MTS Series 793 Utility Software

Transcription

1 MTS Series 793 Utility Software User Information and Software Reference R

2 2015 MTS Systems Corporation. All rights reserved. MTS Trademarks MTS, be certain., Bionix, Echo, ElastomerExpress, FlatTrac, FlexTest, Just In Case, Landmark, Level Plus, MTS Acumen, MTS Criterion, MTS Echo, MTS EM Extend, MTS Exceed, MTS Insight, MTS Landmark, MTS TestSuite, RPC, SWIFT, Temposonics, TestWare, TestWorks are registered trademarks of MTS Systems Corporation within the United States. Acumen, AdapTrac, Advantage, Aero ST, Aero- 90, AeroPro, Criterion, crpc, Exceed, First Road, Landmark, MAST, MicroProfiler, MPT, MTS Exceed, MTS Fundamentals, MTS TestSuite, ReNew, SilentFlo, TempoGuard, TestLine, Tytron, Virtual Test Lab, and VTL are trademarks of MTS Systems Corporation within the United States. These trademarks may be registered in other countries. All other trademarks are the property of their respective holders. Proprietary Software Software use and license is governed by MTS End User License Agreement which defines all rights retained by MTS and granted to the End User. All Software is proprietary, confidential, and owned by MTS Systems Corporation and cannot be copied, reproduced, disassembled, decompiled, reverse engineered, or distributed without express written consent of MTS. Software Verification and Validation MTS software is developed using established quality practices in accordance with the requirements detailed in the ISO 9001 standards. Because MTS-authored software is delivered in binary format, it is not user accessible. This software will not change over time. Many releases are written to be backwards compatible, creating another form of verification. The status and validity of MTS operating software is also checked during system verification and routine calibration of MTS hardware. These controlled calibration processes compare the final test results after statistical analysis against the predicted response of the calibration standards. With these established methods, MTS assures its customers that MTS products meet MTS exacting quality standards when initially installed and will continue to perform as intended over time. Manual Part Number Publication Date Release R (English) May A

3 Contents Technical Support 11 How to Get Technical Support 11 Start with your manuals 11 Technical support methods 11 Outside the U.S. 11 Before You Contact MTS 11 Know your site number and system number 11 Know information from prior technical assistance 12 Identify the problem 12 Know relevant computer information 12 Know relevant software information 13 If You Contact MTS by Phone 13 Identify system type 13 Be prepared to troubleshoot 14 Write down relevant information 14 After you call 14 Problem Submittal Form in MTS Manuals 14 Preface 15 Before You Begin 15 Safety first! 15 Other MTS manuals 15 Documentation Conventions 15 Hazard conventions 15 Other special text conventions 16 Special terms 16 Illustrations 16 MTS Series 793 Utility Software 3

4 Contents Electronic manual conventions 16 Hypertext links 16 HWI-File-Editor Overview 17 About.hwi files 18 About the Hwi File Editor Application 18 Starting Hwi File Editor 18 Hwi File Editor Controls 19 About Multiple.hwi Files 22 Saving Multiple.hwi Files in a Controller Directory 23 Selecting.hwi Files in a Controller Directory 24 Create and Edit an HWI File 25 Create a New File 26 Create New hwi File for Single Box System 26 Hardware Resources 26 Hardware Resources Listed in.hwi File 26 About Detect Hardware Feature 26 Use Detect Hardware Feature 27 About.hwi Miscellaneous Hardware 27 Manually Add VME Board to.hwi File 27 Manually Add Mezzanine Card to.hwi File 28 Manually Add Transition Board to.hwi File 28 Configure Hardware Resource Settings 28 Valve Driver Settings 28 Digital Universal Conditioner (DUC) Settings 28 Analog Input Filter Settings 28 4 MTS Series 793 Utility Software

5 Contents Encoder Type Settings 29 Hydraulic Interface Settings 29 Optional Hardware Resource Name Changes 30 VME Board Address Settings 31 About Actuator Movement When the Servovalve is Clamped 31 Servovalve balance 31 Mechanical balance 31 Electrical balance 31 Inner-loop tuning 31 Where to Find Valve Balance Procedures 32 Mechanical valve-balance procedures 32 Electrical valve-balance and inner-loop tuning procedures 33 HWI Hardware Settings 35 About Hwi File Editor Default Settings 36 Edit Hwi Default Settings 36 Apply Hwi Default Settings 38 Export HWI Defaults 40 Import HWI Defaults 40 System Options Settings 41 System Options icon 41 VME Bus Board Settings 41 About Processor Boards 42 Reconfigure Processor Functions 43 Processor Hwi Settings 43 Model ADDA II Board Settings 45 Model GRES II Board Settings 47 MTS Series 793 Utility Software 5

6 Contents Model 49x.43 Multibox I/O Board Settings 47 Model 49x.40 I/O Carrier Board HWI Settings 48 Model Single-Station System Board Settings 50 Model Single-Station System Board Settings 52 Model Two-Station System Board Settings 56 Model System Board Settings 58 Model ADDA Board Settings 61 Model Digital I/O Board Settings 62 Model GRES II Board Settings 63 Model I/O Carrier Mezzanine Cards 64 Mezzanine Card Compatibility 64 Model 493.1x Valve Driver Settings 65 Model 493.2x DUC Card Settings 66 How to Add Accelerometer Compensation to a Model B/ DUC 66 How to Add a DI/O Load Washer to a Model B/ DUC 67 How to Add a Serial Load Washer to a Model B/ DUC 67 Model Six-Channel A/D Card Settings 67 Model Six-Output D/A Card Settings 68 Model Encoder Card Settings 69 SSI/Gurley Encoder Application Settings 70 Model Accelerometer Input Card Settings 72 Model ADDA II Mezzanine Cards 72 Model / Channel A/D Card Settings 72 Model Channel D/A Card Settings 73 Model x Encoder Card Settings 73 Model I/O Carrier Mezzanine Cards 74 High Speed Data Acquisition Settings 74 6 MTS Series 793 Utility Software

7 Contents Model VD/DUC HWI Settings 75 Model Multi-Range DUC with Acceleration Compensation Card HWI Settings 77 How to Enable Acceleration Compensation on the Model Card 79 How to Add a DI/O Load Washer to a Model Card 79 How to Add a Serial Load Washer to a Model Card 80 Model / DUC HWI Settings 80 Model Input A/D Converter HWI Settings 81 Model Output D/A Converter Card HWI Settings 82 Model Dual UART/Encoder/External Clock HWI Settings 84 SSI/Gurley Encoder Application Settings 87 Model Quad Encoder Interface HWI Settings 88 Model A-10 Eight-Channel Card Settings 89 Model A-11 D/A Card Settings 89 Model A-12 Encoder Card Settings 90 Transition Board Settings 90 Model Digital I/O Transition Board Settings 91 Model HPU Transition Board Settings 92 Model HSM Transition Board 93 Model HSM Transition Board 96 FlexTest IIm Chassis Settings 97 Miscellaneous Device Settings 98 Temperature Controller Settings 100 Remote Station Control (RSC) Settings 102 How to Add Remote Station Controls (RSC) 103 Model Handset Settings 103 Model Handset Hwi File Editor Settings 104 CAN Bus Interface 104 MTS Series 793 Utility Software 7

8 Contents Modbus Interface Settings 105 About EtherCAT 106 About Read-Only HSMs 109 How to Configure a Read-Only HSM 109 Read-Only HSM Control Logic 110 Uninterruptible Power Supplies (UPS) 111 How to Set Model I/O Carrier Address (FlexTest GT/SE, TestStar IIm) 113 How to Set ADDA II Board Address (FlexTest GT, TestStar IIm, FlexTest IIm) 113 How to set the Model I/O Carrier Board Address 114 Controller Management Tool 115 Controller Options 116 For FlexTest SE controllers 116 For Aero ST controllers 116 Controller Attributes tab 117 User Files tab (FlexTest SE only) 119 License Keys tab (FlexTest SE only) 120 Regional Settings tab (FlexTest SE only) 120 Passwords tab (FlexTest SE only) 122 Using the Controller Management Tool 123 FlexTest SE multi Controller Considerations 123 FlexTest SE Version Checking 123 How to put a FlexTest SE Controller in the Service boot mode 124 How to Install or Update System Files on FlexTest SE Controllers 124 How to Update or Backup User Files on FlexTest SE Controllers 125 How to Register a FlexTest SE Controller for Automation 125 How to Unregister a FlexTest SE Controller MTS Series 793 Utility Software

9 Contents How to Set Controller Options on FlexTest SE Controllers 126 How to Configure a FlexTest SE Controller to Boot in a Different Boot Mode 126 How to Configure a New Aero ST Multi Controller System 127 About Rebooting Aero ST Controllers with CMT 127 User File Access for Registered Controllers 127 Acumen System Setup 129 Acumen Hwi Setup 130 Acumen Hwi Settings 130 Index 135 MTS Series 793 Utility Software 9

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11 Technical Support 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. Technical support methods MTS provides a full range of support services after your system is installed. If you have any questions about a system or product, contact Technical Support in one of the following ways. Type of Support Web site Telephone Details > Contact Us (upper-right corner) > In the Subject field, choose To escalate a problem; Problem Submittal Form Worldwide: tech.support@mts.com Europe: techsupport.europe@mts.com Worldwide: toll free in U.S.; outside U.S. Europe: , International toll free in Europe 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: > Global Presence > Choose a Region 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. Example site number: MTS Series 793 Utility Software 11

12 Technical Support 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: US Know information from prior technical assistance If you have contacted MTS about this problem before, we can recall your file based on the: MTS case 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? Know relevant computer information For a computer problem, have the following information available: Manufacturer s name and model number Operating software type and service patch information Amount of system memory Amount of free space on the hard drive where the application resides Current status of hard-drive fragmentation Connection status to a corporate network 12 MTS Series 793 Utility Software

13 Technical Support 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. 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 address Name Company name Company address Phone number where you can be reached If your issue has a case number, please provide that number. A new issue will be assigned a unique case number. 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: Electrodynamic material test system Electromechanical material test system Hydromechanical material test system Vehicle test system Vehicle component test system Aero test system MTS Series 793 Utility Software 13

14 Technical Support Be prepared to troubleshoot Prepare to perform troubleshooting while on the phone: 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 information In case Technical Support must call you: Verify the case 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 case 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. You can access the Problem Submittal Form at > Contact Us (upper-right corner) > In the Subject field, choose To escalate a problem; Problem Submittal Form 14 MTS Series 793 Utility Software

15 Preface Preface Before You Begin Safety first! Before you use your MTS product or system, read and understand the 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. Controller and application software manuals are typically included on the software CD distribution disc (s). 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. (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. MTS Series 793 Utility Software 15

16 Preface Other special text conventions Important: Important notices provide information about your system that is essential to its proper function. While not safety-related, if the important information is ignored, test results may not be reliable, or your system may not operate properly. Note: Notes provide additional information about operating your system or highlight easily overlooked information. Recommended: Recommended notes provide a suggested way to accomplish a task based on what MTS has found to be most effective. Tip: Tips provide helpful information or a hint about how to most efficiently accomplish a task. Access: Access provides the route you should follow to a referenced item in the software. Example: Examples show specific scenarios relating to your product and appear with a shaded background. Special terms The first occurrence of special terms is shown in italics. Illustrations Illustrations appear in this manual to clarify text. They are examples only and do not necessarily represent your actual system configuration, test application, or software. Electronic manual conventions This manual is available as an electronic document in the Portable Document File (PDF) format. It can be viewed on any computer that has Adobe Acrobat Reader installed. Hypertext links The electronic document has many hypertext links displayed in a blue font. All blue words in the body text, along with all contents entries and index page numbers, are hypertext links. When you click a hypertext link, the application jumps to the corresponding topic. 16 MTS Series 793 Utility Software

17 HWI-File-Editor Overview HWI-File-Editor Overview About.hwi files 18 About the Hwi File Editor Application 18 Starting Hwi File Editor 18 Hwi File Editor Controls 19 About Multiple.hwi Files 22 Saving Multiple.hwi Files in a Controller Directory 23 Selecting.hwi Files in a Controller Directory 24 MTS Series 793 Utility Software 17

18 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 files and Station Builder You use the Station Builder application (one of the applications included with MTS System Software) to define test stations by allocating some or all of the resources listed in the.hwi file. Initial.hwi files are typically created at MTS The.hwi file associated with a given controller is typically created at MTS according to the resources included with the controller. It may be necessary to edit this file if system resources are added, removed, or repositioned in the controller chassis. About the Hwi File Editor Application The Hwi File Editor is a utility used to create and edit hardware interface (.hwi) files. Starting Hwi File Editor The typical path to the Hwi File Editor is as follows: Start > Programs > MTS 793 System Software > Service Tools Note: You can also launch the application by typing hwieditor from the command line. Supported MTS Controllers FlexTest 40/60/100/200 FlexTest IIm (498.xx) FlexTest GT/TestStar IIm (493.10) FlexTest SE (493.02) TestStar IIs (493.01) Aero ST (493.20) 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 18 MTS Series 793 Utility Software

19 HWI-File-Editor Overview 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, the Hwi File Editor has a fill-down function that automatically assigns proper channel numbers and resource names. The Detect Hardware feature automatically detects VME and transition bus hardware and adds those resources to the current file opened in the Hwi File Editor application. This is the preferred method when you create a new.hwi file. Changing.hwi files at customer sites While the primary use of the Hwi File Editor is to create.hwi files for systems before they leave MTS, it can also be used to make modifications to.hwi files at customer sites. For instance, if a system in the field adds new hardware because of a need for additional conditioning, the Hwi File Editor can be used to reflect those changes in the system s existing.hwi file. Hwi File Editor Controls MTS Series 793 Utility Software 19

