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MTS FlexTest® Models 40/60/100/200 Controller Hardware
Model 494.41 Single-Station System Board
FlexTest Controller Configurations
58
Control voltages for hydraulic power units vary between models. The
interface between the Model 494.41 System board and an HPU consists of
24-volt logic signals.
Connecting J25 to a non-compliant HPU can damage the board.
Do not connect 24 V DC relay circuitry or 115 V AC circuitry to connector J25 on
the Model 494.41 System board.
Cable specification To maintain EMC compliance, J25 HPU cables must comply with the following
specifications:
Connector—15-contact, type-D, female EMI connector.
Backshell–EMI metallized plastic or metal.
Cable—22 AWG, 10-conductor with braided shield with the shield connected to
metallized plastic or metal backshell to the chassis.
Jumper plug required If connector J25 HPU is not used, you must install a jumper plug to maintain the
integrity of the interlocks. Use jumper plug part number 039-713-301 or jumper
pins 1–7, 2–3–5, 6–9, 8–10–11–12.
CAUTION
- MTS FlexTest 1
- Models 40/60/100/200 1
- Controller Hardware 1
- Publication information 2
- Contents 3
- Before You Contact MTS 8
- If You Contact MTS by Phone 9
- Technical Support 10
- Before You Begin 13
- Conventions 14
- Electronic manual 15
- Safety Information 17
- Name: Rich Baker 20
- Date: 01 November 2007 20
- Safety Circuits 21
- Input/Output Verification 22
- E-Stop Circuits 22
- E-Stop Circuit Testing 23
- Hardware Interlocks 24
- Chapter 2 27
- FlexTest Controller Overview 28
- FlexTest 40 FlexTest 60 29
- Transition Bus 30
- Station A 30
- Station B 30
- Installation 31
- Shorting Bar 37
- Required 38
- UPS System Requirements 43
- Battery power 44
- UPS power 45
- DA Output 48
- Model 494.04 Chassis Boards 50
- Slot 3 - 494.40 I/O Carrier 51
- Slot 2 - 494.40 I/O Carrier 51
- Slot 1 - Processor Board 51
- Slot 4-5 51
- 494.41 System I/O 51
- 494.41 System 56
- E-Stop Box 56
- ON = Normal 57
- ON = HPU ON 57
- 494.41 System I/O Board 59
- HPU E-Stop 2 signal 60
- 494.41 System Board 61
- J43 Interlock 61
- J49 Aux Pwr 62
- 100-240 VAC 63
- 50-60 Hz, 1-2 A 63
- 494.04 Chassis 65
- D/A Output 65
- Estop/Run 72
- 494.42 System 73
- 494.42 System Board 76
- J28 (D9S) 76
- Interlock 78
- J54 Digital Input 80
- J54 Dig In 80
- J55 Digital Output 81
- Note: A custom Y Cable 92
- J29A J29B 94
- J55 Dig Out 98
- 494.44 System 100
- I/O Board 100
- Load Frame 100
- Controller capabilities 101
- 7654321A 102
- ARAMETER SPECIFICATION 103
- FlexTest 100 104
- Digital Controller 104
- 9 8 7 6 5 4 3 2 1 B A 105
- FlexTest 200 107
- VME Bus (Front) 108
- Transition Bus (Rear) 109
- VME Bus Boards 113
- VME Bus Board Overview 114
- Board installation 115
- Board removal 116
- Processor Connections 118
- Wago PLC 119
- Board features 120
- Shunt Calibration 122
- Resistors (front panel) 122
- Address Setting 122
- Bridge Completion 122
- Resistors 122
- Model 494.43 Multibox Board 126
- Master/dependent 130
- Mezzanine Cards 133
- About Mezzanine Cards 134
- ODEL MEZZANINE CARD 135
- UNCTION COMPATIBLE 135
- RANSITION BOARDS 135
