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FlexTest™ SE

1. 201 PVC 17 165 PVP 17 166 rack mounting requirements 33 rack mounting kit 16 Ramp tapered wave shape 131 Ramp wave shape 130 Rate Input Selection 136 Recall buttons 26 reset button 28 Rewind 28 RPC software 36 5 S gain See stabilization gain save station parameter set 93 100 tuning parameters 83 scope plot options 185 signals time base scaling 186 Scope menu 21 Scope panel 21 selecting applications for PC supervised controllers 44 sensor files in PC supervised Controllers 45 Service Port Output 135 Service Port Output Signals 137 servovalve polarity check 64 67 setting polarity 63 Setup menu 21 signal diagram 193 signal limits setting limit detector 156 signal monitoring 18 Sine tapered wave shape 131 Sine wave shape 130 specifications 32 specimens changing 82 Square tapered wave shape 131 Square wave shape 130 stabilization gain 201 with acceleration 202 with differential pressure sensor 202 Stand alone power up 49 standard features 13 14 Index Model 793 53 Auto Tuning 15 Monitor 1 amp 2 BNC connectors 18 Monitor Connectors 17 monitoring signals 18 monitoring waveforms 87 areas of interest 87 MTS Series 793 software 36 MultiPurpose TestWare 36 Navigate buttons 25 Next button 25 Null Pacing compensation about 161 Numeric keypad 27 0 offset conditioner 150 Open Save Parameters 133 optional features 15 P panel settings for PC supervised Co
2. 0 oO 2 T s i 0 Meters Use the Meters panel to monitor station signals You can choose to display a timed meter a Peak Valley meter a mean amplitude meter or a running max min meter Sample Meter Display Use the Meters menu to select the signals you wish to view and to customize the Meters panel Access level Operator Meters lt lt Add Meter gt gt lt lt Reset Meters gt gt Control Meter 1 gt Meter 2 gt Meter 3 gt Meter 4 gt Placement Font Size Note Ifthe Meter is monitoring a command signal that has multiple control modes it will display the dimension and units of the current mode Menus Descriptions 187 Meters Panel Overview FlexTest SE Meters 0 Meter Menu part 1 of 3 T a AA 0000000008 4 ITEM DESCRIPTION a 2 lt lt Add Meter gt gt Adds a new meter to the bottom of the meter panel The 5 maximum number of meters is 16 lt lt Reset Meters gt gt Clears all active meters so new values can be acquired Control Run Starts displaying data on all meters Stop Stops updating the meters Program Control Starts displaying data on all meters when the test program starts The meters stop updating when the test program stops Meter n gt Displays the options available for the currently selected meter 188 Menus Descriptions FlexTest SE Meters
3. E E i 2 104 Common Tasks FlexTest SE How to Perform Advanced Tuning Techniques A WARNING Pressing the Run button will put the actuator in motion A moving actuator can injure anyone in its path Always clear the actuator area before pressing the Run button 5 Press Run to start auto tuning and if desired accept tuning values While auto tuning is in progress the Controller displays Auto Tuning in Progress To terminate auto tuning before completion press lt Stop gt When auto tuning is complete the Controller displays Auto Tuning for this mode has completed successfully Also when auto tuning is complete the results are displayed showing Current tuning values and Reference values Press Accept to apply the Reference values 6 Save the auto tuning values Path Setup gt Open Save Parameters gt lt lt Save gt gt You may save auto tuning values to an existing parameter set or to a new parameter set o D 0 0 FlexTest SE Common Tasks 105 How to Perform Advanced Tuning Techniques Auto tuning the force 1 Install a dummy specimen control mode 2 Set and enable the force feedback signal s limits typically just outside the signal s full scale range Path Setup gt Force gt Limits 3 Set up auto tuning parameters A Select Tuning gt Auto Tuning B For Control Mode select displacement C For Mode to Tu
4. a 5 O i 2 0 FlexTest SE PC Supervised Controllers 35 Basic Description Basic Description In the PC supervised mode the Controller is connected to a PC equipped with MTS Series 793 software which expands capabilities to include e Custom programming and data acquisition with MTS Basic TestWare e State of the art test design with MTS MultiPurpose TestWare e Playout and acquisition of time history files e Inter operability with MTS RPC software for the development iteration and analysis of time history data It also allows you to leverage the ability of the PC to generate test reports and network test data 3 6 3 in FlexTest SE Controller with PC Supervision Using Station Manager When you use the Controller with PC supervision you run the Station with PC Supervi sed Manager program in tandem to the Controller The Station Manager is Controllers included with the Model 793 00 System Software suite that comes with PC supervised Controllers The Station Manager provides another interface with which you can perform test activities N 2 f i i oO 3 o 2 gt ar a 0 oO A 36 PC Supervised Controllers FlexTest SE Using the Interfaces Using the Interfaces When you use the Controller with PC supervision you boot the Controller in the automate
5. D 0 0 FlexTest SE Common Tasks 69 How to Balance the Servovalve 4 In the Station Controls panel s toolbar click lt In the Manual Command window A Select the Channel whose valve balance needs checking B For the Control Mode select a displacement control mode C Select Enable Manual Command D Use the Manual Cmd to position the actuator at or near its midstroke position Manual Command lt TS 3 St MEG Manual Controls Channel Channel 1 JH Control Mode Displacement 4 Ig 10 5000 10 5000 M Enable Manual Command 5 In the Station Manager window s Display menu select Station Setup 6 In the Station Setup window navigation pane s Channels select the channel whose valve balance needs checking 7 In the Station Setup window click Vv In the Tuning panel click the Adjustments tab In this tab A Write down the current I Gain B Zero the I Gain 0 8 E E i 2 70 Common Tasks FlexTest SE How to Balance the Servovalve 8 Set up a meter to view displacement error A Select the Meters icon on the Station Manager tool bar Select the Meter 1 Setup button For Meter Type select Timed GOO In Signal Selection select the channel whose valve balance needs checking For Signal select Displacement Absolute Error 9 Zero the displacement error with the Valve Balance control A In the Station Se
6. 2 Press the Menu Item button additional times to scroll through the list as desired o D 0 0 FlexTest SE Common Tasks 57 How to Use the Front Panel Controls How to use bookmarks You can use the Recall A B buttons to save specific panel views or bookmarks for recall later in the current or subsequent sessions For instance suppose you need to make frequent adjustments of the Trace 1 Settings of the oscilloscope By pressing and holding the Recall A button while the Trace 1 Settings menu has focus you create a shortcut to it for future use making it easier to access than if you used the normal navigation path When you press and hold a recall button a confirmation message appears on the screen which lists the items in the snapshot as shown below Units Div When you press and Recall A is defined as hold a recall button Panel Scope the Controller displays v Disp Menu Scope lt Trace 1 Settings gt 109 a view definition Item Offset Engr Units message viv Force A Force2 2 90 kN muit 4 A Anlg In 43 00 mm paa Display Resolution Current Total Count 595 cycle The A and B buttons operate independently allowing you to create two shortcuts to desired panel snapshots nit 0 8 m E E i o 58 Common Tasks FlexTest SE How To Warm Up Station Hydraulics How To Warm Up
