item Description No Channel Excludes inputs to the selected channel. Channels tab 493.79 Multiple Universal Valve Driver (MUD) For special applications, the Model 493.79 Multiple Universal Driver (MUD) board can provide up to six driver signals to drive standard 252 servovalves. Inputs to the MUD board originate from a Model 493.46 D/A mezzanine card on the Model 493.40 I/O Carrier boards.
HWI Hardware Settings Item Description Changing this name may invalidate existing station configurations. Connector: Identifies the I/O Carrier rear panel connector that is available for MUD board output. This will likely move up to the daughter level. Encoder icon Mode: Specifies what type of device is to be connected. Options are Incremental, Temposonics 24 Bit, Temposonics 25 Bit, and Teledyne (absolute encoder, hardware supports 17-bit resolution). Model 493.
HWI Hardware Settings Item Description and limit detector signals. Each D/A mezzanine card definition is followed by eight signal definitions. Properties tab Filter: On/Off. The 493.57 A/D Card includes an elliptical filter with the following settings (available through the Analog Input icon): off, 500, 1000, 1500, 2000 Hz. Channels tab Analog Input n High Level Specifies an externally conditioned signal in the range of +/-10V. No Channel Excludes inputs to the selected channel. 497.13 AC/497.
HWI Hardware Settings Model 493.59x Encoder Card Settings Encoder mezzanine cards use the following designators for each type of encoder: 1 for absolute encoders, 3 for incremental encoders, and 5 for Temposonics III encoders Item Description 493.59-1 U2 Absolute/ Encoders require a special mezzanine card be plugged into the 493.59-3 U2 Incremental/ ADDA II board. The encoder mezzanine card can occupy any of the 493.59-5 U2 Temposonics four ADDA II address locations.
HWI Hardware Settings High Speed Data Acquisition Settings Each Series 494 DUC has a High Speed Data hwi setting that is used to enable high-speed data acquisition. Note: High-speed data acquisition is required for some applications (for example, the MPT High Speed Timed Acquisition process). High-speed data limitations The Model 494.40 I/O Carrier board allows up to six high-speed data inputs per carrier board. This could be an issue if four Model 494.26 Dual DUCs are installed on a 494.40 I/O carrier.
HWI Hardware Settings Item Description 494.16 Analog Input icon Note: The Analog Input icon only appears if the 494.16 VD/DUC is configured as a two-stage valve driver. Name: Describes this resource as it will appear in Station Builder resource lists when opened against an .hwi file. Changing this name may invalidate existing station configurations. Connector: Describes the front-panel I/O Carrier connector assigned to this input. Application Attribute: Not applicable.
HWI Hardware Settings Item Description CAUTION: Your controller’s hardware interface file (.hwi) includes options to clamp the servovalve when a hydraulic interlock occurs (these options cause the actuator to stop, fully extend, or fully retract). However, if the servovalve is imbalanced, it may move unexpectedly when clamped. Unexpected actuator movement can cause injury and equipment damage. Before enabling the valve clamp feature, ensure that the servovalve is balanced.
HWI Hardware Settings Item Description True=enables high-speed data acquisition. The high-speed rate is determined by the system rate and a number of other factors. False (default) = high-speed data acquisition is not available. The Model 494.40 I/O carrier limits the number of high-speed data inputs on a carrier to a maximum of six. 494.xx DUC icon Mode: Specifies the transducer type (AC/DC) connected to the DUC.
HWI Hardware Settings How to Add a DI/O Load Washer to a Model 494.21 Card 1. Add a 494.21 card resource to the .hwi file. 2. Right-click the DUC icon and select Add DIO Load Washer. A DI/O Load Washer icon appears below the DUC icon. 3. Click the DI/O Load Washer icon and verify that the hardware resource names that appear in the Zero Bit, One Bit, and Enable boxes are correct. 4.
HWI Hardware Settings d) If you want to assign custom names to each range, use the Hwi FIle Editor application to change the range names to match the range names that you will use in the Station Manager application. Note: The range names that appear in the Serial LoadWasher Properties tab must match the range names assigned in the Sensor tab in the Station Manager application. Model 494.25/494.26 DUC HWI Settings The settings for both the Model 494.25 Single DUC and Model 494.
HWI Hardware Settings Model 494.45 8-Input A/D Converter HWI Settings Item Description 494.45 8-Input A/D mezzanine card icon Describes the eight-channel analog-to-digital converter mezzanine card. Properties tab Application Attribute: Not applicable Channels tab Each analog input has a drop-down menu where you can select one of the following input options: High Level Specifies an externally conditioned signal in the range of +/-10V. No Channel Excludes inputs to the selected channel.