20 HWI-File-Editor Overview Number callout in graphic Menu File: Use the File menu commands to create, open, change, save, and print files. You can also exit the application from this menu. Note: Whenever you save an.hwi file that has been modified, a backup copy is automatically created. 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. Once you assign a resource to a configuration, renaming that resource in the.hwi file will invalidate the configuration file. When you select this option, the Hwi File Editor renames all of the analog input/output, digital input/output (except on a GRES card), and HPU and HSM resources using syntax that includes the slot number and connector name in the resource name. For example, a DUC in the first mezzanine location on an I/O Carrier in slot 5 is named DUC S5-J4. Conditioners and valve drivers assigned to A/Ds or D/As use the conditioner/driver model, chassis and connector. For example, a dual DC conditioner in chassis 2, slot 10, and channel 1 is named DDC C2-J1001. After selecting this option, review the new names to make sure they are acceptable. When you create a station with these renamed resources (with Station Builder) and open that station (with Station Manager), the HPU and HSM resources will appear on the Station Manager panel as they are saved in the.hwi file. You can use Station Builder to assign logical display names (such as load, displacement) to other types of resources when allocating those resources to create a test station. Reconfigure Processors: For Controllers equipped with the Time History Playback (THP) option and two processors, this option allows you to change the way the processors are initialized. Note: This option will be grayed-out if your controller is not equipped for THP, or 20 MTS Series 793 Utility Software

21 HWI-File-Editor Overview Number callout in graphic - has only one or three processors. Detect Hardware: This option automatically detects VME and transition bus hardware and adds those resources to the Hwi File Editor tree view pane. 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. The intended slot number for each board is shown in brackets after the resource (type) name. Displays icons of selected controller components in an expandable hierarchical display. Note: You can right-click many of the tree-view icons to perform/set features. 4 - Controller definition pane Contains tabbed pages of various controller components and characteristics. You create an.hwi file by making selections in these tabbed pages. Contains tabbed pages of various controller components and characteristics. You create.hwi files by making selections in these tabbed pages. Note: Some tabs contain fields that contain dimmed or grayed out values. These values are read only, and are provided only for reference. Properties tab Controller Type: The Hwi File Editor applies to several types of MTS Series 793 Controllers. It is important to select the controller type that pertains to your controller before you make any further selections. The available hardware is dependent on the Controller Type. Board tab Chassis tab (FlexTest IIm only) Transition tab Board Slot n: Allows you to select the desired VME board (the available boards vary with controller type) for the selected slot. Chassis n: Allows you to select an Analog Chassis or Hydraulic Control Panel for the selected chassis. Transition Slot n: Allows you select a DIO, HPU, or HSM transition board for the MTS Series 793 Utility Software 21

22 HWI-File-Editor Overview Number callout in graphic - (FlexTest GT, TestStar IIm, Aero ST, FlexTest 60/100/200 only) Miscellaneous tab selected slot. 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. The selections you make in the tabbed pages of the controller definition pane are automatically reflected as text in this pane. About Multiple.hwi Files 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. Custom settings may include different input filtering settings, DUC settings, and external hardware settings. 22 MTS Series 793 Utility Software

23 HWI-File-Editor Overview You can use the Project Manager application to select different.hwi files for use with a controller. Caution: For proper operation, the hardware resources specified in a configuration (.cfg) file must match those in the.hwi file. Changing the hardware resources in an.hwi file can cause the system load operation to fail. 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. Caution: For proper operation, the hardware resources specified in a configuration (.cfg) file must match those in the.hwi file. Changing the hardware resources in an.hwi file can cause the system load operation to fail. When using multiple.hwi files with the same controller, make sure that your.hwi files all have identical hardware resources. 2. Use the HWI File Editor application to create a new.hwi file with a new name and custom settings. 3. From the File menu, click Save As. 4. In the Save As window, select the new controller directory and click Save. The following window appears: If you click Yes, the file is saved in the controller directory and the controller.793settings file is modified to point to the new.hwi file. The next time you start a controller application, it will use the new.hwi file. If you click No, the file is saved in the controller directory but the controller.793settings file is not modified. MTS Series 793 Utility Software 23

24 HWI-File-Editor Overview 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. Caution: For proper operation, the hardware resources specified in a configuration (.cfg) file must match those in the.hwi file. Changing the hardware resources in an.hwi file can cause the system load operation to fail. When using multiple.hwi files with the same controller, make sure that your.hwi files all have identical hardware resources. 2. Start the Project Manager application. 3. From the Tools menu, click Controller Settings. 4. In the controller list, click the Hwi file. 5. In the Hwi File text box, type the name of the.hwi file that you want to use. 6. Click OK. The controller.793settings file is modified to point to the.hwi file. The next time you start a controller application, it will use the.hwi file that you defined above. 24 MTS Series 793 Utility Software

25 Create and Edit an HWI File Create and Edit an HWI File Create a New File 26 Hardware Resources 26 Configure Hardware Resource Settings 28 About Actuator Movement When the Servovalve is Clamped 31 Where to Find Valve Balance Procedures 32 MTS Series 793 Utility Software 25

26 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. Click the Controller icon in the tree view pane. 3. Click the Properties tab, and select a Controller Type from the drop-down list. Hardware Resources Hardware Resources Listed in.hwi File The hardware resources listed in the.hwi file must exactly match the physical location and address settings for each board used in the system. There are two methods to add hardware resources to an.hwi file: Use the Detect Hardware feature to detect VME and transition bus hardware and add those resources to the current file opened in the Hwi File Editor application. Use the Hwi File Editor application to manually add hardware resources. About Detect Hardware Feature The Detect Hardware feature automatically detects VME and transition bus hardware and adds those resources to the current file opened in the Hwi File Editor application. This is the preferred method when you create a new.hwi file. The Detect Hardware feature will also remove hardware resources from an existing.hwi file if that hardware was physically removed from the chassis. The Detect Hardware feature will not detect a Model 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. 26 MTS Series 793 Utility Software

27 Create and Edit an HWI File Use Detect Hardware Feature 1. Open either a new or existing.hwi file. 2. From the Options menu, click Detect Hardware. The detect hardware process adds and removes hardware resources based on what hardware was detected. 3. All detected hardware appears in the hardware resource tree. (Slot numbers for each board appear in brackets.) 4. Manually add any hardware that appears in the Miscellaneous tab (such as, temperature controllers, RSCs, and handsets). About.hwi Miscellaneous Hardware Any hardware listed in the Miscellaneous tab must be added manually using the HWI Editor application. The Detect Hardware feature will not detect or add any hardware listed in the Miscellaneous tab. Manually Add VME Board 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 Controller icon in the tree view pane. 2. Click the Board tab, and select the VME board for each board slot used in the system. MTS Series 793 Utility Software 27

28 Create and Edit an HWI File 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 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. Click the Mezzanines tab, and select the mezzanine card type for each mezzanine location. You can also right-click a resource and select a mezzanine card from the pop-up menu. Manually Add Transition Board 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 Controller in the tree view pane. 2. Click the Transition tab, and select the appropriate DIO, HPU or HSM transition boards for each transition slot. Configure Hardware Resource Settings Valve Driver Settings Each valve driver has settings that may include valve mode (single/dual), current range, and clamp mode settings. In addition, any combination card (Model VD/DUC) must be configured as either a two-stage or three-stage valve driver. Digital Universal Conditioner (DUC) Settings Each DUC card requires a number of hardware settings that you must configure before attempting to use the system. DUC Mode Settings (AC/DC) Each DUC card must be configured as either an AC or a DC conditioner (Default=DC). 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. 28 MTS Series 793 Utility Software

29 Create and Edit an HWI File Encoder Type Settings Each Encoder card requires a number of hardware settings that you must configure before attempting to use the system. Hydraulic Interface Settings Various HSM, HPU, and system boards have hydraulic interface settings that you must define before attempting to run the system. These settings vary with each board and may include first on/last off, proportional-on/off solenoid operation, and proportional rate settings. The drawing shows examples for the following hydraulic interface settings: Number callout in graphic HPU with HSM 2 - HPU Only 3 - Controller Hydraulic Power Unit (HPU) with Hydraulic Service Manifold (HSM) Hydraulic Power Unit (HPU) only Controller chassis MTS Series 793 Utility Software 29

30 Create and Edit an HWI File Number callout in graphic HPU with HSM This setting is available for the HPU transition and system boards (494.41, , , ). 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. Off indicate the HSM can be activated without an HPU activation. HPU On indicates that the HPU must be started (either manually or as first on ) before you can activate an HSM. HPU On w/ Tracking Same function as HPU On, however HSM cannot be at a higher state than the HPU. For example, if HPU and HSM are set to high, and then HPU is set to low, the HSM will follow the HPU state and change to low. If HPU is set to off, HSM will follow and set to off. Optional Hardware Resource Name Changes If you change the name of a hardware resource, you may invalidate existing configuration files. This is because an existing configuration file depends on the names of the resources in the current.hwi file matching the names of the resources with which the configuration was created. (These are the names displayed in the Hardware Resources lists in the Station Builder application.) If the names do not match, the configuration will not load into Series System Software applications. Resource naming convention Hwi files typically use the following resource naming convention for valve driver and conditioner resources: Convention: Resource model; Slot number; Connector number. Example 1: SVD S5-J5. Explanation: An MTS Model Stage Servovalve Driver Board located in Slot 5 of the chassis whose output is available from Connector J5. Example 2: B DUC S3-J4. Explanation: An MTS Model B Digital Universal Conditioner Board located in Slot 3 of the chassis whose input is available at Connector J4. 30 MTS Series 793 Utility Software

31 Create and Edit an HWI File VME Board Address Settings If you use the Hardware Detect feature to add hardware resources, the board addresses are correct and no further action is required. 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 I/O Carrier board, 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. In addition, if a three-stage servovalve is clamped when its third stage is not properly tuned, it may act unpredictably. Servovalve balance To balance a servovalve, you must first perform a mechanical adjustment on the servovalve to achieve gross mechanical balance. You can then use the Series 793 software Valve Balance to perform an electrical adjustment to fine-tune the mechanical adjustment. Mechanical balance The mechanical adjustment must be performed before the electrical adjustment, and is typically performed at the following times: At system installation When a new servovalve is installed in an existing system If the servovalve cannot be electrically balanced At regular service intervals Electrical balance The electrical adjustment is performed with the Valve Balance control, which adjusts the electrical input to the servovalve to compensate for minor mechanical imbalances. When the valve-balance adjustment is complete, there should be no (or minimal) hydraulic fluid flow when the servovalve output signal is at null. Note: The electrical adjustment is typically performed much more frequently than the mechanical adjustment. Inner-loop tuning In addition to mechanical and electrical valve-balance adjustments, three-stage servovalves also have inner-loop tuning controls that may affect clamping behavior. The inner loop is similar to a displacement control mode for the outer-loop. MTS Series 793 Utility Software 31

32 Create and Edit an HWI File The inner control loop resides inside the test system s primary, or outer control loop. So in addition to the pilot spool, three-stage servovalves include a third stage (or main) spool, that is driven by the pilot spool. 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 Feedback 2 Outer Loop 3 Inner Loop 4 Hydraulic Service Manifold (HSM) 5 Hydraulic Power Supply 6 Control Signal Valve Driver 8 Program Command The innerloop (proportional) gain and rate (derivative) adjustments are the same types of adjustments as the proportional and derivative gain adjustments of the outer-loop tuning controls. Where to Find Valve Balance Procedures Mechanical valve-balance procedures For two-stage servovalves, the mechanical valve balance procedure is included in the Series 252 Servovalve Product Manual (PN ), which is typically included in the system documentation set. 32 MTS Series 793 Utility Software

33 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 ), which is typically included in the system documentation set. Electrical valve-balance and inner-loop tuning procedures Electrical valve balance procedures and inner-loop tuning procedures for three-stage servovalves are included in the Series 793 Tuning and Calibration manual (PN ). MTS Series 793 Utility Software 33

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35 HWI Hardware Settings About Hwi File Editor Default Settings 36 Edit Hwi Default Settings 36 Apply Hwi Default Settings 38 Export HWI Defaults 40 Import HWI Defaults 40 System Options Settings 41 VME Bus Board Settings 41 Model I/O Carrier Mezzanine Cards 64 Model ADDA II Mezzanine Cards 72 Model I/O Carrier Mezzanine Cards 74 Model A-10 Eight-Channel Card Settings 89 Model A-11 D/A Card Settings 89 Model A-12 Encoder Card Settings 90 Transition Board Settings 90 FlexTest IIm Chassis Settings 97 Miscellaneous Device Settings 98 How to Set Model I/O Carrier Address (FlexTest GT/SE, TestStar IIm) 113 How to Set ADDA II Board Address (FlexTest GT, TestStar IIm, FlexTest IIm) 113 How to set the Model I/O Carrier Board Address 114 MTS Series 793 Utility Software 35

36 About Hwi File Editor Default Settings The Hwi Defaults feature allows you to change the default HWI settings for most VME- and transitionbus 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. Once you edit the default settings, you can: Apply the new default settings to hardware resources in the current hwi file. Use the Export HWI Defaults function to save the settings to a file and change the HWI File Editor application defaults. Use the Import HWI Defaults function to import default settings from a file and change the HWI Editor application defaults. Edit Hwi Default Settings You can apply default Hwi settings to new and existing controller hardware. 1. On the View menu, click Show HWI Defaults. When Hwi Defaults are displayed, Hwi Default settings appear in an editable tree structure located above the Controller resources. 36 MTS Series 793 Utility Software