7. 493 14 2SVD Slot 4 gt Power Options gt gt System Options gt gt gt HWI file Select existing na Enter new name lt lt Load gt gt lt lt Save gt gt lt lt Delete gt gt gt 493 25 52 Mode gt 493 14 5 Mode gt Power Opti Power Type HSM Type gt System Opt Velocity Limiter C gt Set Date Time Month Day Year Hour lt lt Set gt gt gt gt FG Wave Shape Frequency Setpoint Amplitude gt Stabilization Filter ref F Filter Type Filter Min Filter Max gt 493 25 S2 J n Display name Enabled Type Dimension Display Unit Channel lt lt Add Dual Comp gt gt gt Mon n Anlg Out Dig Input n Dig Output n Display name Enabled gt Meter n Meter Type Signal Display Mode Display Unit Display Resolution Sensitivity P V and M A only lt lt Add Meter After gt gt lt lt Delete Meter gt gt lt lt Shift Meter Up gt gt lt lt Shift Meter Down gt gt gt Edit Configuration Configuration File gt 493 14 S2 J7 Anlg In gt 493 25 S2 J n gt 493 25 S2 J n gt Mon n gt Anlg Out gt Digital Input n gt Digital Output n gt lt Configuration File Select existing name Enter new name lt lt New gt gt lt lt Load gt gt lt lt Save gt gt lt lt Delete gt gt gt 493 14 VD S2 J7 Display name Enabled nclude CLC Power gt gt Anlg In Display n
8. A 2 pa 5 dump dp pec 6 lt a a 4 lols a 5 Pr w 9 eq o pad Q j gt 5 j gee 6 ICDA 166 Jk 36 z TH Py 5 w 5 3 8 8 2 0000 0 0000 6 0 A 0000 0 TRE oooo0o000 00 2000000 g TRE a P gua gt ou 8 Saee TYPE EPC MIP 8 7 PO MEZZANNE CARD 5 3 VMEbus Modules part 1 of 2 SLOT MOobDULE NAME FUNCTION Slot 1 PowerPC Provides PIDF processing for the Controller and management of the other plug in modules in the stand alone configuration Provides an interface between the Controller and an external computer in the automated configuration Slot 2 Model 493 40 I O Carrier Supports up to four daughter boards that can be used for sensor conditioning driving a servovalve and in the automated configuration providing A D and or D A channels FlexTest SE Menus Descriptions 227 Config 9 S VMEbus Modules part 2 of 2 SLOT MopuLE NAME FUNCTION 5 Slot 3 Blank in standard Provides support for additional sensor conditioning and configurations May be in the automated configuration additional A D and or 5 used for optional Model D A channels 493 40 I O Carrier Slots 4 5 Model 493 42 System I O Provides box in and box out connections for daisy chaining multiple Controllers analog and digital I O E Stop and HSM and HPU control 228 Menus Descriptions FlexTest SE Config Config Menu gt
9. Specifies the control mode used when the Function Generator starts Typical selections are force and displacement Specifies the setpoint or mean level at which the program signal s amplitude centers on Specifies the program signal s amplitude The specified amplitude applies equally to both sides of the Target Setpoint Specifies the program signal s frequency or cycles per second The maximum frequency may not exceed 20 of the Controller s update rate Specifies the compensator used by the Function Generator The Compensators that may be available include Null Pacing Peak Valley Control PVC and Peak Valley Phase PVP See About Null Pacing and compensators on page 161 Specifies the number of cycles or segments the function generator will play out You cannot enter half cycles or an odd number of segments FlexTest SE FG FG Menu gt Cyclic ITEM Wave Shape Control Mode Target Setpoint Amplitude Frequency Compensator Preset Count 122 Menus Descriptions 0 i 2 0 0 3 FG When this counter reaches the Preset Count value the function generator stops When the Current Count value and Preset Count value are equal the Current Count value will automatically reset the next time Run is pressed Cyclic Menu part 2 of 2 a ITEM DESCRIPTION F 9 Current Count Displays the number of cycles or segments
10. Technical Support on page 11 How to auto tune Note This procedure requires the optional Auto Tuning feature When you run auto tuning the Controller disregards your current PIDF gain settings and applies the minimum required drive signal to ramp the feedback to 80 of the auto tuning limits It then measures the relationship between the feedback velocity and the valve opening signal and then derives the minimum PIDF gains required to track the command It s good practice to auto tune the displacement control mode first then install a dummy specimen and auto tune the force control mode Note Procedures for Automated Controllers assumes the FlexTest SE Controller is equipped with the PC Supervision option and that Exclusive Control is assigned to Station Manager For more information about Station Manager see the Model 793 00 System Software manual that accompanies your system Auto tuning the 1 Select an access level of Tuning displacement control mode Stand Alone Controllers Status gt Access Level gt Tuning Automated Controllers In the Station Manager window s toolbar select an access level of Tuning 2 Remove the specimen 3 Set and enable the displacement feedback signal s limits typically just outside the signal s full scale range Stand Alone Controllers Setup gt displacement gt Limits Automated Controllers In the Station Setup window s navigation pane click Detectors and th
11. True Enables the resource in the current configuration file False Disables the resource in the current configuration file Enables a special control mode designed for specimen installation and removal It uses one feedback to control the actuator master channel and another feedback to limit the range of the active control mode Cimiting channel To create a CLC control mode you must assign at least two analog input resources as PIDF control modes The first PIDF control mode defined becomes the master channel and the second defined becomes the limiting channel True Enables channel limited channel CLC control on the enabled resource False Disables CLC control on the enabled resource None Allows operation of the Controller without a hydraulic service manifold HSM selection HSM 7 Requires the Controller to be cabled to the specified HSM Menus Descriptions 217 Config Menu gt Edit Config gt 493 15 SV S n J n ITEM Display Name Enabled Include CLC Power FlexTest SE Config Config Menu gt Edit Config gt Anlg In 493 25 5 493 47 S n J n The analog input resource consists of a BNC type connector located to the rear of the Controller Anlg In with associated scaling electronics It is used to receive analog signals preconditioned by an external source or to receive external command input N i 2 0 0 3 The Model 49
12. When operating the Controller in the automated mode the following signals are also available to the MultiPurpose TestWare and Basic TestWare data acquisition processes with the exception of Command and Compensated Command oO 0 oO 2 T i 0 Note Time Hourly Rollover Time Running Time and Segment Count are not available for the Scope Peak Valley Mean Amplitude or Max Min meters Station Signals part 1 of 2 DESCRIPTION Displays the time reference signal derived from the internal clock that increments continually This signal exists to support data acquisition by test applications It is not practical to monitor the Time signal Displays the time reference signal derived from the internal clock that resets every hour Like the Time signal this signal exists to support data acquisition by test applications and is not practical to monitor the Hourly Rollover Time Displays the accumulated time in which the test program is running The Rewind control resets this value the Stop and Hold controls do not Pressing Run after pressing Stop or Hold causes this value to resume incrementing Displays the signal that goes into the valve driver in volts Displays various types of sensor feedback signals in engineering units Force and Displacement are typically sensor signals Displays the number of segments played out so far in the selected channel When monitoring signals with a meter this signa
13. 100 077 223 C 2002 MTS Systems Corporation All rights reserved MTS Temposonics and TestWare are registered trademarks of MTS Systems Corporation FlexTest MPT MultiPurpose TestWare Station Builder Station Manager and TestStar are trademarks of MTS Systems Corporation Adobe is a registered trademark of Adobe Systems Inc Acrobat is a trademark of Adobe Systems Inc PowerPC is a registered trademark of International Business Machines Corporation Microsoft and Windows are registered trademarks of Microsoft Corporation 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 100 077 223 A September 2002 100 077 223