HWI Hardware Settings Item Description 49x.79 Multiple Universal Valve Driver Specifies that this output is used to drive one of the valve drivers on the Model 49x.79 8-Channel Valve Driver transition board. When you select the 49x.79 Valve Driver, the Assign Channels window appears. # of Channels: Specifies the number of analog output channels to which the MUD board applies. By default, this number will include the current and all descending channels.
HWI Hardware Settings Item Description Encoder Properties Note: The following settings only appear if Encoder was selected from the Type menu. Application Attribute: Not applicable Mode : specifies the type of encoder used with this card: Gurley (Teledyne), Incremental/Velocity, SSI (Temposonics R), PWM (Temposonics G). Debounce Filter: specifies the filtering applied to the input signal.
HWI Hardware Settings Item Description Encoder icon Mode Selections include Rotary or Linear. Turns Counting (rotary encoders only): (only available for SSI (Temposonics R) and Gurley (Teledyne) settings) True: the firmware adds an offset to the signal that reflects the number of turns (for each turn, the firmware adds 360 degrees to the encoder output signal.) For example, if the device powers up at 0 degrees and rotates 1.5 positive revolutions, the encoder channel will read 540 degrees.
HWI Hardware Settings Item Description Input Filter Settings: Filter Type: Used to select the type of digital filter used to filter the input signal. Filter selections include: Disabled, Bessel, Butterworth, and Elliptical. (Default=Bessel, 300 Hz.) Filter: This is the frequency where the filter, selected in the Filter Type box, attenuates the signal by 3 dB. Low frequency limit = >0 Hz (A setting of 0 disables the filter.) High frequency limit = 1/2 the system rate.
HWI Hardware Settings Item Description UART Serial Comm icon Note: Only appears when UART is selected as the device type. Connector: the connector that joins the resource to the chassis. Name: describes this resource as it will appear in Station Builder resource lists when opened against an .hwi file. Note: Changing this name may invalidate existing station configurations. Baud Rate: select the baud rate for the serial device. Type: select the type of device (2-wire or 4-wire).
HWI Hardware Settings Application Encoder Settings Type = Signed Type = Unsigned Physical Zero Position at Mid Stroke (device dependent) N/A Velocity from Device (Temposonics R option) N/A Note: The graphs shown above represent a 12-bit linear device.
HWI Hardware Settings Application Encoder Signal Range Encoder Settings Power-up Signal range Type Turns Counting Position Filter Signed True Yes Signed False See Note Operating Signal range Position-Limited Rotation Power-up signal range: -180 to +180 degrees Unlimited Rotation Operating-signal range: -180 to +180 degrees Note: Rotary SSI/Gurley devices with Turns Counting = False: filtering may be undesirable because as the signal is filtered, the angle step that occurs every 360 degrees
HWI Hardware Settings Item Description Resolution (bits): this setting must match the number of bits in the encoder’s data stream. Baud Rate: specifies the communications clock rate between the processor and the encoder. Igel Wheel Force Transducers are typically set to 250 or 500. Type: specifies the type of encoding (Binary or Gray Scale) used by the encoder. Igel Wheel Force Transducers are typically set to Binary.
HWI Hardware Settings Item Description Filter Type: Used to select the type of digital filter used to filter the input signal. Filter selections include: Disabled, Bessel, Butterworth, and Elliptical. (Default=Bessel, 300 Hz.) Filter: This is the frequency where the filter, selected in the Filter Type box, attenuates the signal by 3 dB. Low frequency limit = >0 Hz (A setting of 0 disables the filter.) High frequency limit = 1/2 the system rate.
HWI Hardware Settings Model 498.65A-10 Eight-Channel Card Settings Item Description 498.65A-10 8-A/D mezzanine card icon The Model 498.65A-10 8-A/D mezzanine card, available for installation on ADDA boards, provides 8 channels of A/D with digital filtering. Filter settings can be applied to controller feedback, scope, meter, and limit detector signals. Each D/A mezzanine card definition is followed by eight signal definitions.
HWI Hardware Settings Item Description Properties tab Address: Describes the proximity of the mezzanine card within the circuit board. This value is generated during initialization, and should be changed only if the value read in from an existing .hwi file is in error. Filter: Off/On. Channels tab Analog Output n High Level Specifies an externally conditioned signal in the range of +/-10V. No Channel Excludes inputs to the selected channel. 497.15 3-Stage/497.26 Chassis: Not applicable.