37 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. Note: Optional Use the Export HWI Defaults function to save the default setting in a file. The export function also changes the Hwi Editor application defaults. The Hwi Editor application will use the exported default values for any subsequent Hwi files that you create. MTS Series 793 Utility Software 37

38 Apply Hwi Default Settings Hwi Default values can be universally applied to all the hardware resources in the controller tree or selectively applied to specific hardware resources. Use one of the following methods to apply Hwi defaults to existing hardware Right-click the Controller icon and click Apply HWI Defaults. HWI defaults are applied to all the hardware resources used in the Controller tree. 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 hardware resource. 38 MTS Series 793 Utility Software

39 Right-click a specific hardware resource in the HWI Defaults tree and click Apply HWI Defaults. The HWI default is applied to any instance of that particular hardware resource that appears in the Controller tree. In this example, the default values for the VD/DUC will be applied to all instances of the in the Controller tree. MTS Series 793 Utility Software 39

40 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. Export HWI Defaults Default Hwi values can be exported to a file for future use. After HWI Defaults are exported, 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 export an HWI Defaults file that includes all the default settings from the Hwi Defaults tree view: On the File menu, click Export HWI Defaults. OR Right-click the HWI Defaults icon and click Export HWI Defaults. OR Right-click the Controller icon and click Export HWI Defaults. 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. OR Right-click the Controller icon and click Import HWI Defaults. 40 MTS Series 793 Utility Software

41 System Options Settings System Options icon Velocity Limiter: When enabled (true), limits actuator movement to a maximum of 10 mm/sec. when displacement is commanded from the RSC or handset. This feature provides compliance to CE requirements. When Velocity Limiter=True, the manual command control is locked. Interlocks: When the Hwi File Editor reads existing.hwi files, this value represents the number of interlock chains in the file. If you are creating a new.hwi file, enter the desired number of interlock chains. VME Bus Board Settings VME Board FlexTest IIM (498.xx) FlexTest GT, Teststar IIM (493.10) Aero ST (493.20) FlexTest SE (493.02) FlexTest 40 (494.04) Processor X X X X X X Model I/O Carrier Model I/O Carrier Model ADDA II Model 49x.43 Multi-Box I/O Model GRES II Model GRES III Model ADDA Model Digital I/O X X X X X X X X X X X X X X FlexTest 60/100/200 (494.06/.10/.20) X MTS Series 793 Utility Software 41

42 VME Board FlexTest IIM (498.xx) FlexTest GT, Teststar IIM (493.10) Aero ST (493.20) FlexTest SE (493.02) FlexTest 40 (494.04) FlexTest 60/100/200 (494.06/.10/.20) Model System Board X Model System Board X Model System Board X About Processor Boards Each controller requires one or more processor boards that are installed in the VME chassis. Each processor board includes at least one CPU (core). Core functions Each core performs predefined CPU functions such as, Supervisor (SUP), Digital Signal Processing (DSP), and Time History Playback (THP). The function(s) assigned to each core depends on the number of processor boards and the types of options installed. One processor board The single core performs SUP and DSP functions. 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. The core in Processor [3] performs the THP function (if that option is installed) or the hybrid simulation (SIM) function (if that option is installed). Dual-Core Processor Although these boards occupy one slot, they contain two cores that perform different CPU functions: Core 1 - performs SUP and THP functions. 42 MTS Series 793 Utility Software

43 Core 2 - performs the DSP function. Note: Controllers can only have one dual-core processor with no other processor boards. Reconfigure Processor Functions For controllers with the Time History Playback (THP) option and two processors, this option allows you to change the way the processors are initialized. Note: This option will be grayed-out if your controller is not equipped for THP, or has only one or three processors. 1. From the Options menu, click Reconfigure Processors. The Reconfigure Processors window shows how your controller is currently configured. 2. If necessary, change the processor setting. Default Setting: The Shared SUP/THP on 1 and DSP on 2 default setting is recommended for configuring new controllers. 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 MTS Series 793 Utility Software 43

44 Processor circuit board icon Processor properties Address: Describes the proximity of the circuit board within the chassis. This value is generated during initialization, and should be changed only if the value read in from an existing.hwi file is wrong. Slot: Specifies which slot the circuit board occupies in the chassis. More than one function (such as SUP, DSP, THP, or SIM) may occupy the same slot. Application Attribute: Not applicable # of Cores: (applies to dual-core processors only): If a dual-core processor (such as the 7100) is used, set the number of cores to two. All other single-core processors should be set to one. Note: This setting cannot be changed if you use the HWI Detect Hardware feature. Core icon Function icon Each processor board includes at least one core that represents the CPU on that board. Under each Core icon are Function icons that specify what functions are performed by the CPU (core). Name: shows the function assigned to that CPU (core). The function(s) assigned to each core depends on the number of processor boards and the types of options installed. SUP = Supervisor DSP = Digital Signal Processing THP = Time History Playback 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. 2. Click the SIM Function icon and define the number of input and output ports. Note: 44 MTS Series 793 Utility Software

45 Hybrid Simulation is set up by MTS personnel only. This is described in an internal MTS document. Reflective memory icon optional) Some options, such as Hybrid Simulation (external model), require a reflective memory module that is mounted on the processor card. To add reflective memory to a processor, right-click the DSP Function icon and click Add Reflective Memory. Note: Hybrid Simulation is set up by MTS personnel only. This is described in an internal MTS document. Input/Output Port icons (optional) Input and output ports are user-defined portions of memory associated with: Reflective memory (external simulation model). When you add reflective memory to the DSP core function, you will see a port icon for each import and export port specified in the Reflective Memory properties. OR The memory on a processor board that is running the hybrid simulation (SIM) function (internal simulation model). The input/output port icons appear when you add the hybrid simulation (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 ADDA II Board Settings This board is compatible with Aero ST, FlexTest GT, FlexTest IIm, and TestStar IIm controllers. MTS Series 793 Utility Software 45

46 ADDAII circuit board icon When the optional Model ADDA II board is being used, the.hwi file describes this board and the A/D, D/A, DSPAD, and encoder mezzanine cards that are installed on it. The following ADDA II mezzanine cards can be installed: Model A/D (8-Channel) Model D/A (8-Channel) Model A/D (8-Channel) Model U2 Absolute Model U2 Incremental Model U2 Temposonics III Each mezzanine card can be assigned to one of the four ADDA II board rear panel connectors. Each mezzanine card definition is followed by four or eight signal definitions. The analog I/O definitions provide A/D channels and D/A channels for analog inputs and outputs from the 498 Analog In transition boards. The channel numbers for the analog inputs represent the available analog-to-digital converters following the list of AC and DC conditioner signals. The channel numbers for the analog outputs represent the available digital-to-analog converters following the list of valve command signals. Properties tab Address: Describes the proximity of the circuit board within the chassis. This value is generated during initialization, and should be changed only if the value read in from an existing.hwi file is in error. 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 The Medium System Rate is typically MTS Series 793 Utility Software

47 Mezzanines tab Mezzanine: describes the mezzanine cards that are installed on the ADDA board. Model GRES II Board Settings This card is compatible with FlexTest IIm controllers GRES II circuit board icon The Model GRES II board supports both the Remote Station Controller (RSC) and the temperature controller. It must be added to your system when using either of these components before the components are installed in the chassis. The GRES II board communicates to the RSC or temperature controller via a serial transition card located to the rear of the chassis. Address: Describes the proximity of the circuit board within the chassis. This value is generated during initialization, and should be changed only if the value read in from an existing.hwi file is in error. Slot: Specifies which slot the circuit board occupies in the chassis. Clock Type: Master, Dependent. For Master Clocks Clock Mode: Decimal, Binary. System Rate: 1024, 2048, 4096 and 6144 Hz (binary). 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 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.43 Multibox I/O Board Settings This board is used with Aero ST controllers. MTS Series 793 Utility Software 47

48 49x.43 Multi-box I/O circuit board icon Slot: Specifies which slot the circuit board occupies in the chassis. System Rate: 512, 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 The Medium System Rate is typically 256. Model 49x.40 I/O Carrier Board HWI Settings These settings are for the Model and I/O Carrier boards. The Model board is compatible with Aero ST, FlexTest GT, FlexTest SE, and TestStar IIm controllers. The Model board is compatible with FlexTest 40/60/100/200 controllers. Note: When a 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 I/O Carrier To avoid system-load errors, the Model I/O carrier that connects to the paddle board (a circuit board with ribbon cables that connect the VME bus to the transition bus) must be configured as follows: The paddle board must connect to the with the lowest VME address. The board must be configured as Clock type=master. 48 MTS Series 793 Utility Software

49 49x.40 I/O Carrier circuit board icon Describes each Model 49x.40 I/O Carrier board installed in the Chassis and their installed mezzanine cards. Each I/O Carrier board can support up to four mezzanine cards. The first I/O Carrier board in slot three (typical) provides the master clock (Clock Type=Master) for all other I/O Carrier boards. If a GRES III board is added (typically in Slot 10), the clock type for this I/O Carrier board must be changed to Clock Type=Dependent. For FlexTest SE and FlexTest 40 controllers, the System Board provides the master clock (Clock Type=Master) for the system, so all I/O Carrier boards must be set to Clock Type= Dependent. 49x.40 Properties tab Address: Describes the proximity of the circuit board within the chassis. This address setting must match the address switch settings on the 49x.40 board. Note: The Detect Hardware feature automatically detects the correct address setting from the board and enters it in the.hwi file. Slot: Specifies which slot the circuit board occupies in the chassis. Application Attribute: an editable string that can be queried by a controller application. Clock Type: Master/Dependent. For Master Clocks (Clock Type = Master): Clock Mode: Binary/Decimal. Note: Changing the clock mode (from binary to decimal or from decimal to binary) on systems with Series 494 hardware affects the calibration of AC conditioners which can result in inaccurate readings. If you want to run in a different clock mode, you must 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 The Medium System Rate is typically x.40 Mezzanines Mezzanine: describes the mezzanine cards that are installed on the I/O Carrier board. MTS Series 793 Utility Software 49

50 tab Model Single-Station System Board Settings The Model board is used with FlexTest 40 controllers System Board circuit board icon Properties tab The System Board defines digital and analog inputs and outputs, and hydraulic power unit (HPU) and hydraulic service manifold (HSM) functionality. Slot: 4. Slot 4 in the FT-40 chassis is reserved for the system board. System Rate: 1024, 2048, 4096 and 6144 Hz (binary). 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 The Medium System Rate is typically 256. Low System Rate: Digital Input/Digital Output icons Analog Output icons Name: Describes this resource as it will appear in Station Builder resource lists when opened against an.hwi file. The name includes the connector number (for example: Dig In 1-J54 ). Changing this name may invalidate existing station configurations. 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 chassis). Changing this name may invalidate existing station configurations. Hydraulic Interface icon (HPU) Connector: J25. HPU with HSM: True: Indicates the system s HPU supplies HSMs. False: used for HPU only systems (allows HPU selection to be available to Station Builder). 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 50 MTS Series 793 Utility Software

51 without pressing the HPU buttons. Last Off: True: Causes the last HSM turned off to turn off the HPU. The First On/Last OFF settings are only available if the HPU with HSM setting is True. 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. Visible: True: Indicates whether or not the HPU button is visible on the control panel. Changing Visible to False turns off the HPU button display on the Station Manager window, provided both First On and Last Off are True. The Visible setting is only available when both the First On and First Off settings are set to True. Hydraulic Interface icon (HSM) Connector: J28 Name: Describes the hardware resource as it will appear in Station Builder resource lists. Changing this name may invalidate existing station configurations. Type: Solenoid, Proportional, On/Off Solenoid. If you select On/Off Solenoid, only two HSM control buttons (Off/On) will appear on the Station Manager Station Controls 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. 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. Time to achieve 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 achieve low pressure). Example: If Low Percent value = 25, High Percent value = 100, and HSM Rate = Slow (4 seconds): MTS Series 793 Utility Software 51

52 Time to achieve low pressure = 0.25 x 4 = 1 second. Time to achieve high pressure = (1 x 4) - (1) = 3 seconds. Interlock Interface icon Connector: J43,J29. Assign to Interlock: Set to 1. Gate Interlock: True or False, True = the controller responds to the gate interlock signal on pins 3 and 4 of J29. (Default=True.) False=J29 pins 3 and 4 are reserved for Program Stop interlock. Caution: Failure to enable the gate interlock option on systems that can operate in Slow (low-flow) mode can result in unexpected actuator movement when switching the system from Slow mode to Fast mode. 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 Single-Station System Board Settings The Model board is used with FlexTest 40 controllers System Board circuit board icon Properties tab The System Board defines digital and analog inputs and outputs, and hydraulic power unit (HPU) and hydraulic service manifold (HSM) functionality. Slot: 4. Slot 4 in the FT-40 chassis is reserved for the system board. System Rate: 1024, 2048, 4096 and 6144 Hz (binary). 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 The Medium System Rate is typically 256. Low System Rate: Digital Name: Describes this resource as it will appear in Station Builder resource lists when opened against an.hwi file. The name includes the connector number (for example: 52 MTS Series 793 Utility Software