14. 192 Menus Descriptions N i 2 0 0 3 0 oO 2 T s i 0 Meters Signal diagram This diagram shows where various station signals you can monitor with the Scope and Meters are derived Compensated Command Command Output Valve Driver Signals from Other Modes of PIDF Controller this Channel Command Compensator Test Null Pacing 2 Output Command Peak Valley Scalar APC convert control AIC Mode signal to counts ALC goo Switch 7 a Closed Absolute Error Loop Generator Se ae Dela P Load Cell Feedback Stabilization Feedback Input Signal Conditioning Signal Inner Outer Error Detector LVDT Feedback pee a Input Signal Conditioning Signal Absolute Error Error Sensor Signal Stabilization FlexTest SE Menus Descriptions 193 Tuning Tuning Note This menu is available only when you boot the Controller in the Stand Alone mode Config gt Local Settings gt Networking gt Boot Location When booted in the Automated mode and used with PC supervision this menu is disabled Use Station Manager to tune your system N i 2 0 0 3 Overview Use the Tuning menu to adjust the stability and response of the servo control loop Proper tuning ensures that the servo loop respo
15. Save Restore 5 In the Shunt tab perform the calibration A As required select the Current Range needing calibration B In Select Shunt Type select either Shunt or Shunt FlexTest Im systems only C For the Shunt Reference Value units select mV D Click H to apply the shunt E Compare the Current Shunt Value to the Shunt Reference Value Recalibrate the sensor conditioner pair if the values differ by more than 20 mV F To make the Current Shunt Value the new Shunt Reference Value click Update G Click to remove the shunt Note Leaving the Shunt tab or choosing another item in the navigation panel will automatically remove the shunt o D 0 0 FlexTest SE Common Tasks 81 How to Manually Tune the Control Loop How to Manually Tune the Control Loop About manual tuning When you tune the control loop manually you make individual adjustments to the PIDF controls to optimize the stability and response of the control loop Time Lag phase shift Proper tuning reduces error and phase lag Program Command Feedback higher Proportional gain Feedback lower Proportional gain Inaccurate tuning increases the error and phase lag between the program command and the sensor feedback Large error reduces control accuracy and repeatability and keeps the full program command from being applied to the specimen e Optimal system o
16. Zero reference 7 shifts down X Y plot mode Using the X Y plot mode to plot load versus displacement displays a Lissajou figure as shown to the right Lissajou figures are useful for displaying feedback hysteresis FlexTest SE Scope Panning traces The scope temporarily records the trace up to 10 times the time of the time base of the trace To review trace history look back in time simply stop the trace press the Scope menu button to bring focus to highlight the scope then enable the Dial and rotate it counter clockwise Figure A Figure B 1 To view trace history stop the trace 6 D 3 and the trace history will appear Scope gt Control gt Stop and Enabled bring focus to the scope 4 5 2 Enable then rotate the Dial counterclockwise Time markers in When panning traces time markers will be present at the lower left the pan display hand and lower right hand corners of the display The right hand number will be at or near zero when the trace is stopped zero is last point acquired The numbers becomes increasing negative the further you pan into trace history In Figure A above the trace was stopped while the waveform was in progress In Figure B which is same waveform the beginning of the waveform occurred approximately 7 5 seconds before the trace was stopped 186 Menus Descriptions FlexTest SE 0 i 2 0 0 3
17. h Command 200 h Active Festiback MRO ramidi 6 Fe ZO sup If you press the Function the FG Menu 6 Status Generator menu button C Scope PPears on the Control Mode screen 0 20 Secidiv Disp C Meters 2 72 mm 272 Access L C Tuning Applicatit Amplitude 2 72kN Control 6 000mm n Running 5 Confi Frequency 6 vane 13 00 mm Preset Ci 5 2 Hz Current C imi Compensato 6 Limits 4 CD tos Menu Status Scope When you press the Status Scope Meters and Log buttons once the Meters and Log Controller brings focus to their associated information panels on the screen When you press any of these buttons again the Controller displays the associated menu on the screen subsequent presses alternately dismiss and bring focus to the menu h Command 2 00 tinvdiv 1 00 mm Meters lt Meter Ch Active Feetback 0 04 2 00 mr Display Mode 0 20 Secidiv Engr Units Display Unit mm i Resolution 4 lt lt Add Meter After h Command 200 Ch Active Feetback MAOR 0 20 Secidiv Parameter Set 5 i a iv i Access Level Application Control Mode Running Time 9315 Sec Preset Count 0 Current Count 294 cycled Total Count 294 cycles lt lt Deletegyleter gt gt 4 Pressing the Meters button once brings focus pressing the Meters button again brings to the Me
18. 0 0000 100 0000 Wave Shape Compensator 9 EIEY IE o D 0 0 FlexTest SE Common Tasks 75 How to Adjust Dither 5 Set up the Station Manager window s Scope to display the channel s command and feedback signals A In the Station Manager window s toolbar click B Set up the Scope window to display the channel s command and feedback signals The following shows a typical setup 2 ed cal oof 5 O Channel Signal Units div Units Offset Bh channe X E Command v Hi 0 20000 a em x is 2000 Bh Channel E Displaceme 0 20000 E fem 3 Plot Mode Time WH Trace Time 20000 Sec aj 5 000 7 T 5 000 aj j 3 O 3 5 f F 5 420 1 00 5 8 8 3 1 5 2 0 0000 1 0000 2 0000 Time Sec WARNING Applying station hydraulic pressure can put actuators in motion A moving actuator can injure anyone in its path Always clear the actuator area before applying hydraulic pressure 6 Apply station hydraulic power 7 In the Station Manager window s Station Controls panel click to start the displacement command 0 8 E E i 2 76 Common Tasks FlexTest SE How to Adjust Dither 8 Use the scope to observe the feedback signal If the feedback signal shows a smooth ramp y
19. 8 V DC 0 8 m E E i o 110 Common Tasks FlexTest SE How to Perform Advanced Tuning Techniques C Adjust Conditioner gt Phase until the Meter displays maximum voltage The phase adjustment matches the phase of the inner loop LVDT feedback with the 10 kHz demodulator reference signal This adjustment provides a maximum output for the maximum LVDT spool position offset Note This adjustment must be set for the initial calibration servovalve replacement cable replacement or valve driver replacement Once the phase is correctly set readjustment is not necessary during routine calibration D Readjust Conditioner gt Gain until the Meter reads 10 V DC E Return Conditioner gt Polarity to its original setting Automated Controllers In the Drive panel Conditioner tab A Reverse the Polarity setting to drive the inner loop spool into one of the end caps B Adjust Gain until the meter reads approximately 8 V DC C Adjust Phase until the meter displays maximum voltage The phase adjustment matches the phase of the inner loop LVDT feedback with the 10 kHz demodulator reference signal This adjustment provides a maximum output for the maximum LVDT spool position offset Note This adjustment must be set for the initial calibration servovalve replacement cable replacement or valve driver replacement Once the phase is correctly set readjustment is not necessary during routine calibration D
20. ABBREVIATION ACTUAL NAME CLC Channel Limited Channel control mode Config Configuration as in the station s configuration file FG Function Generator HPU Hydraulic Power Unit HSM Hydraulic Service Manifold or actuator manifold PIDF P Proportional gain I Integral gain D Derivative gain F Feed forward gain PVC Peak Valley Compensation PVP Peak Valley Phase compensation FlexTest SE Introduction 17 The Emergency Stop button is a mechanically latching button that commands the hydraulic pressure to turn off removes the program signal and lights the Interlock indicator When pressed you cannot apply hydraulic pressure again until you return the button to its inactive position by turning it clockwise until it unlatches Press the Reset button to extinguish the Interlock indicator Front Panel Controls Emergency Stop 7 7 2 Emergency Stop Monitor 1 amp 2 connectors The Monitor 1 and Monitor 2 BNC connectors allow easy connection to external monitor devices You can use the menus to select the signal for each connector Refer to the Setup menu on page 132 for information about assigning station signals to these connectors The display screen or screen for short displays various types of Controller information including information panels menus and messages The Controller can display the following types of information panels e Scope e Meters