HWI Hardware Settings Transition Board Settings Transition boards are used in FlexTest GT, TestStar IIm, Aero ST, and FlexTest 60/100/200 controllers. Model 493.72 Digital I/O Transition Board Settings Item Description 493.72 DI/O transition board icon The DI/O Transition Board definition describes the Model 493.72 Digital I/O Transition Panel digital input and outputs. The information shown defines 16 digital inputs and 16 digital outputs.
HWI Hardware Settings Item Description Off-low-high–three HPU control buttons (Off/Low/High) will appear on the Station Manager Station Controls panel. First On: True: Indicates that the first HSM turned on activates the HPU. False: Setting First On and Last Off to False allows the HPU to turn on independent of HSM power. Setting First On and Last Off to True allows HSM Low selection to activate HPU high without pressing the HPU buttons. Last Off: True: Causes the last HSM turned off to turn off the HPU.
HWI Hardware Settings Item Description Hydraulic Interface icon (continued) Low Percent: 25. HSM low pressure setting as a percentage of full-scale. High Percent: 100. HSM high pressure setting as a percentage of full-scale. HSM Rate: Slow = 4 seconds. Fast = 2 seconds.
HWI Hardware Settings Unexpected actuator movement can result in injury to personnel or damage to the equipment. Enable the gate interlock option for systems that include a Slow (low-flow) mode for specimen installation. Model 494.74 HSM Transition Board Item Description 494.74 HSM transition board icon The hydraulic control definition assigns the Hydraulic Power Unit (HPU) transition board and each Hydraulic Service Manifold (HSM) transition board to their appropriate rear panel connectors.
HWI Hardware Settings Item Description Assign to Interlock: Select a interlock chain (1–8) for the HSM interlocks. Typically, the interlock chain assignment that you make in the .hwi file should match the interlock chain that you assign to the station when you load it in Station Manager. Low Flow Interlock: True or False, True=controller responds to a low-flow interlock signal on J3.
HWI Hardware Settings Miscellaneous Device Settings Use the drop-down lists in the Miscellaneous tab to add various external devices to the .hwi file. The devices listed here are not automatically added by the Hardware Detect option. Temperature Controller Settings Item Description Temperature Control icon This indicates a Eurotherm Series 2200 or Series 2400 temperature controller is connected to the controller. A Model 409 Temperature controller may contain multiple Eurotherm controller channels.
HWI Hardware Settings Item Description If a GRESIII board is used, you must set the baud rate for the serial port to 9600. Channels: Specifies the number of temperature controllers on that will share the serial port. For example, a Model 409 Temperature controller may contain multiple Eurotherm temperature controllers that all share the same serial port. For FTIIm Systems–The maximum number of temperature controllers that can be supported is 16, four on each of the four GRES ports.
HWI Hardware Settings Temperature Controller Settings Item Description Temperature Control icon This indicates a Eurotherm Series 2200 or Series 2400 temperature controller is connected to the controller. A Model 409 Temperature controller may contain multiple Eurotherm controller channels. A GRESIII board or Model 494.47 Dual UART/Encoder card is required to support a temperature controller. Type: Enter the name of the temperature controller as desired.
HWI Hardware Settings Remote Station Control (RSC) Settings The RSC can not be used with Series 494 hardware. Note: The FlexTest SE and FlexTest 40/60/100/200 Controllers do not support RSCs. Item Description Remote Station Control icon The Remote Station Controller (RSC) is a table-top, stand-mounted, or hand-held device that is primarily used for specimen installation and the starting and stopping of tests. A GRES III board is needed to support an RSC in your system.
HWI Hardware Settings Model 494.05 Handset Settings Item Description Handset icon The Model 494.05 Handset is primarily used for specimen installation and the starting and stopping of tests. The handset requires a hardware resource with serial ports (such as the Model 494.47 UART card, Ramix Serial Card, or GRES III card). Name: Specifies the desired resource name. Changing this name will not cause file conflicts. Serial Port: Select the serial port where the Handset is connected.
HWI Hardware Settings CAN Bus Interface Note: CAN Bus interface support is not available for MTS FlexTest SE Controllers. CAN Bus Interface Requirements A controller area network (CAN) bus interface requires a CAN bus controller mezzanine card that is installed on a processor board. The CAN bus card can include multiple CAN controllers that are configured and assigned independently. The mezzanine card provides a network connector for each CAN bus port. CAN Bus Interface Setup 1. Open the .hwi file. 2.