53 Input/Digital Output icons Analog Output icons Dig In 1-J54 ). Changing this name may invalidate existing station configurations. 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 chassis). Changing this name may invalidate existing station configurations. An Acumen system requires an Analog Output that provides a motor command signal for the Elmo motor drive. To designate an analog output for the motor command signal (Elmo Drive), right-click on the Analog Output icon and click Elmo Output. An Elmo Output icon appears. Click on this icon to display a list of settings required for the Acumen system. Hydraulic Interface icon (HPU) 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: J25. HPU with HSM: True: Indicates the system s HPU supplies HSMs. False: used for HPU only systems (makes the HPU selection available to Station Builder). 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. 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. The First On/Last OFF settings are only available if the HPU with HSM setting is True. Visible: MTS Series 793 Utility Software 53

54 True: the HPU button is visible on the Station Manager control panel. False: Removes the HPU button display from the Station Manager control panel, provided both First On and Last Off are True. The Visible setting is only available when both the First On and First Off settings are set to True. Hydraulic Interface icon (HSM) Name: Describes the hardware resource as it will appear in Station Builder resource lists. Changing this name may invalidate existing station configurations. Connector: J28 Type: Solenoid, Proportional, On/Off Solenoid. Solenoid: three HSM control buttons (Off/Low/High) will appear on the Station Manager Station Controls panel. On/Off Solenoid: only two HSM control buttons (Off/On) will appear on the Station Manager Station Controls panel. For the other types, three HSM control buttons will appear (Off/Low/High). 54 MTS Series 793 Utility Software

55 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). Connect to HPU: Off indicate the HSM can be activated without an HPU activation. HPU On indicates that the HPU must be started (either manually or as first on ) before you can activate an HSM. HPU On w/ Tracking Same function as HPU On, however HSM cannot be at a higher state than the HPU. For example, if HPU and HSM are set to high, and then HPU is set to low, the HSM will follow the HPU state and change to low. If HPU is set to off, HSM will follow and set to off. 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. Time to achieve 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 achieve 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 icon Connector: J43,J29. Assign to Interlock: Set to 1. Gate Interlock: True or False, True = the controller responds to the gate interlock signal on pins 3 and 4 of J29. (Default=True.) False=J29 pins 3 and 4 are reserved for Program Stop interlock. Caution: Failure to enable the gate interlock option on systems that can operate in Slow (low-flow) mode can result in unexpected actuator movement when switching the system from Slow mode to Fast mode. Unexpected actuator movement can result in injury to personnel or damage to MTS Series 793 Utility Software 55

56 the equipment. Enable the gate interlock option for systems that include a Slow (low-flow) mode for specimen installation. Model Two-Station System Board Settings The Model board is used with FlexTest 40 controllers System Board circuit board icon Properties tab The System Board defines digital and analog inputs and outputs, and hydraulic power unit (HPU) and hydraulic service manifold (HSM) functionality. Slot: 4. Slot 4 in the FT-40 chassis is reserved for the system board. System Rate: 1024, 2048, 4096 and 6144 Hz (binary). 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 The Medium System Rate is typically 256. Low System Rate: Digital Input/Digital Output icons Analog Output icons Name: Describes this resource as it will appear in Station Builder resource lists when opened against an.hwi file. The name includes the connector number (for example: Dig In 1-J54 ). Changing this name may invalidate existing station configurations. 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 back of the Model chassis). Changing this name may invalidate existing station configurations. Each Acumen system requires an Analog Output that provides a motor command signal for the Elmo motor drive. To designate an analog output for the motor command signal (Elmo Drive), right-click on the Analog Output icon and click Elmo Output. An Elmo Output icon appears. Click on this icon to display a list of settings required for the Acumen system. 56 MTS Series 793 Utility Software

57 Hydraulic Interface icon (HPU) Connector: J25. HPU with HSM: True: Indicates the system s HPU supplies HSMs. False: used for HPU only systems (makes HPU selection available in Station Builder). 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. Type: Off/low/high: three HPU control buttons (Off/Low/High) will appear on the Station Manager Station Controls panel. 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. The First On/Last OFF settings are only available if the HPU with HSM setting is True. Visible: True: Indicates whether or not the HPU button is visible on the control panel. False: hides the HPU button display on the Station Manager window (only if both First On and Last Off are True). The Visible setting is only available when both the First On and First Off settings are set to True. Hydraulic Interface icon (HSM) Connector: J28A or J28B Name: Describes the hardware resource as it will appear in Station Builder resource lists. Changing this name may invalidate existing station configurations. Interlock: 1 (default for J28A ), 2 (default for J28B). Type: Solenoid, Proportional, On/Off Solenoid. MTS Series 793 Utility Software 57

58 Solenoid: three HSM control buttons (Off/Low/High) will appear on the Station Manager Station Controls panel. On/Off Solenoid: only two HSM control buttons (Off/On) will appear on the Station Manager Station Controls panel. Proportional: 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. 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. 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 icon Connector: J43,J29. Assign to Interlock: Set Interlock Interface 1 to 1or 2, set Interlock Interface 2 to 1 or 2. Gate Interlock: True or False, True=the controller responds to the gate interlock signal on pins 3 and 4 of J29. False=J29 pins 3 and 4 are reserved for Program Stop interlock. Caution: Failure to enable the gate interlock option on systems that can operate in Slow (low-flow) mode can result in unexpected actuator movement when switching the system from Slow mode to Fast mode. 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 System Board Settings The Model board is used with FlexTest SE controllers. 58 MTS Series 793 Utility Software

59 System Board circuit board icon Properties tab The System Board defines digital and analog inputs and outputs, and hydraulic power unit (HPU) and hydraulic service manifold (HSM) functionality. Address: Describes the proximity of the circuit board within the chassis. This value is generated during initialization, and should be changed only if the value read in from an existing.hwi file is in error. Slot: 4. System Rate: 1024, 2048, 4096 and 6144 Hz (binary). 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 The Medium System Rate is typically 256. Low System Rate: Miscellaneous tab Digital Input/Digital Output icon # of HPU Interfaces: Allows you to add or remove the HPU interface. # of HSM Interfaces: Allows you to add or remove the HSM interface. 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: J54. Channel: Not applicable. Hydraulic Interface icon (HPU) 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: J25. HPU with HSM: True: Indicates the system s HPU supplies additional HSMs. False: used for HPU only systems (allows HPU selection to be available to Station Builder). 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 MTS Series 793 Utility Software 59

60 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. Visible: True: Indicates whether or not the HPU button is visible on the control panel. Changing Visible to FALSE turns off the HPU button display on the Station Manager window, provided both First On an Last Off are True. Hydraulic Interface icon (HSM) Name: Describes the hardware resource as it will appear in Station Builder resource lists. Changing this name may invalidate existing station configurations. Connector: J28 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). If you select On/Off Solenoid, only two HSM control buttons (Off/On) will appear on the Station Manager Station Controls panel. For the other types, three HSM control buttons will appear (Off/Low/High). Remote: select if more than one controller share the same HSM and the control of the HSM is performed remotely on another controller. 60 MTS Series 793 Utility Software

61 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. Time to achieve 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 achieve low pressure). Example: Suppose 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 icon Analog Input/Output icons Connector: J43,J29. Assign to Interlock: Set to 1. 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. For FlexTest SE Controllers, the first two analog output resources are displayed as Monitor I and Monitor 2 by default. These resources represent BNC connectors on the Controller s front panel. The third analog output resource (Anlg Out) is the BNC connector on the system board. Address: Not applicable. Model ADDA Board Settings This card is compatible with FlexTest IIm controllers. MTS Series 793 Utility Software 61

62 ADDA circuit board icon When the optional Model ADDA board is being used, the.hwi file describes this board and the A/D, D/A, and various mezzanine cards that are installed on it, as follows: Model A-10 8-A/D (8-Channel) Model A-11 8-D/A (8-Channel) Model A-12 Encoder Model A-15 Temposonics Model A-16 Temposonics III Model A-17 Heidenhain 417 Model A-18 Heidenhain 425 Model A-61 U2 Incremental Model A-62 U2 Temposonics III Model A-66 U2 Absolute Each mezzanine card can be assigned to one of the four ADDA board connectors. Each mezzanine card definition is followed by four or eight signal definitions. Properties tab Address: Describes the proximity of the circuit board within the chassis. This value is generated during initialization, and should be changed only if the value read in from an existing.hwi file is in error. Slot: Specifies which slot the circuit board occupies in the chassis. Mezzanines tab Mezzanine n Model Digital I/O Board Settings This card is compatible with FlexTest IIm controllers. 62 MTS Series 793 Utility Software

63 DI/O circuit board icon Address: Describes the proximity of the circuit board within the chassis. This value is generated during initialization, and should be changed only if the value read in from an existing.hwi file is in error. Slot: Specifies which slot the circuit board occupies in the chassis. Digital Input/Output icon 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: Not applicable. Model GRES II Board Settings This card is compatible with FlexTest IIm controllers GRES II circuit board icon The Model GRES II board supports both the Remote Station Controller (RSC) and the temperature controller. It must be added to your system when using either of these components before the components are installed in the chassis. The GRES II board communicates to the RSC or temperature controller via a serial transition card located to the rear of the chassis. Address: Describes the proximity of the circuit board within the chassis. This value is generated during initialization, and should be changed only if the value read in from an existing.hwi file is in error. Slot: Specifies which slot the circuit board occupies in the chassis. Clock Type: Master, Dependent. For Master Clocks Clock Mode: Decimal, Binary. System Rate: 1024, 2048, 4096 and 6144 Hz (binary). 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 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. MTS Series 793 Utility Software 63

64 Model I/O Carrier Mezzanine Cards The Model board is compatible with FlexTest GT, Aero ST, and TestStar IIm controllers. Mezzanine Card Compatibility The following table lists the different mezzanine cards and the type of carrier board where they can be used. Mezzanine Card I/O Carrier I/O Carrier ADDA Board ADDA II Board SVD Mezzanine Card Compatibility on page 64 X SVD Mezzanine Card Compatibility on page 64 X DUC, B DUC, DUC X A/D X output D/A X Encoder Card X Accelerometer Input X A/D (8-Channel), A/D (8-Channel) X D/A (8-Channel) X U2 Absolute, U2 Incremental, U2 Temposonics III X VD/DUC X Single DUC, Dual DUC X Input A/D X Output D/A X Dual UART/Encoder X A-10 8-A/D (8-Channel) A-11 8-D/A (8-Channel) A-12 Encoder, A-15 Temposonics,493.65A-16 Temposonics III, A-17 Heidenhain 417,493.65A-18 Heidenhain 425, A-61 U2 Incremental,493.65A-62 U2 Tempo III, A-66 U2 Absolute X X X 64 MTS Series 793 Utility Software

65 Model 493.1x Valve Driver Settings The following settings apply to the Model Two-Stage Valve Driver and the Model Three-Stage Valve Driver SVD mezzanine card icon SVD mezzanine card icon Analog Output icon Describes the valve driver mezzanine card. Connector: the connector that joins the resource to the chassis. This will likely move up to the daughter level. 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. Analog Output icon continued Caution: Unexpected actuator movement is possible when the servovalve is clamped. Unexpected actuator movement can cause injury and equipment damage.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. Before enabling the valve clamp feature, ensure that the servovalve is balanced. Clamp Mode: Causes the servovalve to clamp as specified to prevent unwanted actuator movement when a hydraulic interlock occurs. Disabled Valve does not clamp. This is the default action if the clamp entry is omitted. Hardware will short the servovalve drive signal if a software failure is detected. 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. MTS Series 793 Utility Software 65

66 2SVD icon Range: Defines the output (in ma) of the valve driver. The settings are 25 or 50. Mode: Identifies single or multiple valve driver support. The settings are Single or Dual. Dual valve driver support requires a special manifold. Model 493.2x DUC Card Settings Settings for the Model DUC Card, B DUC Card, and DUC card x DUC mezzanine card icon Analog Input icon The conditioner definitions describe the characteristics of the Digital Universal Conditioner (DUC) mezzanine card. 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 connector that joins the resource to the chassis. This will likely move up to the daughter level. Filter: Settings include: 0 (no filter), 50 (Hz), 100 (Hz), 300 (Hz), 500 (Hz), or 1000 (Hz). DUC icon Mode: Specifies the type of conditioning (AC or DC) the DUC will perform. DUC Icon Right-click Options Right-click the B or DUC icon to select from the following options: Add Acceleration Compensation Add DIO Load Washer Add Serial Load Washer How to Add Accelerometer Compensation to a Model B/ DUC This procedure only applies to Model B and DUCs. 1. Add a Accelerometer Conditioner board to the.hwi file. 2. Right-click the DUC icon and select Add Accelerometer Compensation. A 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. 66 MTS Series 793 Utility Software

67 How to Add a DI/O Load Washer to a Model B/ DUC This procedure only applies to Model B and DUCs. 1. Add a DI/O board 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. If the hardware resource names are not correct, change the hardware resources names in these boxes to match the Digital Inputs where these signals are physically connected. 5. 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 DI/O Load Washer Properties tab must match the range names assigned in the Sensor tab in the Station Manager application. How to Add a Serial Load Washer to a Model B/ DUC This procedure only applies to Model B and Model DUCs. 1. Add a serial comm resource to the.hwi file (for example, B GRES III or Ramix serial card). 2. Right-click the DUC icon and select Add Serial Load Washer. A Serial LoadWasher icon appears below the DUC icon. 3. Configure the Serial LoadWasher. 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. 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 Six-Channel A/D Card Settings MTS Series 793 Utility Software 67