21. Limits Error Detectors gt Tuning gt Null Pacing gt PVC gt PVP gt Setup Menu gt PIDF Control Mode gt Calibration Use the items on the Calibration menu to set the calibration values for the sensor and conditioner associated with the selected control mode Each sensor requires calibration to ensure that its output accurately represents the condition it senses The controls and menus vary according to the type of calibration you choose Enter initial calibration values from the calibration sheets that accompany your system when you receive it and recalibrate each sensor conditioner pair as required FlexTest SE 138 Menus Descriptions 0 i 2 0 0 3 Setup s lt For information about how to perform calibrations see the FlexTest SE Servi anual ervice manual 5 9 Access Level Calibration ee sz Calibration control mode k Calibration Calibration Minimum Maximum Display Unit Polarity Resolution encoder Temposonic sensors only Cal Type Cal Types Cal Type mv v Pos Compress Neg Tension Pos Compression Excitation Balance Option DC only lt lt Auto Zero gt gt Fine Zero Shunt Display DC only Shunt Ref DC only lt lt Update gt gt DC only Shunt State DC only Menus Descriptions 139 Cal Type mv v Pos Tension Neg Compression Pos Tension Excitation Balance Option DC only lt l
22. i 2 0 0 3 oO 0 oO 2 T i 0 Tuning Manual PIDF Tuning Controls part 3 of 3 DESCRIPTION For bandstop filters enter a frequency that defines the frequency range of the attenuation band The center of the attenuation band is the value entered for the Frequency control For example if you set Frequency to 300 Hz and Bandwidth to 50 Hz the filter will attenuate frequencies from 275 Hz to 325 Hz Defines the characteristics of the stabilization filter which works with the S Gain to integrate a second signal into the control mode as a stabilizing factor Note This feature is available only if the control mode being tuned includes a stabilization input Filter Type 1 Hz High Pass or Band Pass 1 Hz High Pass Attenuates signals below 1 Hz This is the default selection Band Pass Attenuates signals outside of the band defined by the Filter Min and Filter Max controls For example if you set the lower frequency to 10 Hz and the upper to 200 Hz you create a 190 Hz band in which signals can pass without attenuation For band pass filters only sets the minimum frequency of the band ITEM Bandwidth Stabilization Filter Filter Type Filter Min Filter Max For band pass filters only sets the maximum frequency of the band Menus Descriptions 197 FlexTest SE Tun
23. select Continuous for Sweep Mode C On the Manual Tuning submenu increase the P Gain adjustment until you see a little overshoot and a little ringing D Slowly increase the D Gain adjustment to reduce the overshoot and ringing Small adjustments of D can have large effects on the system E Repeat C and D until you achieve a optimum waveform High BNS Rate D CN SN ON Low Gain P High For actual testing if your system goes unstable it will sound unstable that is it will emit an annoying high pitched sound accompanied by high frequency actuator movement that is quite different from the usual tuning sound ka chunk ka chunk If your system begins to go unstable quickly readjust the control that caused the instability o D 0 0 Common Tasks 99 Overshoot The middle waveform is the optimum waveform In some cases the waveform will have no overshoot or ringing Unstable sounds FlexTest SE How to Manually Tune the Control Loop 10 Adjust the I Gain tuning control Stand Alone and Automated Controllers Set up a peak valley meter to monitor the peaks and valleys of the sensor signal The peaks and valleys should be balanced Before adjusting reset I Gain be sure the feedback signal is repeatable that is the same peaks and valleys are achieved If the command is not centered on zero monitor the difference between peaks and valleys of the sensor feed
24. that have played out Q E a To manually reset this value press the Rewind button or enter 0 Total Count Specifies the total number of cycles that have been played out since the last time the Rewind button was pressed FlexTest SE Menus Descriptions 123 FG FG Menu gt External Command Note This menu will be available only if an analog input signal is assigned as an external command For more information see page 218 Use the External Command selection to assign program attributes to a command signal that is generated externally and delivered to the Controller as an analog input Before the Controller can accept the external command you must assign an analog input resource to the control channel when you define the configuration Config gt Edit Configuration gt Anlg In see page 218 External Command Control Mode Target Setpoint Soft Start Stop Compensator External Command Menu DESCRIPTION Specifies the control mode of the external command The control modes available will be compatible with the dimension selected for the analog input resource used for receiving external command allocated when the configuration was created Specifies the setpoint or mean level at which the dynamic portion of the external command begins and operates around Enable Causes the external command to taper from zero to 100 over two seconds while starting and from 100 to zero over two seconds when st
25. 01 seconds the default is 2 0 seconds Displays the options available for the currently selected trace Selects the signal you want to monitor For more information see Station signals on page 191 Sets the distance between the grid lines on the display Changes the zero reference mid point between minimum and maximum of the signal from the center of the display Sets the display in terms of engineering units or volts If the Display Mode is set to engineering units this control specifies the type of engineering units desired Otherwise the display units are shown as volts Sets the number of digits the Scope displays Displays the options available for scaling trace signals for optimal display FlexTest SE Scope 0 Ez aos A 8 ITEM 2 Control Sweep Mode p Plot Mode Trace Time Trace 1 2 Settings gt Signal Units Div Offset Display Mode Display Unit Display Resolution Auto Scale gt 182 Menus Descriptions Scope When auto scaling is on the maximum value for the y axis will be determined from the data so that the entire trace is visible Auto scaling increases the maximum value as needed but never decreases the maximum If you enter a value for the maximum value auto scaling will turn off and manual scaling will be in effect Scope Menu part 2 of 2 a ITEM DESCRIPTION F 9 Auto Scale Turns
26. 2 The parameter set and panel view associated with the configuration file the configuration does load 3 The panel view associated with the configuration file the configuration and parameter set does load Note Timing is important You must press the selected button immediately after the MTS logo appears on the screen and hold the button down until the boot process is complete io i i cS 0 FlexTest SE Boot Options 247 N i i 5 i i co 248 Boot Options FlexTest SE C carrying handle kit 16 changing the position of panels 51 CLC 17 defining the control modes 204 example 205 using the controls 205 compensation Null Pacing about 161 Peak Valley Compensation PVC about 165 Conditioner menu for three stage valve drivers 136 conditioners electrical zero 151 offset 150 Config 17 Config menu 22 configuration file 29 configuration file cfg 29 connectors BNC 18 control modes dual compensation modes 223 types of 221 Controller files 29 creating parameter sets 30 Current Count 123 D default panel positions 19 delta P sensor 202 Derivative gain 200 Dial 17 26 Dial and Increment Decrement buttons 26 differential pressure using delta P sensors 202 displacement tuning prerequisites 88 procedure 89 when to tune 88 display resolution 54 display screen 18 dither about 72 Dither Amplitude Frequency 135 documentation for PC Supervis