- Mezzanine 139
- Connector 139
- I/O Carrier 139
- 4. Insert the mezzanine card 140
- ≤1% typical 146
- SPECIFICATION 147
- Full-bridge 148
- Half-bridge 149
- I/O Carrier Board 150
- Transducer 150
- Model 494.25 Single DUC Card 154
- Hardware 155
- Cable Grounding 156
- Model 494.26 Dual DUC Card 157
- PARAMETER SPECIFICATION 161
- RJ-50 Pin Assignments 165
- (front view) 165
- Front-Panel 166
- RJ-50 Connector 166
- Compensation Card 168
- Pin Assignments 174
- Elastomer Adapter Box 175
- Load Cell 175
- Accelerometer 175
- Model 494.40 I/O 177
- Carrier Board 177
- Transition 178
- Card Cage 178
- VME Card CageAnalog 178
- 494.46 8-Output D/A 180
- Mezzanine Card 180
- VME Card Cage 181
- VME Card Cage Servovalves 182
- Digital transducer 183
- RJ-50 Connectors 191
- JXA and JXB 191
- RJ-50 Pin 192
- Assignments 192
- Temposonics G 193
- Model 493.80 195
- Encoder Interface Board 195
- Quad Encoder 200
- Transition Board 200
- Counters I/O Carrier Board 200
- G transducers) 203
- TEDS Transducer ID Module 206
- Chapter 5 207
- Digital I/O Hardware Devices 208
- Digital I/O Channels 209
- Inputs Outputs 209
- Model 493.31 213
- DI/O Breakout Box 213
- Breakout box 214
- Model 493.72 board 214
- 493.31 DI/O Breakout Box 215
- 493.72 Digital I/O 215
- Model 493.72 216
- Digital I/O 216
- Model 494.31 218
- Model 493.72 Digital I/O 219
- 494.44 System Board 221
- Output circuits 222
- Input circuits 222
- Inputs 1-4 use PWR 1 225
- Inputs 5-8 use PWR 2 225
- External 226
- Power Supply 227
- Electrical 228
- Environmental 229
- Dimensions 229
- Output Pwr cable 233
- Input Pwr cable 233
- Model 494.31 DI/O 233
- Breakout Box 233
- Power Connections 234
- Model 494.32 DI/O 235
- Transition Boards 237
- Model 493.73 Specifications 239
- E-STOP IN 241
- 493.73 HPU Board 243
- HPU Board 244
- To calculate ramp rates 250
- 493.74 HSM Board 251
- External Device 252
- Run/Stop status 254
- (all SSI or all non-SSI) 259
- Mode Settings 260
- Mode Settings for use with 260
- J49 AUX PWR 261
- J3A STA 261
- J3B STA 261
- J28A HSM 261
- J28B HSM 261
- Single two-stage valve 274
- Dual two-stage valves 274
- To 493.42 276
- System I/O 276
- Module (J25) 276
- COMPATIBLE WITH JUMPERS 277
- 039-713-7XX 278
- Converter box 279
- Controller 280
- Series 494 Cable Part Numbers 281
- Series 494 Cable Connections 282
- Chassis Troubleshooting 285
- Service Connections 288
- Chassis Maintenance 289
- Six-Station Configurations 291
- Eight-Station Configurations 292
- Aero Multibox Systems 293
- Aero Multibox Overview 294
- Multibox Hardware 295
- J8 Intlk In 296
- J9 Intlk Out 296
- J51 Box In 296
- J52 Box Out 296
- Chassis (box) 296
- Multibox Processor Settings 301
- (Master) 304
- (Dependent) 304
- Box 1 (Master) 305
- Box 2 (Dependent) 305
- Model 49x.43 307
- Multibox Board 307
- Processor 307
- Gigabit Ethernet 308
- Reboot the Controllers 315
- OXES 1-6 BOXES 7-12 319
- Define the VME Slot Locations 320
- Configure Servo Valve Outputs 324
- “Disabled.” 327
- Model 793 Multibox Systems 331
- Optional–Delete the 334
- Multibox Configuration 338
- Numerics 339
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