HWI Hardware Settings Item Description Modbus icon(s) This icon represents a Modbus device connected to the controller through an Ethernet switch. Type: This field is set to Generic by default. Select Wago if the Modbus node is Wago. If the Type is Wago and both input and output process image offsets are 0 (zero), 793 Sysload will perform a Modbus node module verification. IP Address: Enter the IP address that was previously assigned to the Modbus node (using the manufacturer’s configuration hardware).
HWI Hardware Settings How to Configure a Read-Only HSM Read-only HSMs require digital input resources that monitor digital HSM pressure signals. The HWI Editor application assigns two digital inputs to each read-only HSM. 1. Make sure that the controller has the digital input resources required by the read-only HSM. 2. Click the Controller icon and then click the Miscellaneous tab. 3. Select the # of Read-only HSMs from the drop-down list. A Read-only HSM icon appears in the navigation pane. 4.
HWI Hardware Settings “On Bit” Digital Input “High Bit” Digital Input HSM State High High High HSM Pressure Single input The following table shows the control logic for systems where both the On Bit and High Bit digital input resource name assignments are the same. Digital Input HSM State Low HSM Off High High HSM Pressure Note: Refer to the controller hardware manual to determine digital input wiring and specifications. Uninterruptible Power Supplies (UPS) The Model 493.
HWI Hardware Settings UPS Input/Output Description UPS Low Battery (Digital Input 2) This input changes state when the UPS normally open Low Battery contacts open to indicate that UPS battery power is low (regardless of whether the UPS is supplying power to the system or not). UPS External Event (Digital Only supported in systems that use a Model 493.73 HPU Input 3) board. UPS Off (Digital Output 1) Not Used. b) Define the State, Persistence, and Polarity settings for each UPS input.
HWI Hardware Settings Slot Number 1 2 Address PPC 3 4 5 6 7 8 9 10 C20 C22 C24 C26 C28 C2A C2C C2E The DIP switch settings for address C20 is shown below.
HWI Hardware Settings How to set the Model 494.40 I/O Carrier Board Address The address setting for the I/O Carrier board must match the settings used by the system control software. 1. Determine the I/O Carrier address. 2. Locate address switches SW1 and SW2 on the I/O Carrier circuit board and set the board address using the settings shown below.
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Controller Management Tool Topics: • • Controller Options Description..............................................................................................92 Using the Controller Management Tool.................................................................................
Controller Management Tool Controller Options Description Selecting Controller Options on the Controller Management Tool window opens the Controller Options window, which allows you to configure local settings on the Controller. The activities you can perform with the Controller Options window varies with the type of Controller you have. For FlexTest SE controllers The Controller Options window includes Controller Attributes, Passwords, User Files, Regional Settings, and License Keys tabs.
Controller Management Tool For Aero ST controllers The Controller Options window displays only the Controller Attributes tab. Note: The Controller Type for FlexTest SE Controllers is always set to Independent. Aero ST Controllers may be set to either Master, Dependent, or Independent. Controller Attributes tab Multi controller considerations Important: Ensure that the ID of each Controller you plan to use in a network is unique before changing it.
Controller Management Tool Item Description Controller Name Specifies the controller’s name. By default, the name will be the serial number of the Model 493.42 System I/O Board (for FlexTest SE Controllers) or Model 493.43 System I/O Board (for Aero ST Controllers) in the Controller chassis. You can change this name as desired. When operating in the automation mode, the controller name may appear in the title bar of the Station Builder and Station Manager applications.
Controller Management Tool Item Description This value is read by the CMT application from the switch setting on the Model 493.43 System I/O Board. The displayed value is read-only. Important: During system setup, the Model 493.43 System I/O Board in one of the controllers must be set to 0 to provide a Master Controller. If no controller or more than one controller is designated as a Master, the controller network will not operate.
Controller Management Tool Item Description Independent: Specifies controllers which are not subordinate to the Master Controller. Note: If you change the Controller Type you must re-register the controller using the Register Multiple Controllers control. Note: Aero ST hwi files are automatically labeled “aero.hwi” for new systems (existing .hwi names are preserved). User Files tab (FlexTest SE only) Use the User Files tab to select the name of both the hardware configuration file (.
Controller Management Tool Regional Settings tab (FlexTest SE only) Use the Regional Settings tab to change elements of the controller that pertain to localization. For instance, you can select how the controller displays the date, and the units with which the controller displays data values. Item Description Language English is the standard language installed on the Controller and displayed on the interface. If available, select other languages as desired.