27. Excitation Phase Offset Gain Polarity FlexTest SE Setup Setup Menu gt Output Overview 134 Menus Descriptions 0 i 2 0 0 3 Setup the actuator extends or retracts in response to positive command 5 Output Menu 2 ITEM DESCRIPTION Polarity Sets the polarity of the valve drive signal which determines whether 5 7 The Polarity cannot be changed when station pressure is on Valve Balance Applies a voltage that compensates for minor mechanical imbalances in the servovalve When adjusted properly the actuator will not move when the valve driver output is zero A second Valve Balance displays if you have dual valves Dither Amplitude Adjusts the amplitude and frequency of dither Dither is a small Frequency high frequency sinewave applied to the servovalve spool to keep it in motion and prevent it from sticking Dither adjustment is probably needed if you note that a low frequency low amplitude test waveform is distorted at its maximum and minimum points A guideline for dither adjustment is to increase amplitude until you can hear its effect on the servovalve and then back off the adjustment until it is not audible For dual valve configurations adjusts dither in both valves simultaneously Inner Loop For three stage valve drivers displays the Inner Loop submenu See Inner Loop Menu for Three Stage Valve Drivers on page 1
28. Level cm 0 Error 1 Initial Feedback 2 Test Command Amplitude 3 Error 4 5 FlexTest SE Menus Descriptions 165 Peak Valley Phase PVP compensation improves the amplitude and phase tracking of the command and sensor feedback PVP performs the following e Alters the command phase to correct for phase lag e Increases the command amplitude to correct for amplitude roll off e Adjusts the mean command level if it detects mean level divergence in the feedback signal Basically the PVP is a phase compensator cascading into a peak valley compensator The peak valley algorithm is identical to the one used by PVC PVP Compensator Actuator Phase Peak Valley Compensator Compensator A A PDF FlexTest SE Setup About PVP Segment Generator 166 Menus Descriptions 0 i 2 0 0 3 Setup Setup Menu gt CLC Control Mode This selection is a Channel Limited Channel CLC control mode which uses one input channel to control the servo loop Active P gain while using a second input channel Limiting P gain to restrict the active channel The CLC control mode is the typically used for specimen installation oO 0 oO 2 T i 0 With the associated menu you can e Set up error detector settings and actions to mini
29. MTS If you do not have or do not know your MTS site number contact your MTS sales engineer Start with your manuals Technical support numbers MTS web site www mts com E mail Telephone Fax Before you contact MTS Know your site number and system number 8 Preface Technical Support Example site number 571167 When you have more than one MTS system the system number identifies which system you are calling about You can find your job number in the papers sent to you when you ordered your system Example system number US1 42460 If you have contacted MTS about this problem before we can recall your file You will need to tell us the e MTS notification number e Name of the person who helped you Describe the problem you are experiencing and know the answers to the following questions e How long has the problem been occurring e Can you reproduce the problem e Were any hardware or software changes made to the system before the problem started e What are the model and serial numbers of the suspect equipment If you are experiencing a computer problem have the following information available e Manufacturer s name and model number e Operating software type and service patch information Examples Windows XP Service Pack 1 SP1 Windows 2000 Service Pack 3 SP3 Windows NT 4 0 Service Pack 7 SP7 e Amount of system memory Example 640 MB of RAM e Amount of free space on the
30. P Gain box type 1 No other tuning controls need to be set Note For three stage servovalves the initial maximum P Gain setting is 0 8 so enter an initial value 0 5 3 Select the polarity of the servovalve signal A Ensure that the correct displacement control channel is selected in the navigation panel B Click the Channel Drive icon to open the Channel Drive panel and then click the Valve tab C Set the valve polarity If you do not know which polarity to use for your servovalve click Normal default o D 0 0 FlexTest SE Common Tasks 65 How to Set Servovalve Polarity 4 On the Station Controls panel perform the following setup A Click the Manual Command button to open the Manual Command window B In the Channel selection box select the desired control channel C Inthe Control Mode selection box ensure that displacement control mode is selected D Click on the Enable Manual Command check box to enable manual command E On the Station Controls panel ensure that the Master Span is set for 100 F Ifthe Interlock indicator is lit determine the cause correct it and then click Reset G If it lights again you will need to determine the cause of the interlock and correct it before proceeding H Inthe power selection box click the Power Low button and then Power High for the appropriate hydraulic service manifold HSM 5 Check the movement of the a
31. Timeout Action DNP Error Tolerance DNP Timeout DNP Timeout Action WARNING Changing compensation values with hydraulic pressure on can result in unexpected actuator movement A moving actuator can injure anyone in its path Always clear the actuator area before changing values 160 Menus Descriptions FlexTest SE Setup 5 Null Pacing Menu ITEM DESCRIPTION 2 SNP Error Tolerance Sets the maximum error as a percentage of the command signal allowed 3 a gt before Static Null Pacing holds the command 5 SNP Timeout Sets the time allowed for feedback to come within tolerance 7 SNP Timeout Action Sets the test station s action when the Timeout is exceeded See Actions on page 155 DNP Error Tolerance Sets the maximum error as a percentage of the command signal allowed before Dynamic Null Pacing slows the command DNP Timeout Sets the time allowed for feedback to come within tolerance DNP Timeout Action See Actions on page 155 About Null Pacing Null Pacing PVC and PVP see page 163 are compensators and compensators Compensators monitor sensor feedback to ensure the command is applied completely to the specimen For PVC and PVP if the feedback is not reaching the commanded level the compensator boosts the command to ensure the proper result For example suppose while programming a sine wa
32. Tuning menu controls see page 194 Config The Config menu creates and modifies configuration files modifies hardware settings and performs other tasks such as entering license keys setting regional and local preferences and setting the time and date For a description of Config menu controls see page 207 Limits The Limits table pressing the Limits button displays a special kind of menu that looks like a table displays limit and error values and associated actions for station signals Pressing the Limits button alternates display of limit and error tables which displays the limit setting status and action for all associated input signals in the station For detailed information see Limits on page 238 Log The Log panel displays log entries which record station and test events as they occur including file events resource mismatches hydraulic status changes station state changes and detector activity Use the Log menu to assign display attributes to log entries screen whether or not messages are written to the log based on severity level clear log entries and position the Log panel on the screen i gt ih i For detailed information see Limits on page 238 22 Introduction FlexTest SE Front Panel Controls FG Setup Tuning When you press the FG Setup Tuning or Config buttons the and Config Controller displays the associated menu on the screen