68 Input A/D mezzanine card icon Channels tab High Level No Channel Analog Input icon Describes the six-channel analog-to-digital converter mezzanine card. Analog Input n Specifies an externally conditioned signal in the range of +/-10V. Excludes inputs to the selected channel. 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 connector that joins the resource to the chassis. This will likely move up to the daughter level. Model Six-Output D/A Card Settings Output D/A mezzanine card icon Properties tab Channels tab High Level No Channel Describes the six-channel digital-to-analog converter mezzanine card. Analog Output n Specifies an externally conditioned signal in the range of +/-10V. Excludes inputs to the selected channel. 68 MTS Series 793 Utility Software

69 Channels tab Multiple Universal Valve Driver (MUD) For special applications, the Model 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 D/A mezzanine card on the Model I/O Carrier boards. When you select a MUD board, the Assign Channels dialog appears with the following fields: # 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. Transition Slot #: Specifies the slot in which the MUD board is installed in the chassis. Channel #: Specifies the channel number that maps to the selected analog output. Analog Output icon 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: Identifies the I/O Carrier rear panel connector that is available for MUD board output. This will likely move up to the daughter level MUD icon Slot: Specifies which slot the circuit board occupies in the chassis. Channel: Not applicable. Model Encoder Card Settings Interlock Enable: Indicates the status of cable loss detection: false=disabled, true=enabled. Range: Identifies the range of the valve driver s output (in ma). The settings are 0, 25, 50, or 75. The 0 setting requires an on-board userselectable resistor. MTS Series 793 Utility Software 69

70 Encoder mezzanine card icon Analog Input icon The encoder definition describes the optional Digital Encoder mezzanine card. This board must be installed if you want to monitor encoder or Temposonics sensor feedback. 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: 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). SSI/Gurley Encoder Application Settings Application Physical Zero Position at Minimum or Maximum Stroke (device dependent) Encoder Settings Type = Signed N/A 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. 70 MTS Series 793 Utility Software

71 Application Encoder Signal Range Encoder Settings Power-up Signal range Operating Signal range Type Turns Counting Position Filter Position-Limited Rotation Unsigned True Yes Power-up signal range: 0 to 360 degrees Unlimited Rotation Unsigned False See Note Operating-signal range: 0 to 360 degrees Position-Limited Rotation Signed True Yes Power-up signal range: -180 to +180 degrees Unlimited Rotation Signed False See Note 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 causes ringing due to the high-frequency content of the step. Filtering occurs normally if the encoder is operated in a range that does not include the angle step. MTS Series 793 Utility Software 71

72 Model Accelerometer Input Card Settings Accel. Input mezzanine card icon Accel. Input icons On systems affected by acceleration induced errors, an optional acceleration conditioner board can be linked to a conditioner (DUCB only) to perform acceleration compensation. The acceleration conditioner definition specifies a list of auxiliary inputs that the DUC conditioners can use on the acceleration mezzanine card. (Each DUC mezzanine card definition is enhanced to allow an auxiliary input to be defined.) 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: Not applicable. Model ADDA II Mezzanine Cards The mezzanine cards listed in this section can be used in the Model ADDA II board. The Model board is compatible with FlexTest IIm, FlexTest GT, Aero ST, and TestStar IIm controllers. Model / Channel A/D Card Settings and A/D mezzanine card icon Properties tab The Model A/D mezzanine card, available for installation on ADDA II 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. Filter: On/Off. The 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 High Level No Channel AC/ AC/ Dual DC Conditioner icon Analog Input n Specifies an externally conditioned signal in the range of +/-10V. Excludes inputs to the selected channel. Chassis: Not applicable. Slot: Specifies which slot the circuit board occupies in the chassis. Channel: Not applicable. Filter: On/Off. Connector: Not applicable. 72 MTS Series 793 Utility Software

73 Model Channel D/A Card Settings D/A mezzanine card icon The analog output definition describes the D/A Analog Output mezzanine card. Properties tab Channels tab The connector specification identifies the rear panel connector that is available for analog outputs. Filter: On/Off. Analog Output n High Level Specifies an externally conditioned signal in the range of +/- 10V. No Channel Stage/ Dual 2- Stage Valve Driver icon Excludes inputs to the selected channel. Chassis: Not applicable. Slot: Specifies which slot the circuit board occupies in the chassis. Channel: Not applicable. Filter: Not applicable. Connector: Not applicable. Model x 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 MTS Series 793 Utility Software 73

74 U2 Absolute/ U2 Incremental/ U2 Temposonics III mezzanine card icons Encoders require a special mezzanine card be plugged into the ADDA II board. The encoder mezzanine card can occupy any of the four ADDA II address locations. The encoder mezzanine card supports four encoder signals. The encoder mezzanine card processes the pulse stream from an encoder. Temposonics III sensors require a special mezzanine card on the ADDA board. The Temposonics III mezzanine card can occupy any of the four ADDA address locations. The Temposonics III mezzanine card supports two double-wide Temposonics sensor signals. The Temposonics III mezzanine card processes pulses from the digital output of a Temposonics III sensor. Filter: On/Off. Baud Rate: ( U2 Absolute and U2 Temposonics III only) Select a baud rate. Allows you to change the baud rate if the cable length requires a slower baud rate Analog Input icon 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 connector that joins the resource to the chassis. This will likely move up to the daughter level. Model I/O Carrier Mezzanine Cards The mezzanine cards listed in this section can be used in the Model I/O Carrier board. The Model board is compatible with FlexTest 40/60/100/200 controllers. 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 I/O Carrier board allows up to six high-speed data inputs per carrier board. This could be an issue if four Model Dual DUCs are installed on a I/O carrier. 74 MTS Series 793 Utility Software

75 Setting True Enables high-speed data acquisition. The high-speed rate is determined by the system rate and a number of other factors. See your test application documentation for details. False (default) High-speed data acquisition is not available. Model VD/DUC HWI Settings MTS Series 793 Utility Software 75

76 VD/DUC mezzanine card icon Describes the valve driver/duc mezzanine card. Application Attribute: Not applicable Type: defines how the card is used and what resources are available. DUC and 2SVD: when configured as a two-stage valve driver, the DUC portion of this card is available as a system resource. 3SVD: when configured as a three-stage valve driver, the DUC portion of this card is reserved for the valve LVDT Analog Input icon Note: The Analog Input icon only appears if the VD/DUC is configured as a twostage 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. Filter Type: Used to select the type of filter used to filter the digital output of the DUC. 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. A setting of zero disables the filter. High Speed Data: 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 I/O carrier limits the number of high-speed data inputs on a carrier to a maximum of six Analog Output icon 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. Application Attribute: Not applicable. Connector: Describes the front-panel I/O Carrier connector that joins the resource to the chassis. 76 MTS Series 793 Utility Software

77 Clamp Mode: Causes the servovalve to clamp as specified to help prevent unwanted actuator movement when a hydraulic interlock or various processor errors occur. Disabled Valve does not clamp. This is the default action if the clamp entry is omitted. 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. 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. 2SVD Analog Output icon Mode: Select Single to configure this card to drive a single servovalve; select Dual to configure this card to drive dual servovalves. Range: Enter the full-scale current value for the servovalve driven by this card (100 ma maximum per output). Model Multi-Range DUC with Acceleration Compensation Card HWI Settings This card combines a DUC and an accelerometer compensation input on a single card. The summing of the two signals is done on the card based on settings in your test application. MTS Series 793 Utility Software 77

78 DUC mezzanine card icon 494.xx Analog Input icon Describes the valve driver/duc mezzanine card. Connector: Describes the front-panel I/O Carrier connector assigned to this input. 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. Filter Type: Used to select the type of filter used to filter the digital output of the DUC. Selections include: Disabled, Bessel, Butterworth, and Elliptical. Filter: This is the frequency where the filter, selected in the Filter Type box, attenuates the signal by 3 db. A setting of zero disables the filter. (Default=Bessel, 300 Hz.) High Speed Data: 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 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. Bridge Type (DC only): specifies the type of bridge (full, half, quarter) and the number of wires. The High Level option is used for high-level voltage inputs (typically ± 10 V DC). Shunt Excitation/Shunt Feedback (DC only): the shunt excitation and shunt feedback settings determine where the shunt calibration resistor is applied. 494.xx Accel Input icon The Accel Input icon only appears if you right-click the DUC icon and and select Add Accelerometer Compensation. 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. Input Selection: specifies the type of accelerometer that you will connect to the acceleration input. Bridge Device: this selection provides an input for the output from a bridge-type 78 MTS Series 793 Utility Software

79 accelerometer. Current Source: this selection provides a 3.5 ma current source excitation and a differential amplifier for direct accelerometer connections. Acceleration compensation settings appear in your control software. Select None to disable acceleration compensation in your control software. How to Enable Acceleration Compensation on the Model Card You must enable acceleration compensation on the Model Elastomer DUC card before you can connect an accelerometer. 1. Add the DUC to an I/O carrier. 2. Right-click the DUC icon and select Add Accelerometer Compensation. How to Add a DI/O Load Washer to a Model Card 1. Add a 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. If the hardware resource names are not correct, change the hardware resources names in these boxes to match the Digital Inputs where these signals are physically connected. 5. 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 DI/O Load Washer Properties tab must match the range names assigned in the Sensor tab in the Station Manager application. MTS Series 793 Utility Software 79

80 How to Add a Serial Load Washer to a Model Card 1. Add a serial comm resource to the.hwi file. 2. Right-click the DUC icon and select Add Serial Load Washer. A Serial LoadWasher icon appears below the DUC icon. 3. Configure the Serial LoadWasher. 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. 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 / DUC HWI Settings The settings for both the Model Single DUC and Model Dual DUC mezzanine cards are the same - with the exception of Acceleration Compensation. Accelerometer Compensation - The Model Dual DUC can be configured for accelerometer compensation. When configured for accelerometer compensation, the A input is used for the load cell and the B input is used for the accelerometer. To configure a dual DUC for accelerometer compensation, right-click on the top DUC icon and click Add Accelerometer Compensation. Once configured, an Auxiliary Input property that lists the connector number for the accelerometer input appears at the bottom of the list. 80 MTS Series 793 Utility Software

81 494.xx DUC mezzanine card icon 494.xx Analog Input icon Describes the valve driver/duc mezzanine card. 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. Filter Type: Used to select the type of filter used to filter the digital output of the DUC. Selections include: Disabled, Bessel, Butterworth, and Elliptical. Filter: This is the frequency where the filter, selected in the Filter Type box, attenuates the signal by 3 db. A setting of zero disables the filter. (Default=Bessel, 300 Hz.) High Speed Data: 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 I/O carrier limits the number of high-speed data inputs on a carrier to a maximum of six. Connector: Describes the front-panel I/O Carrier connector assigned to this input. 494.xx DUC icon Mode: Specifies the transducer type (AC/DC) connected to the DUC. Bridge Type (DC only): specifies the type of bridge (full, half, quarter) and the number of wires. The High Level option is used for high-level voltage inputs (typically ± 10 V DC). Shunt Excitation/Shunt Feedback (DC only): the shunt excitation and shunt feedback settings determine where the shunt calibration resistor is applied. See the following table and figure. Model Input A/D Converter HWI Settings Input A/D mezzanine card icon Properties tab Channels tab Describes the eight-channel analog-to-digital converter mezzanine card. Application Attribute: Not applicable Each analog input has a drop-down menu where you can select one of the following input options: MTS Series 793 Utility Software 81

82 High Level No Channel Analog Input icon Specifies an externally conditioned signal in the range of +/-10V. Excludes inputs to the selected channel. 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. Application Attribute: Not applicable Filter: This is the frequency where the filter, selected in the Filter Type box, attenuates the signal by 3 db. A setting of zero disables the filter. Connector: Describes the I/O Carrier board connector that joins the resource to the chassis. This will likely move up to the daughter level. Filter Type: Used to select the type of filter used to filter the digital output of the A/D Converter. Selections include: Disabled, Bessel, Butterworth, and Elliptical. (Default=Bessel, 300 Hz.) Model Output D/A Converter Card HWI Settings Input D/A mezzanine card icon Properties tab Channels tab High Level No Channel 49x.79 Multiple Universal Valve Driver Describes the eight-channel digital-to-analog converter mezzanine card. Application Attribute: Not applicable Each analog output has a drop-down menu where you can select one of the following output options: Specifies an analog output in the range of +/-10V. Excludes outputs to the selected channel. Specifies that this output is used to drive one of the valve drivers on the Model 49x 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. Transition Slot #: Specifies the slot in which the Valve Driver board is installed in the 82 MTS Series 793 Utility Software

83 chassis. Channel #: Not applicable Analog Output icon 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. Application Attribute: Not applicable Connector: Describes the I/O Carrier board connector that joins the resource to the chassis. This will likely move up to the daughter level. Each Acumen system that runs on a FlexTest 60 Controller requires an Analog Output that provides a motor command signal for the Elmo motor drive. The analog output is provided by a Model mezzanine card. To designate an analog output for the motor command signal (Elmo Drive), right-click on the Analog Output icon and click Elmo Output. An Elmo Output icon appears. Click on this icon to display a list of settings required for the Acumen system MUD icon Slot: Specifies which slot the circuit board occupies in the chassis. Channel: Not applicable. Interlock Enable: Indicates the status of cable loss detection: false=disabled, true=enabled. Range: Sets the range of the valve driver s outputs (in milliamps). There are two different ways to set the valve driver s output range: For most standard servo valves - Enter one of the following valve-driver range values: 25, 50, or 75. Range values are in milliamps, for example: 25=25 ma, 50=50 ma, and 75=75 ma. For non-standard servo valves - MTS installs resistors on the board that set the valve-driver range. When resistors are installed, you must set the Range value to zero. Important: If factory-installed resistors are used to set a non-standard valve-driver range, this range is added to each of the allowable Hwi range settings (0, 25, 50, 75). For example, if the resistor provides a 15 ma range: a range setting of 0 becomes 15 ma, a setting of 25 becomes 40 ma, a setting of 50 becomes 65 ma, and a setting of 75 becomes 90 ma. MTS Series 793 Utility Software 83