Controller Management Tool Item Description Date Format Selects the format in which the date stamp is displayed on the message log. Select M/D/Y, D/M/Y, or D.M.Y. Appearance examples: M/D/Y, 4/24/2002; D/M/Y, 24/4/2002; D.M.Y., 24.4.2002. Time Format Selects the format in which the time stamp is displayed on the message log. Select 12-hour or 24-hour. Appearance examples: 12-hour, 6:31:23 PM; 24-hour, 18:31:23.
Controller Management Tool Passwords tab (FlexTest SE only) Use the Passwords tab to enter passwords for tuning, calibration, and configuration level access for the selected controller. Important: Passwords should only contain characters found on the controller’s front panel’s numeric keypad. These are the only keys available when entering passwords in stand-alone mode.
Controller Management Tool FlexTest SE multi Controller Considerations Important: If you intend to operate the controller in a network, ensure the ID and name of each controller in the network is unique. Do this before cabling the controllers to the hub of the supervising PC and launching the Controller Management Tool. It is good practice to examine the ID of every controller you wish to operate in a controller network before you cable the network.
Controller Management Tool Path: Start > Programs > MTS 793 System Software > Tools You can also launch the application by typing ctrmgmttool from the command line. 5. In the CMT Controllers list, select the controller you just rebooted. 6. In the Next Controller Boot Mode selection list, select Service. 7. Reboot the controller again. Press the CMT Reboot Controller button. The controller will boot up in the Service mode, displaying the MTS logo. 8. Perform the desired service operation.
Controller Management Tool To avoid running out of flash memory, make sure that the backup directory does not contain an excessive number of files. 4. If desired, select Backup User Files to copy the user files in the controller to the servicing PC. The files are copied to a designated root directory destination or to a new folder. 5. Perform other operations as desired. 6. In the Next Controller Boot Mode selection list, select Standalone, Standalone/Net, or Automated, as appropriate. 7.
Controller Management Tool How to Set Controller Options on FlexTest SE Controllers From the controller’s front panel, press Config > Local Settings to change Controller options. Note: You typically use the controller’s front panel to change the controller options. CMT offers the Controller Options window as a convenience. If you are using CMT to accomplish another task, you may find it efficient to use CMT to change controller options as well. Otherwise, use the front panel of the FlexTest SE Controller.
Controller Management Tool 3. Select Controller Options. 4. Under the Controller Attributes tab, give the controller a unique name and verify proper controller type (Master, Dependent). 5. Repeat steps 2 through 4 for all controllers in the list. 6. Select Register Multiple Controllers. About Rebooting Aero ST Controllers with CMT When the system and a station is loaded When a station is loaded, you cannot reboot any controller (Master or Dependent) from CMT.
Index 409 temperature controller 66 493.1x Valve Driver 47 493.2x DUC mezzanine card 48 493.42 System Board 41 493.45 6-A/D mezzanine card 50 493.46 6-D/A mezzanine card 50 493.47 Encoder mezzanine card 51 493.48 Accel. Input mezzanine card 52 493.55 8-A/D mezzanine card 52 493.56 8-D/A mezzanine card 53 493.57 8-A/D mezzanine card 52 493.59-1 U2 Absolute mezzanine card 54 493.59-3 U2 Incremental mezzanine card 54 493.59-5 U2 Temposonics III mezzanine card 54 493.72 DI/O transition board 73 493.
D D/A 50, 53 493.46 Six-Output D/A 50 493.56 8-channel D/A 53 decimal separator 97 digital I/O definition 73 DUC 48, 49, 57, 59, 60 493.2x 48 494.21 57 494.25/494.26 60 accelerometer compensation 49 DI/O load washer 49, 59 serial load washer 49, 59 E elastomer DUC 57 494.21 mezzanine card 57 encoders 51, 54, 62, 64, 70 493.47 51 493.59x 54 494.47 Dual UART/Encoder/External Clock 62 494.49 Quad Encoder 70 autozero on index pulse (494.47/494.49) 64 external clock 62 494.
stand-alone boot mode stand-alone w/network boot mode status bar description system options, updating 92 T temperature controllers 79 Temposonics sensors 54 definitions (hwi file) 54 time format control 98 U UART 62 uninterruptable power supply (UPS) 86 unit assignment set 98 unregister controller control update/backup user files 101 update system files update user files UPS 86, 87 line fault detector 86 low battery detector 87 user file access for registered automated controllers 104 user files 101 upda
108 MTS Series 793 Utility Software
100-147-132 L