33. When you create a new control mode or if the sensor for a control mode is changed e The end levels or frequencies are significantly different from those observed earlier in the test For example you notice that the specimen characteristics change during the test this could also mean the specimen is failing 0 8 m E E i o 84 Common Tasks FlexTest SE How to Manually Tune the Control Loop Tasks related The following are tasks that should be completed before you tune It is to manual tuning not necessary to perform every task each time you tune The condition of your system dictates which of the following tasks you must perform For example a new system or a system freshly recalibrated requires all of the following to be completed If you are performing periodic or fine tuning review the following and determine which tasks you need to complete e Balance the servovalve The electrical valve balance adjustment compensates for minor mechanical imbalance it is an intermediate adjustment Refer to How to Balance the Servovalve on page 68 e Calibrate each sensor used for a control mode or data acquisition Perform the appropriate calibration procedure Refer to the FlexTest SE Service manual e If your sensor calibration schedule does not require calibration at this time perform a shunt calibration check to determine if your DC sensor DC conditioner is within tolerance Refer to How to Perfo
34. afraid of your test system but you should always maintain a healthy respect for it Improper installation operation or maintenance of MTS equipment in your test system can result in hazardous conditions that can cause severe personal injury or death and damage to your equipment and specimen Again read and understand the Safety manual before you continue It is very important that you remain aware of hazards that apply to your test system In addition to this manual you may receive additional MTS manuals in paper or electronic form If you have purchased a test system it may include an MTS System Documentation CD This CD contains an electronic copy of all of the MTS manuals that pertain to your test system including controller manuals hydraulic and mechanical component manuals assembly drawings and parts lists and operation and preventive maintenance manuals Conventions 6 Technical Support 8 Preface 5 Safety first Other MTS manuals Contents The following paragraphs describe some of the conventions that are used in your MTS manuals Hazard notices are embedded in this manual and contain safety information that is specific to the task to be performed Hazard notices immediately precede the step or procedure that may lead to an associated hazard Read all hazard notices carefully and follow the directions that are given Three different levels of hazard notices may appear in your manuals Following are examples of
35. all three levels Note For general safety information see the Safety manual included with your system Danger notices indicate the presence of a hazard which will cause severe personal injury death or substantial property damage if the danger is ignored For example High intensity light and dangerous radiation are emitted by class 3B lasers Viewing a class 3b laser directly or viewing it using optical instruments will cause immediate and severe injury Avoid eye or skin exposure to the laser beam Ensure that all power to the laser is off before attempting any maintenance service or adjustment procedure Warning notices indicate the presence of a hazard which can cause severe personal injury death or substantial property damage if the warning is ignored For example Hazardous fumes can accumulate in the test chamber as a result of testing Breathing hazardous fumes can cause nausea fainting or death Ensure the chamber is properly ventilated before you open the chamber door or put your head or hands into the chamber To do this ensure the temperature controller is off and allow sufficient time for the ventilation system to completely exchange the atmosphere within the chamber Conventions Conventions Hazard conventions Danger notices Warning notices Preface 6 Conventions Caution notices indicate the presence of a hazard which will or can cause minor personal injury cause minor equipment damage
36. and increase the gain setting e Ifthe actuator does not move at all return to Step 2 and increase the gain setting 7 Set servovalve polarity to achieve desired actuator movement 64 Common Tasks FlexTest SE 0 8 E E i 2 How to Set Servovalve Polarity Note Procedures for Automated Controllers assumes the FlexTest SE Controller is equipped with the PC Supervision option and that Exclusive Control is assigned to Station Manager For more information about Station Manager see the Model 793 00 System Software manual that accompanies your system Automated 1 Get things ready Controllers This step establishes the required conditions for the remaining steps A You need displacement control mode If you have not created this type of a control mode create it now B Ensure that the actuator can be fully extended without contacting anything You may need to remove any obstructions C On the Station Manager Toolbar select Tuning in the User Level access box 2 Enter an initial tuning value first time only The actuator can not move unless an adequate gain tuning value is set If you already have a gain setting for the displacement control mode skip this step A On the Station Manager Display menu select Station Setup B Ensure that the correct displacement control channel is selected in the navigation panel Click the Channel Tuning icon to open the Tuning panel D In the
37. auto scaling on or off By default auto scaling is turned on Q a lt lt Rescale gt gt When in the time plot mode this control adjusts the units division to improve the waveform display For instance to make an off scale waveform fit the display it increases the units division To maximize a compressed waveform it decreases the units division While Autoscale continually adjusts the spacing to keep the waveform visible Rescale makes a single adjustment affecting the values currently displayed Same Scale Locks the scaling of the displayed signals together If the scale is changed on one by Auto scaling or by manual adjustment the scaling for the other signal is adjusted similarly Auto Scale Mode Specifies whether the Auto scale control affects sensitivity and offset or just sensitivity Sens itivity amp Offset allows the Auto scale and Rescale controls to change both the Y axis units division and the offset Sensitivity allows the Auto scale and Rescale controls to change only the Y axis units division Placement Moves the Scope panel around the display FlexTest SE Menus Descriptions 183 If the display is off scale or too compressed you can click lt lt Rescale gt gt to quickly adjust the units division and offset This scales the scope display to the minimum and maximum values of the data being collected lt lt Rescale gt gt can be clicked whether Auto Scale is
38. changes Edit Hardware gt lt lt Save gt gt and reboot before the changes take effect Access level Configuration Edit Hardware HWI File ftse hwi gt 493 25 S2 J4 493 25 S2 J5 493 14 VD S2 J7 gt Power Options gt System Options gt The hardware resources available to the Controller are defined by the hardware interface file ftse hwi The Controller reads this file to determine what VMEbus modules are available to your system where the modules are located and which rear panel connectors are associated with them The hardware resource name contains information regarding the resource type slot location and connector number For example consider the following resource name 493 25 S2 J4 The resource named 493 25 S2 J4 refers to a conditioner module located in slot 2 of the chassis at connector J4 FlexTest SE About the hwi file Resource naming conventions 226 Menus Descriptions N i 2 0 0 3 0 oO 2 T s i 0 Config VMEbus modules VMEbus compatible modules are installed in chassis slots according to the following guidelines e The processor module is installed in slot 1 e The I O carrier module is installed in slot 2 e An optional I O carrier module may be installed in slot 3 e The System I O module is installed in slots 4 and 5 Slot Position 5 3 3 5 g 5 Dm A