84 Model Dual UART/Encoder/External Clock HWI Settings You can configure this card to condition two UART devices, or two encoders, or to provide an external clock output Dual UART/Encoder/External Clock mezzanine card icon Encoder Properties Type: specifies the type of device used with this card: Encoder, UART, or external clock output. The external clock selection provides an external clock output (RS-485 differential output) on the front-panel JXA connector located on the Model I/O Carrier. The external clock output can be used to synchronize subsystems (such as data acquisition) to the controller clocks. 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. Debounce filtering is typically used clean up the shape of the pulse in situations where there are long cable runs or signals with long rise and fall times (for example, a proximity switch counting gear teeth) with noise riding on the signal. The default setting (40 ns) works for most applications. Incremental/velocity encoder signals (especially single-ended counter types) are somewhat more susceptible to noise. If the noise results in extra counts, you may need a longer debounce time setting. If the debounce setting is too long, the debounce filter will filter out the encoder signal. SSI (Temposonics R) /Gurley (Teledyne) encoders only: Resolution (bits): this setting must match the number of bits in the encoder s data stream. Gurley=16 or 17 bits; SSI=1-32 bits. Baud Rate: specifies the communications clock rate between the processor and the encoder. Type: specifies the type of encoding (Binary or Gray Scale) used by the encoder. Encoder icon Application Attribute: Not applicable Type 84 MTS Series 793 Utility Software

85 For Incremental/Velocity and PWM (Temposonics G) encoders, selections include Quadrature or Counter (single ended). For SSI (Temposonics R) and Gurley (Teledyne) encoders, selections include Signed or Unsigned. For rotary devices, this setting is user preference. When Turns Counting (see below) is enabled, the Signed/Unsigned setting only affects the range of the initial reading at power up. For linear devices, the Signed/Unsigned selection is based on the behavior described below. Signed the reading from the device represents both positive and negative values. For example, -180 to +180 degrees for a rotary device, -100mm to +100mm for a linear device. Unsigned the reading from the device represents only positive values. For example, 0 to 360 degrees for a rotary device, 0mm to +200mm for a linear device. 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. False: the encoder channel represents the actual reading from the device. Each time the encoder signal reaches 360 degrees, the encoder output resets to zero. For example, if the device powers up at 0 degrees and is rotated 1.5 positive rotations, the encoder channel will read 180 degrees. Encoder icon AutoZero on Index Pulse (only available for the Incremental/Velocity setting): True: the encoder position signal is zeroed each time an index pulse is read. False (default): after a maximum count of 231, the encoder position signal resets to -231 and continuously counts up to 231 and resets. MTS Series 793 Utility Software 85

86 Analog Input icons Each encoder input includes two analog-input icons: Analog Inputs (position) with encoder icons allow you to set input filtering for the encoder position signals. Analog Input (velocity) icons allow you to set input filtering for the velocity signal derived (by firmware) from the encoder s position signal. Connector: the connector number for that input. 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. Application Attribute: Not applicable 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. Important: 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 causes ringing due to the highfrequency content of the step. Filtering occurs normally if the encoder is operated in a range that does not include the angle step. 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: 86 MTS Series 793 Utility Software

87 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). This setting defines which pins are used and how the system communicates with the UART device. Note: Model 409 Temperature Controllers are 2-wire devices; Model Handsets are 4-wire devices. Application Attribute: Not applicable External Clock icon Note: Only appears when external clock is selected as the device type. Name: Describes this resource. Note: Changing this name may invalidate existing station configurations. Output Clock Rate: enter the frequency (Hz) for the clock output. Application Attribute: Not applicable SSI/Gurley Encoder Application Settings Application Physical Zero Position at Minimum or Maximum Stroke (device dependent) Physical Zero Position at Mid Stroke (device dependent) Encoder Settings Type = Signed N/A Type = Unsigned N/A Velocity from Device (Temposonics R option) N/A MTS Series 793 Utility Software 87

88 Note: The graphs shown above represent a 12-bit linear device. Application Position-Limited Rotation Power-up signal range: 0 to 360 degrees Encoder Signal Range Power-up Signal range Operating Signal range Encoder Settings Type Turns Counting Unsigned True Yes Position Filter Unlimited Rotation Operating-signal range: 0 to 360 degrees Unsigned False See Note Position-Limited Rotation Power-up signal range: -180 to +180 degrees Signed True Yes Unlimited Rotation Operating-signal range: -180 to +180 degrees Signed False See Note 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 causes ringing due to the high-frequency content of the step. Filtering occurs normally if the encoder is operated in a range that does not include the angle step. Model Quad Encoder Interface HWI Settings You can configure this card to condition four encoders, or to provide an external clock output. When configured for encoders, each encoder includes two signals: The position signal from the encoder A velocity signal derived from the encoder s position signal 88 MTS Series 793 Utility Software

89 With the exception of no support for UART devices, the Model HWI settings are identical to the Model HWI settings. Model A-10 Eight-Channel Card Settings A A/D mezzanine card icon Properties tab The Model A-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. 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 High Level No Channel AC/ AC/ Dual DC Conditioner icon Analog Input n Specifies an externally conditioned signal in the range of +/-10V. Excludes inputs to the selected channel. Chassis: Not applicable. Slot: Specifies which slot the circuit board occupies in the chassis. Channel: Not applicable. Filter: Off/On. Connector: Not applicable. Model A-11 D/A Card Settings A-11 8-D/A mezzanine card icon Properties tab The analog output definition describes the D/A Analog Output mezzanine card. The connector specification identifies the rear panel connector that is available for analog outputs. 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 MTS Series 793 Utility Software 89

90 High Level No Channel Stage/ Dual 2-Stage Valve Driver icon Specifies an externally conditioned signal in the range of +/-10V. Excludes inputs to the selected channel. Chassis: Not applicable. Slot: Specifies which slot the circuit board occupies in the chassis. Channel: Not applicable. Filter: Not applicable. Connector: Not applicable. Model A-12 Encoder Card Settings A-12 Encoder/ -15 Temposonics/ - 16 Temposonics III/ -17 Heidenhain 417/ - 18 Heidenhain 425/ -61 U2 Incremental/ - 66 U2 Absolute mezzanine card icon The analog input definition describes the encoder mezzanine card. The connector specification identifies the rear panel connector that is available for analog inputs. 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. Analog Input icon Name: Describes this resource as it will appear in Station Builder resource lists when opened against an.hwi file. Transition Board Settings Changing this name may invalidate existing station configurations. Address: Not applicable. Connector: Describes the connector that joins the resource to the chassis. This will likely move up to the daughter level. Transition boards are used in FlexTest GT, TestStar IIm, Aero ST, and FlexTest 60/100/200 controllers. 90 MTS Series 793 Utility Software

91 Model Digital I/O Transition Board Settings DI/O transition board icon The DI/O Transition Board definition describes the Model Digital I/O Transition Panel digital input and outputs. The information shown defines 16 digital inputs and 16 digital outputs. Transition Slot: Specifies the transition slot where this board is installed. Digital Input/Digital Output icon 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 connector that joins the resource to the chassis. This will likely move up to the daughter level. MTS Series 793 Utility Software 91

92 Model HPU Transition Board Settings HPU transition board icon Hydraulic Interface icon Transition Slot: Specifies the transition slot where this board is installed. Name: Describes the hardware resource as it will appear in Station Builder resource lists. Changing this name may invalidate existing station configurations. Connector: J25. HPU with HSM: True: Indicates the system s HPU supplies additional HSMs. False: used for HPU only systems (makes HPU selection available in Station Builder). 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. Power Type: Select Electric or Hydraulic depending upon system power. 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. Visible: True: Indicates whether or not the HPU button is visible on the control panel. Changing Visible to False turns off the HPU button display on the Station Manager window, provided both First On and Last Off are True. 92 MTS Series 793 Utility Software

93 Model HSM Transition Board MTS Series 793 Utility Software 93

94 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. Each of the two HSM transition boards allowed in your system can support up to two HSM stations. Transition Slot: Specifies the transition slot where this board is installed. Hydraulic Interface icon Changing this name may invalidate existing station configurations. Name: Describes this resource as it will appear in Station Builder resource lists when opened against an.hwi file. Connector: J28A or J28B. Type: Solenoid, On/Off Solenoid, Proportional. 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 types, 3 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. HSM low pressure setting as a percentage of full-scale. High Percent: 100. HSM high pressure setting as a percentage of fullscale. HSM Rate: Slow = 4 seconds. Fast = 2 seconds. Ramp time from zero to low pressure = Low Percent value x HSM Rate value Ramp time from low to high pressure = High Percent value x HSM Rate value / Ramp time from zero to low pressure Time to achieve low pressure from zero = (Low Percent value) x (HSM Rate value). Time to achieve high pressure from low pressure = (High Percent value x HSM Rate value) - (Time to achieve low pressure). Example: Suppose 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 94 MTS Series 793 Utility Software

95 Time to achieve high pressure = (1 x 4) - (1) = 3 seconds Connect to HPU: Off indicate the HSM can be activated without an HPU activation. HPU On indicates that the HPU must be started (either manually or as first on ) before you can activate an HSM. HPU On w/ Tracking Same function as HPU On, however HSM cannot be at a higher state than the HPU. For example, if HPU and HSM are set to high, and then HPU is set to low, the HSM will follow the HPU state and change to low. If HPU is set to off, HSM will follow and set to off. Interlock Interface icon Connector: J29A or J29B. Assign to Interlock: Select a interlock chain (1 8) for the J29 interlocks. You can assign more than one J29 interlock to the same interlock chain to provide redundancy. Note: 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. Gate Interlock: True or False, True=the controller responds to the gate interlock signal on pins 3 and 4 of J29. False=J29 pins 3 and 4 are reserved for Program Stop interlock. Caution: Failure to enable the gate interlock option on systems that can operate in Slow (low-flow) mode can result in unexpected actuator movement when switching the system from Slow mode to Fast mode. 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. MTS Series 793 Utility Software 95

96 Model HSM Transition Board 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. Each of the two HSM transition boards allowed in your system can support up to two HSM stations. Transition Slot: Not applicable. Hydraulic Interface icon Changing this name may invalidate existing station configurations. Name: Describes this resource as it will appear in Station Builder resource lists when opened against an.hwi file. Connector: J28A or J28B. Type: Solenoid or On/Off Solenoid. On/Off Solenoid: only two HSM control buttons (Off/On) will appear on the Station Manager Station Controls panel. Solenoid: three HSM control buttons will appear (Off/Low/High). Power Type: Select Electric or Hydraulic depending upon system power. Connect to HPU: Off indicate the HSM can be activated without an HPU activation. HPU On indicates that the HPU must be started (either manually or as first on ) before you can activate an HSM. HPU On w/ Tracking Same function as HPU On, however HSM cannot be at a higher state than the HPU. For example, if HPU and HSM are set to high, and then HPU is set to low, the HSM will follow the HPU state and change to low. If HPU is set to off, HSM will follow and set to off. Hydraulic Interface icon Changing this name may invalidate existing station configurations. 96 MTS Series 793 Utility Software

97 Name: Describes this resource as it will appear in Station Builder resource lists when opened against an.hwi file. Connector: J28A or J28B. 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. Type: Solenoid or On/Off Solenoid. Interlock Interface icon Connector: J3. 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. FlexTest IIm Chassis Settings The following hardware settings are only available on the Chassis tab that appears for FlexTest IIm controllers. MTS Series 793 Utility Software 97

98 Analog Chassis chassis icon There can be up to two Model Analog Chassis. This block defines a chassis number. See the ADDA definition for more information. Chassis: Not applicable. Host Port: Not applicable Hydraulic Control Panel chassis icon The hydraulic station definition describes the Model Hydraulic Control Panel chassis. At least one HSM must be defined. The FlexTest IIm software and the Model Chassis supports up to 4 stations. Chassis: Not applicable. Host Port: Not applicable. Hydraulic Interface 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. Connector: The connector number represents a rear panel connector on the chassis. 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. 98 MTS Series 793 Utility Software

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100 Temperature Controller Settings 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 Dual UART/Encoder card is required to support a temperature controller. Type: Enter the name of the temperature controller as desired. Interlock Temperature (deg C) Define the default temperature. This temperature will be sent to the temperature controller whenever the station is interlocked or not loaded. Use Interlock Temperature: Select True to use the interlock temperature feature. Com Timeout Delay (sec): Enter the amount of time to wait for communication timeout with a temperature controller before reporting an error. Serial Port: Select the serial port where you will connect the temperature controller. If a GRESIII board is used, you must set the baud rate for the serial port to 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. Since RSCs must be on an interlock chain numerically equal to their port number (Intlk 1 = Port 1, etc.), a station on interlock X will not be able to use an RSC if there is a temperature controller on port X. Analog Output icon 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. Address: Not applicable. How to Add Temperature Controllers Before you can add temperature controllers, you must add a GRES III board or Dual UART/Encoder mezzanine card. 1. Select Controller in the tree view pane. 2. Click the Miscellaneous tab. 100 MTS Series 793 Utility Software

101 3. Specify the number of temperature controllers. Each temperature controller is associated with a specific Serial Port. Up to four temperature control channels may be specified per temperature controller (Serial Port). 4. Select the correct Serial Port on the Temperature Control Properties tab. Important: If a GRESIII board is used, you must set the baud rate for the serial port to Optional define default temperature. Set the Use Interlock Temperature field to True. Enter the Interlock Temperature. This temperature will be sent to the temperature controller whenever the station is interlocked or not loaded. 6. In the Com Timeout Delay field, enter the amount of time in seconds to wait for a communication time-out with a temperature controller before reporting an error. 7. Select the number of temperature control Channels on the Temperature Control tab. Up to four channels may be specified per temperature controller. MTS Series 793 Utility Software 101

102 Temperature Controller Settings 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 Dual UART/Encoder card is required to support a temperature controller. Type: Enter the name of the temperature controller as desired. Interlock Temperature (deg C) Define the default temperature. This temperature will be sent to the temperature controller whenever the station is interlocked or not loaded. Use Interlock Temperature: Select True to use the interlock temperature feature. Com Timeout Delay (sec): Enter the amount of time to wait for communication timeout with a temperature controller before reporting an error. Serial Port: Select the serial port where you will connect the temperature controller. If a GRESIII board is used, you must set the baud rate for the serial port to 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. Since RSCs must be on an interlock chain numerically equal to their port number (Intlk 1 = Port 1, etc.), a station on interlock X will not be able to use an RSC if there is a temperature controller on port X. Analog Output icon 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. Address: Not applicable. 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. 102 MTS Series 793 Utility Software

103 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. Remote Station Controllers are not available with the optional 6 or 8-station system configurations The FlexTest IIm/CTC controller can support an RSC for each station (for a total of four RSCs) on the 498 RS-485 Transition Board. Name: Specifies the desired resource name. Changing this name will not cause file conflicts. Host Port: The host port entry specifies which Com port on the GRES III plug-in board the Model Serial Interface transition board port is mapped to. (This determines which port the RSC must be plugged into.) Interlock: Specifies the interlock chain number. By default, the interlock chain number and the RSC number are equal. If you want to map an RSC with a different interlock chain (if available), change this value. How to Add Remote Station Controls (RSC) Before you can add RSC or Handsets, you must add a GRES III board or Dual UART/Encoder mezzanine card. Note: FlexTest SE Controllers do not support Remote Station Controls (RSCs). 1. Select Controller in the tree view pane. 2. Click the Miscellaneous tab. 3. Specify the number of remote station controls. Each RSC is associated with a specific Host Port. 4. On the Remote Station Control Properties tab, select the correct HOST PORT. Model Handset Settings Handset icon The Model 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 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. Once you select a a serial port, you must configure that port for a baud rate of MTS Series 793 Utility Software 103

104 Model Handset Hwi File Editor Settings To initially install the handset: 1. Physically install the serial boards required for the number of handsets used by the system: The Model Handset requires one of the following serial boards: FlexTest 40, 60, 100, 200 systems a Model Dual UART/Digital Transducer Conditioner mezzanine card that is installed on a Model I/O Carrier board can support up to two handsets. FlexTest IIM, GT, and TestStar IIM systems a Model GRES III board can support up to four handsets. 2. Use the Hwi File Editor application to add the required serial board resources to the.hwi file. A. Click the Controller icon. B. Click the Board tab and add the GRES III board. GRES III boards are typically placed in VME Bus slot 10. or For Series 494 systems, right-click an empty I/O carrier slot and select the Model UART mezzanine card. 3. Define the number of handsets used with the system. A. Click the Controller icon. B. Click the Miscellaneous tab and select the # of Handset Controls from the drop-down list. 4. Click each handset icon to select the card and the serial port used by the handset. 5. Click the serial board icon and set a baud rate for each Serial Comm port assigned to a handset. 6. Set the comm port Type for Model UART cards to 4 Wire. 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. 104 MTS Series 793 Utility Software

105 CAN Bus Interface Setup 1. Open the.hwi file. 2. Click the Controller icon, and then click the Miscellaneous tab. 3. From the # of CAN Bus Interfaces list, select 1. A series of CAN bus icons appear under the processor icon. 4. Configure the CAN bus interface as shown in the following table. CAN Bus Icon Port Icon (s) Type: Select the model number of the CAN bus controller mezzanine card that is installed on the processor board. Each port icon represents a separate CAN bus controller port that you can configure independently. Baud Rate: Enter baud rate for the CAN bus port s RS-485 interface. Frame Format: select the frame (message) format required by the CAN. Selections include Basic or Extended. Modbus Interface Settings A Modbus Interface consists of a networked Modbus node that connects to the controller processor through an Ethernet network switch. A Modbus node includes a Modbus chassis (DIN rail) populated with various modules including an Ethernet TCP/IP Fieldbus Coupler. MTS Series 793 Utility Software 105

106 Miscellaneous Tab (Controller icon) Modbus icon (s) # of Modbus Interfaces: Enter the number of Modbus interfaces. Each Modbus interface (Modbus node) consists of a DIN rail, modules, and an Ethernet TCP/IP Fieldbus Coupler. 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). Protocol: Select TCP or UDP Clock rate: Enter the clock rate (Hz) of the Modbus node. The default clock rate is 64 Hz. The clock rate can be adjusted based on the number of modules and the type of application. Process Image Input Offset and Process Image Output Offset: Specify a value for the input and output process image offsets. The values for the input and output process image offset are passed to the node as part of the Modbus protocol. # of Modules: Enter the number of modules mounted on the DIN rail. Only count modules that provide data to the process image For example, do not include the Fieldbus Coupler module or the End module. Right-clicking a module provides a list of supported modules. Module icons Module Assignments: Right-click each module and select the module type from the pop-up lists. Modules must be assigned in the order that they appear on the DIN rail. About EtherCAT 106 MTS Series 793 Utility Software

107 Series 793 software includes a keyed option that provides support for EtherCAT devices. EtherCAT is an Ethernet-based real-time network that uses a master-slave approach. In the 793 environment, the FlexTest controller is the master device. There are two unique file types associated with EtherCAT functionality: ENI (EtherCAT network information) files ESI (EtherCAT slave information) files A third-party configuration tool is used to define the network and create ESI files for all slaves in the system. The final output from the configuration tool is an ENI file that gets loaded into a sub-directory of your 793 controller folder. EtherCAT Settings To add EtherCAT to your station, right-click on the Controller icon in the Hwi Editor application tree view, and select EtherCAT. Digital I/O and Analog I/O signals are available to EtherCAT. MTS Series 793 Utility Software 107

108 The signals associated with the EtherCAT network listed in the Hwi Editor tree view will appear in the Station Builder and Station Manager applications. EtherCAT Settings To add EtherCAT to your station, right-click on the Controller icon in the Hwi Editor application tree view, and select EtherCAT. Digital I/O and Analog I/O signals are available to EtherCAT. 108 MTS Series 793 Utility Software

109 Name Version Interlock Action Signal names are generated by the configurator tool, and users may choose to edit the names in the configurator tools prior to adding EtherCAT to the 793.hwi file. Signal names can also be modified later in the Station Builder application. About Read-Only HSMs A read-only HSM refers to a hydraulic pressure source that is controlled by an external system (or manually) and monitored by the MTS controller. The read-only HSM state (pressure) is monitored using one or two dedicated digital inputs. The Hwi Editor application assigns these inputs to the readonly HSM. 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. MTS Series 793 Utility Software 109

110 3. Select the # of Read-only HSMs from the drop-down list. A Read-only HSM icon appears in the navigation pane. 4. (Optional) Click the Read-only HSM icon and change the digital input resource names that were automatically assigned to the read-only HSM. Read-only HSM icon Name: Specifies the desired resource name. Changing this name will cause file conflicts. Read-Only HSM Control Logic Connector: use this field to annotate the hwi editor file. On Bit: this is the digital input signal that indicates low HSM pressure. This name must match the resource name of the digital input. High Bit: this is the digital input signal that indicates High HSM pressure. This name must match the resource name of the digital input. Make sure that the digital input resource name in the On Bit and High Bit fields matches the physical input used for these signals. For HSMs that are either on or off (no low pressure setting), make both the On Bit and High Bit digital input resource name assignments the same. Dual input The following table shows the control logic for systems where different digital inputs are used for the On Bit and High Bit digital input resources.. On Bit Digital Input High Bit Digital Input HSM State Low Low HSM Off Low High High HSM Pressure High Low Low HSM Pressure 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. 110 MTS Series 793 Utility Software

111 Digital Input Low High HSM State HSM Off High HSM Pressure Note: Refer to the controller hardware manual to determine digital input wiring and specifications. Uninterruptible Power Supplies (UPS) The Model HPU board, Model system board, and Model system board have dedicated digital inputs that can monitor a UPS. These inputs monitor normally open UPS Line Fault and UPS Low Battery contacts on the UPS. Note: FlexTest SE, FlexTest 40 (Model ), TestStar IIs, and FlexTest IIm Controllers do not have dedicated UPS monitoring inputs. With these controllers, you can configure the digital inputs that are part of general-use DI/O for UPS support. How to Add an Uninterruptible Power Supply (UPS) 1. Add the UPS interface. A. Select Controller in the tree view pane. B. Add the appropriate hardware resource (for example, a Model HPU board). C. Click the Miscellaneous tab. D. Select 1 for the # of UPS Interfaces. MTS Series 793 Utility Software 111

112 2. Configure the UPS interface. A. Double-click the UPS icon to display UPS inputs and outputs: UPS Input/Output UPS Line Fault (Digital Input 1) UPS Low Battery (Digital Input 2) UPS External Event (Digital Input 3) UPS Off (Digital Output 1) This input changes state when the UPS normally open Line Fault contacts open to indicate that AC power is lost and that the UPS is supplying battery power to the system. 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). Only supported in systems that use a Model HPU board. Not Used. B. Define the State, Persistence, and Polarity settings for each UPS input. UPS Setting State The State setting is locked in the Enabled state. Future - Determines whether or not the line fault detector changes state if power is supplied by the UPS. The default setting is Enabled. Persistence Polarity Time value in milliseconds. This is the number of milliseconds in which the state must persist before the software recognizes the change. The default setting is 0, which means the change in state is recognized immediately. Normal or Inverted. The default value depends on the type of hardware resource used to monitor the UPS: For Model and Model system boards: Default = Normal For Model HPU boards: Default = Inverted These default polarity settings are based on normally open contacts. 112 MTS Series 793 Utility Software

113 3. Define Station UPS Options with the Station Manager application. When you open a station configuration created with an.hwi file that includes a UPS, you can select UPS options in the Station Setup window. For more information on, see the Series 793 Control Software manual (PN ). How to Set Model I/O Carrier Address (FlexTest GT/SE, TestStar IIm) Use the DIP switch (S1) and rotary DIP switch (S2) on each I/O Carrier board to set its address in accord with its chassis slot as follows: Slot Number Address PPC C20 C22 C24 C26 C28 C2A C2C C2E The DIP switch settings for address C20 is shown below. Set the rotary DIP switch to complete I/O Carrier board addressing How to Set ADDA II Board Address (FlexTest GT, TestStar IIm, FlexTest IIm) Set the board s rotary DIP switches (S3, S2) and the front-panel rotary DIP switch on each ADDA II board to the address that matches the chassis slot number where the board is installed (see below). Slot Number Address PPC PPC C40 C41 C42 C43 C44 C4A C4C The DIP switch settings for address C40 are shown below. Set the front-panel DIP switch to complete ADDA II board addressing. MTS Series 793 Utility Software 113

114 How to set the Model 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. 114 MTS Series 793 Utility Software

115 Controller Management Tool Controller Management Tool Controller Options 116 Using the Controller Management Tool 123 MTS Series 793 Utility Software 115

116 Controller Management Tool Controller Options 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. You can use this window to perform the tasks you normally perform in Config > Local Settings on the FlexTest SE Controller s front panel. This includes changing controller attributes, passwords, adding license keys, selecting hardware configuration files, station configuration files, and unit assignment sets. 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. 116 MTS Series 793 Utility Software

117 Controller Management Tool 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. You can use Controller ID to examine and change the Controller s ID. MTS Series 793 Utility Software 117

118 Controller Management Tool Controller Name Specifies the controller s name. By default, the name will be the serial number of the Model System I/O Board (for FlexTest SE Controllers) or Model 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. In a multicontroller FlexTest SE network (in which each controller operates independently) each unique instance of Station Manager displays the name of its associated controller in its title bar. The controller name appears on the title bar of the Station Builder application in the same way. Independent Aero ST controllers work as described above. In an Aero ST controller network (which consists of master and dependent controllers), Station Builder and Station Manager applications display only the name of the master controller in their title bars. Note: If you change the Controller Name you must re-register the Controller. When changing the original Controller name, use the Unregister Controller control. Controller ID (FlexTest SE Controllers only) Specifies the controller s network identification number (0-15), which determines the TCPIP address of the controller on the network. You can enter the Controller ID as desired. Each controller in the network must have a unique address. Important: This number must be an integer in the range of Note: If you change the Controller ID you must re-register the controller. Controller ID (Aero ST Controllers only) Specifies the controller s network identification number (0-15), which determines the TCPIP address of the Controller on the network. This value is read by the CMT application from the switch setting on the Model System I/O Board. The displayed value is read-only. Important: During system setup, the Model 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. 118 MTS Series 793 Utility Software