39. control a servovalve You use control modes to apply your command in a specific dimension such as displacement force strain acceleration and so forth You must define at least one control mode for each control channel FlexTest SE Menus Descriptions 221 The Controller employs three types of control modes 2125 CLC and dual compensation You define the control mode type in the Config menu PIDF control modes are the normal control modes used for testing Proportional integral derivative and feed forward gain adjustments are available to tune the servo loop response CLC channel limited channel control modes require two sensor feedbacks and are typically used for specimen installation and removal Using a CLC control mode you apply the program in the dimension of the master channel usually displacement but the signal is restricted by the limits you define for the second limiting channel usually force Dual compensation control modes are typically used to program channels that use a dimension whose feedback is too noisy to provide adequate control Dual compensation control modes require two feedback signals The first is used by the compensator to provide command compensation The second is used by the PIDF Controller to close the loop FlexTest SE Config Types of control modes 222 Menus Descriptions N i 2 0 0 3 Config More about dual D
40. control is assigned to either interface e HPU Off HSM Off Gf available All Off Gf available and Reset program and hydraulic interlock are functional on both interfaces Emergency Stop Always functional on both interfaces 0 ES 2 s rT 2 gt pm O 2 42 PC Supervised Controllers FlexTest SE PC Supervised Controller Files PC Supervised Controller Files When used in the automated mode the FlexTest SE Controller and MTS Series 793 Software use the following files and attribute sets in their specified locations to generate program command maintain control and perform tests e Hardware Interface files hwi Stored in the PC see page 29 Configuration files cfg Stored in the PC see page 29 e Parameter sets Stored in the PC see page 30 e Sensor Calibration files scf Stored in the PC see the Model 793 00 System Software manual gt Panel View Set files cfv Stored in the Controller see below e Test files tst Created with Basic TestWare and stored in the PC For information about Test files see the Model 793 00 System Software manual see the Model 793 00 System Software manual gt Procedure files 000 Created with MultiPurpose TestWare and stored in the PC see the Model 793 10 MultiPurpose TestWare manual Panel View Set files When a Controller operates in the automated mode panel settings are saved in a separate view
41. desktop o D 0 0 FlexTest SE Common Tasks 49 How to Power Up the Controller 6 Allow System Manager to load The message Waiting for a station to connect to is displayed on the Controller when System Manager loading is complete 7 Select the desired Configuration file and if available the desired Parameter set from the displayed list and wait for the station to load 8 Select Exclusive Control for either the System Manager or the Controller To select the System Manager for Exclusive Control click the Exclusive Control checkbox on the Station Controls panel To select the Controller for exclusive control use the following path Status lt Exclusive Control gt Enabled Master slave power up Power up sequence If you have more than one Controller connected to each other apply power to the master first allowing the software to fully boot Then apply power to the slave Controllers in sequence beginning with the slave Controller connected to the master Controller To remove power from the chain reverse the order of operations beginning with the end of run slave Master slave connection You connect Controllers to each other via the J51 Box In and J52 Box information Out connectors on the 493 42 System I O module in the Controller s rear panel The master Controller will have an open Box In connector and a cable attached to the Box Out connector A middle run slave Controller
42. following procedure for your specific system Note Procedures for Automated Controllers assumes the FlexTest SE Controller is equipped with the PC Supervision option and that Exclusive Control is assigned to Station Manager For more information about Station Manager see the Model 793 00 System Software manual that accompanies your system 1 Select the following settings in the tuning function generator Stand Alone Controllers Tuning gt Manual gt FG Automated Controllers Click on Station Manager CONTROL SETTING Wave Shape Square Frequency 1 Hz Target Setpoint 0 mm Amplitude 10 of full scale 2 Set up the Scope Note You can use an oscilloscope instead of the software scope if you want To do that you must define a Readout channel to connect the oscilloscope Stand Alone Controllers Select Scope and set up scope parameters to display the displacement feedback signal Automated Controllers A On the Display menu select Scope B Select the displacement signal for display C Set the Trace Time to 5 seconds D Ensure Auto Scale is on the default position is ON o D 0 0 FlexTest SE Common Tasks 89 How to Manually Tune the Control Loop Note To improve your view of the waveform click the 850816 button to maximize the waveform on the display AR WARNING Do not place any part of your body in the path of a moving actuator A crush zone exis
43. for X Y Use the scope to Display up to two channels simultaneously Time e Plot one channel versus another channel X Y 0 20 Secidiv Sample Scope Display Use the Scope menu to select the signals you wish to view and to customize the Scope panel Access level Operator Scope Control Sweep Mode Plot Mode Trace Time Trace 1 Settings gt Trace 2 Settings gt Auto Scale gt Placement Menus Descriptions 181 The Scope provides an analog display of digital signals being Panel Menu Scope FlexTest SE Scope Menu part 1 of 2 DESCRIPTION Starts and stops the signal trace Determines how the Scope s signal trace sweeps across the display Continuous Starts the Scope with a continuous trace sweep The scope continues to run until you stop the signal trace The Scope starts a continuous sweep as soon as it is opened Single sweep Starts the Scope with a single trace sweep When the trace fills the display the Scope stops To acquire another sweep press the lt Enter gt button Program Starts the Scope with a continuous trace sweep when the test program starts The trace stops when the test program stops Sets the type of plot the Scope will display Time Plots up to two signals against time X Y Plot two signals against each other Sets the length of time for a trace to cross the Scope display You can select a maximum Trace Time of up to 100 seconds and a minimum of 0
44. gt lt lt Reboot gt gt Press and hold the Menu Item button next to the Setpoint control to display the Display Parameters The Formatting number defines the number of digits displayed to express the Minimum and Maximum range values For instance if the Setpoint control s maximum range value is 10 and you enter a formatting number of 3 the maximum range is displayed as 10 0 Once the formatting number is applied to the range values the number of digits displayed to the right of the decimal point in the range values is maintained in the control value display regardless of the total number of digits displayed For instance suppose you enter a Formatting number of 4 which results in the Maximum and Minimum ranges values being displayed as 10 00 and 10 00 respectively In this case if the actual Setpoint value is 1 5 it will be displayed as 1 50 even though the formatting number is 4 o D 0 0 Common Tasks 55 menu More about the Display Parameters menu FlexTest SE How to Use the Front Panel Controls The Resolution value defines the smallest value with which you can make adjustments to the control To continue the previous example if the Setpoint value displayed is 1 50 and you enter a resolution value of 0 01 then pressing the Increment button once would result in a Setpoint display of 1 51 If you had entered a resolution value of 0 001 instead of 0 01 then