119 Controller Management Tool IP Address Controller Type (FlexTest SE Controllers only) Controller Type (Aero ST Controllers only) Displays the address of the processor in four-part numerical format, giving the processor a unique identification in its TCP/IP network. All FlexTest SE Controllers are configured as Independent Controller types. This selection is read-only. Specifies Master, Dependent, and Independent Controller assignments. The CMT application automatically assigns Master and Dependent roles according to Controller ID settings. Any controller that has a board ID of 0 is designated as a Master. To change an assignment you must change the Controller ID number on the Model board. Master: Specifies the network s Master Controller. The Master Controller synchronizes the distribution of command and data acquisition to and from the Dependent Controllers, as well as interfacing directly with system hydraulics. Note: CMT automatically assigns any controller that has a board ID of 0 as a Master. A controller network must include one Master (so if a controller network contains only one controller, it must be a Master). However, a controller network cannot have more than one Master. Dependent: Specifies controllers that are subordinate to the Master Controller. 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 (.hwi) and station configuration file (.cfg) for the controller selected on the Controller Management Tool window. The Configuration File selection box is typically not used for Aero ST applications. (Aero ST applications typically do not use Station Builder and Station Manager applications, which require a cfg file.) MTS Series 793 Utility Software 119

120 Controller Management Tool License Keys tab (FlexTest SE only) Use the License Keys tab to install purchased software options for your controller. Check the appropriate option box, and then enter the corresponding option key provided by MTS. 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. 120 MTS Series 793 Utility Software

121 Controller Management Tool Language Decimal Separator English is the standard language installed on the Controller and displayed on the interface. If available, select other languages as desired. Specifies the decimal symbol used in numbers. Select Period (.) or Comma (,). Appearance using Period (.): Appearance using Comma (,): ,00 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., MTS Series 793 Utility Software 121

122 Controller Management Tool 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. Unit Assignment Set Specifies the unit assignment set used by the Controller to display measurements of all types. For instance, SISET - SI defines a set of units that contains customary international (metric) units. It provides force, and force-related units, in kn. The following unit assignment sets are available: CGSSET - Centimeters, Grams, Seconds: Defines a set of units that is based upon centimeters, grams, and seconds. ENGSET - U.S. Engineering Units: Defines a set of units that contains customary U.S. engineering units. It provides force, and force-related units, in kip. ENGSETSM - U.S. Engineering Units (small) Defines a set of units that contains customary U.S. engineering units. It provides force, and force-related units, in lbf. SISET - SI (Systeme International d Unites) Defines a set of units that contains customary international (metric) units. It provides force, and force-related units, in kn. SISETSM - SI (Systeme International d Unites) - small Defines a set of units that contains customary international (metric) units. It provides force, and force-related units, in N. SYSDEF - System Units Definition Contains a copy of the units that are used in the hardware and software to represent test values of interest. 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. 122 MTS Series 793 Utility Software

123 Controller Management Tool Using the Controller Management Tool The CMT tasks are modular; you may perform them separately or in combination, depending on your circumstances. For instance, if you want to register a standalone FlexTest SE Controller for automated operation, you will not have to perform all of the tasks listed. CMT is not intended to be run concurrently with other testing applications (for instance, CMT is not intended to be used as a status checking application that you keep open on the desktop). Use CMT to perform the tasks listed in this manual as required, then exit the application before continuing normal use of your Controller. Running CMT continuously may interfere with Controller performance and result in unpredictable operation. 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. You can do this by operating each controller in the Stand-Alone boot mode and examining the ID as follows: Path: Config > Local Settings > Networking > Controller ID FlexTest SE Version Checking Before performing most tasks, the Controller Management Tool (CMT) checks software version differences between the Series 793 software in the servicing PC and the Series 793 software in the flash disk of the controller currently being serviced. MTS Series 793 Utility Software 123

124 Controller Management Tool If a version difference is detected, CMT displays a warning message while the requested task proceeds. Because of the software mismatch, however, unexpected results may occur. To correct the version mismatch, a software upgrade is recommended for either the controller being serviced or the PC servicing the controller. Note: The detection of a version mismatch is typical while updating system files during a normal software upgrade. How to put a FlexTest SE Controller in the Service boot mode 1. Ensure the controller is cabled to a PC equipped with MTS Series 793 software. You can select Standalone w/network boot mode in the next step (in place of Automation). If you do, ensure the controller is cabled to your PC. If it is not cabled to your PC you will experience long boot times (three minutes or more). 2. Switch to the Automation boot mode. From the controller s menu, select the Automation boot mode as follows: Path: Config > Local Settings > Networking > Boot Mode > Automation 3. Reboot the controller. Press one of the reboot buttons on the controller s menu (e.g. Path: Status > <<Reboot>>), or use the power button located to the rear of the chassis. The controller will boot up in the Automated mode. 4. Launch the Controller Management Tool (CMT) on the PC. Once MTS software is installed, you can launch the Controller Management Tool from the Start menu as follows: 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. How to Install or Update System Files on FlexTest SE Controllers This procedure copies system files from the servicing PC to the selected FlexTest SE Controller. System files include the executable code for the Controller and unit assignment sets(.uas). 1. If required, perform the procedure to put the controller in the Service boot mode. 2. Select the controller you wish to service from the displayed list of controllers. 124 MTS Series 793 Utility Software

125 Controller Management Tool 3. Copy necessary system files to the selected controller. Select either Install System Files or Update System Files. Selecting Install System Files will delete all existing files before copying system files to the controller. Be sure to back up files to the PC before making this selection. 4. Perform other operations as desired. 5. In the Next Controller Boot Mode selection list, select Standalone, Standalone w/network, or Automated, as appropriate. 6. Reboot the controller. Press CMT s Reboot Controller button, or press the <<Reboot>> key on the controller s front panel. The controller will boot in the selected boot mode. How to Update or Backup User Files on FlexTest SE Controllers The update procedure copies user files from the servicing PC to the selected controller. The backup procedure copies files from the controller to the servicing PC. User files include the hardware interface files (.hwi) and station configuration files (.cfg). 1. If required, perform the procedure to put the controller in the Service boot mode. If you do not have a station loaded, you can also update or backup user files in the Automation, Remote, or Local boot modes. 2. Select the controller you wish to service from the displayed list of controllers. 3. If desired, select Update User Files to copy user files in the servicing PC to the selected controller. If the same files already exist on the controller, you will be prompted to verify overwriting the existing files. 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. Reboot the controller. Press CMT s Reboot Controller button, or press the <<Reboot>> key on the controller s front panel. The controller will boot in the selected boot mode. How to Register a FlexTest SE Controller for Automation 1. Launch CMT and verify that all controllers appear in the main window as connected. 2. Select the controller that you want to register. 3. Register the selected controller. A. Select Register Controller to create a controller-specific folder in the Controllers directory on the servicing PC. MTS Series 793 Utility Software 125

126 Controller Management Tool B. The hwi file and config folder are then copied to this new folder from the controller being registered. 4. In the Next Controller Boot Mode selection list, select the desired boot mode. 5. Perform other operations as desired. 6. Reboot the controller. Press CMT s Reboot Controller button, or press the <<Reboot>> key on the controller s front panel. The controller will boot in the selected boot mode. How to Unregister a FlexTest SE Controller 1. Launch CMT and verify that all controllers appear in the main window as connected. 2. Select the controller that you want to unregister. 3. Unregister the selected controller. A. Select Unregister Controller. B. The controller-specific directory is optionally removed from the servicing PC. You may want to set the controller to boot in the Stand-alone boot mode rather than the Automation boot mode after you unregister it. 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. 1. Press the Controller Options button to display the Controller Options window. Change system options, passwords, initial hardware interface file (.hwi), station configuration file (.cfg), unit assignment set (.uas) and other controller attributes as desired. The changes you make are recorded in the FlexTest SE registry.ini file. 2. In the Next Controller Boot Mode selection list, select Stand-alone or Automation as desired. 3. Perform other operations as desired. 4. Reboot the controller. Press CMT s Reboot Controller button, or press the <<Reboot>> key on the controller s front panel. The controller will boot in the selected boot mode. How to Configure a FlexTest SE Controller to Boot in a Different Boot Mode If the controller is not currently in the Service boot mode running the Controller Management Tool, the quickest way to change boot modes is from the controller s front panel, as follows: Path: Config > Local Settings > Networking > Standalone, or Standalone/Net 126 MTS Series 793 Utility Software

127 Controller Management Tool Note: You cannot select the Service or Automation boot mode from the controller s front panel. To put the controller in the Service or Automation boot mode, select the Standalone/Net boot mode (if necessary), reboot, and run the Controller Management Tool application. Note: This procedure applies only to FlexTest SE Controllers. 1. In the Next Controller Boot Mode selection list, select the boot mode as desired. 2. Reboot the controller. How to Configure a New Aero ST Multi Controller System This procedure assumes that all controller hardware has been configured and successfully booted, and that.hwi files have been created for each box and stored in separate directories on the PC. 1. Launch CMT and verify that all controllers appear in the main window as connected. 2. Starting with the first box in main window list, select Install System Files. 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. When only the system is loaded When the system is loaded (after the System Loader application has been run), you cannot reboot individual Dependent Controllers with CMT. In this case, you can only reboot the Master Controller, which will reboot all Dependent Controllers. When the system is not loaded When the system is not loaded, you may independently reboot the Master or any Dependent Controller with CMT. Note: Rebooting from CMT (using the Reboot Controller button) may not work if communication problems exist in the controller network. If you cannot reboot a controller from CMT, use the reboot button on the affected controller s processor card, or remove and reapply power to affected controller. User File Access for Registered Controllers MTS Series 793 Utility Software 127

128 Controller Management Tool When you register a controller, the application copies user files from the controller and places them in a controller-specific directory on the servicing PC s disk. (FlexTest SE Controllers only) Once a controller is registered (FlexTest SE or Aero ST), applications on the PC access user files from the following: Hardware configuration files (.hwi) are accessed from the root of the directory created for the controller. Station configuration files (.cfg) are accessed from the Config directory at the root of the directory created for the controller. 128 MTS Series 793 Utility Software

129 Acumen System Setup Acumen System Setup Acumen Hwi Setup 130 MTS Series 793 Utility Software 129

130 Acumen System Setup Acumen Hwi Setup Acumen Hwi Settings This section lists the Hwi settings for each piece of MTS FlexTest Controller hardware required by the Acumen system. The slot location of individual mezzanine cards my vary depending on the type of controller used. Model Dual DUC - Load Cell with Acceleration Compensation When configured for acceleration compensation, the A input is used for the load cell and the B input is used for the accelerometer. To configure a dual DUC for acceleration compensation (see the following figure), right-click on the top DUC icon [1] and click Add Accelerometer Compensation. Once configured, an Auxiliary Input property [2] that lists the connector number for the accelerometer input appears at the bottom of the list. Acceleration Compensation Setup Model Incremental Displacement Encoder The displacement encoder used in the Acumen system connects to a Model Dual UART/Encoder card. The settings for this card are shown below. Important: The name for the encoder input (for example: Encoder S2-J2A) must be entered in the Encoder box in the Elmo Output window. 130 MTS Series 793 Utility Software

131 Acumen System Setup Temposonics R DUC The Temposonics R transducer used in the Acumen system provides an absolute position reference for the actuator. The transducer s analog output is conditioned by a Model Dual DUC card. The settings for this card are shown below. Important: The name for the Temposonics input (for example: DUC S2-J3A) must be entered in the Absolute Temposonics R box in the Elmo Output window. Handset/Frame Status Model Dual UART card A Model Dual UART/Encoder card configured for UART (serial) communications is required for the following devices: MTS Series 793 Utility Software 131

132 Acumen System Setup Communications between the controller and the frame control panel (handset). Communications between the controller and the frame electronics (for status information). Note: If necessary, each of the two serial communications can reside on different Model cards. The settings for the Model card are shown in the following figures. Note: The settings for the frame control panel are identical to a Model Handset. Important: The name for the Frame Status input (for example: UART S2-J4B) must be entered in the Serial Port box in the Elmo Output window. Elmo Output Settings Each Acumen system requires an Analog Output that provides a motor command signal for the Elmo motor drive. For a Flextest 40 Controller, the system uses the analog output on the Model or system board. For a FlexTest 60 Controller, the analog output is provided by a Model mezzanine card. To designate an analog output for the motor command signal (Elmo Drive), right-click on the Analog Output icon and click Elmo Output. An Elmo Output icon appears. Click on this icon to display a list of settings required for the Acumen system. These settings are listed in the table below. 132 MTS Series 793 Utility Software

133 Acumen System Setup Elmo Output Settings Setting Parameter File Program File Checksum File Firmware File Bootload File Download File Encoder Absolute Temposonics R Serial Port Used to update the motor drive software. Used to update the motor drive software. Used to update the motor drive software. Used to update the Acumen frame firmware. Used to update the Acumen frame firmware. Used to update the Acumen frame firmware. Enter the name for the displacement encoder input (for example: Encoder S2-J2A) in the Encoder box. Enter the name for the Temposonics input (for example: DUC S2-J3A) in the Absolute Temposonics R box. Select the Frame Status input (for example: UART S2-J4B) from the Serial Port drop-down list. MTS Series 793 Utility Software 133