45. information about what is currently loaded in the Controller including the parameter set an attribute of the configuration file the user access state the active application the current running time and if available counter information The Status menu displays many frequently used Controller features such as Access levels control mode and Set Point and Span For a description of the Status panel and Status menu controls see page 178 The Scope panel is like an external oscilloscope used to view analog displays of signals being processed by the Controller The Scope menu selects the signals you wish to view on the Scope panel and customizes the Scope panel For a description of the Scope panel and Scope menu controls see page 181 Introduction 21 MENU FG Setup Status Scope optional FlexTest SE Front Panel Controls Menu Function part 2 of 2 MENU DESCRIPTION Meters The Meters panel is like an external meter used to view numerical displays of the signals being processed by the Controller You can choose to display a timed meter a Peak Valley meter a mean amplitude meter or a running max min meter The Meters menu selects the signals you wish to view on the Meters panel and customizes the Meters panel For a description of the Meters panel and Meter menu controls see page 187 Tuning The Tuning menu adjusts the stability and response of the servo control loop For a description of
46. limit the Controller performs the action that you assign with the limit action fields 0 i 2 0 0 3 If the sensor output exceeds a limit and if upper limit detected es the selected action is Hydraulics Off the Tem pee ree test stops and hydraulic pressure is turned off i 0 cm specimen breaks 1 em H nn one Tee ee ee lower limit 1 1 cm Setting limits Set the limits to establish a normal operating range for the sensor during a test and then select an action you want performed if a limit is detected For example suppose you are testing a specimen using a displacement control mode Also assume the LVDT has a displacement of 5 mm and you design the test to operate over the range of 2 mm Setting the limits for either the displacement signal at 2 1 mm and 2 1 mm should protect your system from damage Unknown limits If you do not know what the limit setting should be for a test you will need to run the test and monitor the sensor signal Set up a Peak Valley or a max min meter to determine the maximum and minimum sensor values While running the test note the upper and lower values Valid limits can be more than the upper value and less than the lower value Note t is good practice to establish limits for at least one input signal to prevent damage to the test equipment if the servo contro loop is broken for example if a cable becomes unplugged or the specim
47. numbers Note To adjust the resolution and range of the controls see page 54 Using the Dial 1 Press the Menu Item button next to the desired menu item to bring focus to it 2 Press the Enable button to enable the Dial The Enabled indicator lights 3 While observing the value in the menu item rotate the Dial to adjust the value Using the Increment 1 Press the Menu Item button next to the desired menu item to Decrement buttons bring focus to it 2 Press the Increment Decrement buttons to change the value Each button press changes the value by one point of resolution to adjust the resolution and range of the adjustment see page 54 mi Press the Menu Item button next to the desired menu item to bring focus to it Using numeric keypad 2 Enter the desired number with the numeric keypad 3 Press enter Note Ifyou are making adjustments such as gain while the hydraulics are on MTS recommends using the Dial rather than the numeric buttons Using the numeric buttons can cause a slight bump in the actuator movement due to the sudden change in value For a smoother transition use the Dial o D 0 0 FlexTest SE Common Tasks 53 How to Use the Front Panel Controls How to change the range and display resolution of controls Various controls such as Setpoint Manual Offset Limits and so on have parameters which can be changed for purposes of display including range res
48. oO 0 oO 2 T i 0 Peaks f Amplitude True Max Data Points Time Increments Valleys 0 l 1st Max Not Max e Min 151 Min 2nd Min Tru Menus Descriptions 189 Meter Menu part 2 of 3 DESCRIPTION Timed Meter The timed meter displays signal values at user defined intervals Peak Valley Meter The Peak Valley meter displays the highest peak value and the lowest valley value for each cycle monitored Mean Amplitude Meter The mean amplitude meter displays the midpoint value and the difference between the peak and valley values for each cycle monitored Running Max Min Meter The running max min meter displays the highest and lowest values attained while the meter is running ITEM Meter Type FlexTest SE Meter Menu part 3 of 3 DESCRIPTION Selects the signal the meter will monitor Note Time and Segment Count signals are not available for Peak Valley Mean Amplitude and Max Min meters If auxiliary input channels have been defined for the station auxiliary input signals will also be available If the conditioner gain of the selected signal is set to zero the Meters will not be able to monitor the signal Selects engineering units or volts If Volts is selected you can use the list box to select mV or V If the Display Mode is set to engineering units this control specifies the type of engineering
49. of 2 ITEM Fine Zero Shunt Display Shunt Reference lt lt Update gt gt Shunt State ITEM Neg Compression Pos Tension Excitation Phase AC only Balance Option DC only FlexTest SE Setup 9 5 Cal Type mv v Pos Tension part 2 of 2 E ITEM DESCRIPTION 0 lt lt Auto Zero gt gt Zeroes the sensor signal and makes the current output the new zero 2 reference Fine Zero Applies a fine zero high resolution offset to the sensor s output signal Shunt Display See Shunt Calibration on page 148 Shunt Reference lt lt Update gt gt Shunt State 146 Menus Descriptions FlexTest SE 0 oO 2 T i 0 Setup Cal Type mv v Pos Compression DESCRIPTION Sets the gain relationship between the negative output of the sensor Gn millivolts to the associated amplified voltage in the conditioner Gn volts This value is typically supplied with the calibration information that accompanies the system Sets the gain relationship between the positive output of the sensor Gn millivolts to the associated amplified voltage in the conditioner in volts that causes the actuator to move in a compressive direction This value is typically supplied with the calibration information that accompanies the system Sets the excitation voltage applied to the sensor which is usually specified by the
50. on Specifies the program signal s amplitude The specified amplitude applies equally to both sides of the Target Setpoint Specifies the program signal s frequency or cycles per second The maximum frequency may not exceed 20 of the Controller s update rate Menus Descriptions 127 FG Menu gt Sweep ITEM Sweep Settings Target Setpoint Amplitude Frequency FlexTest SE FG Sweep Dwell and Sweep Down buttons according to the current sweep state If the sweep transitions occur faster than four times per second the highlighting may not be accurate N S Sweep Menu part 2 of 2 E ITEM DESCRIPTION a lt lt Sweep Up gt gt Note When a sweep is in progress the Controller highlights the Sweep Up c Starts an upward sweep toward the upper frequency limit lt lt Sweep Dwell gt gt Holds the sweep at its current frequency lt lt Sweep Down gt gt Starts a downward sweep toward the lower frequency limit Sweep Settings Menu part 1 of 2 ITEM DESCRIPTION Control Mode Specifies the control mode used when the Function Generator starts Typical selections are force and displacement Wave Shape Specifies the program signal s wave shape as Square Ramp Sine Square Tapered Ramp Tapered or Sine Tapered Tapered shapes will ramp from zero to amplitude when starting and from amplitude to zero when stopping or holding See About Wave Shapes on page 130
51. or endanger test integrity if the caution is ignored For example This specimen can develop sharp edges as a result of testing Handling the specimen with unprotected hands can result in cuts and slivers Always wear protective gloves when you handle the specimen Other conventions used in your manuals are described below Notes provide additional information about operating your system or highlight easily overlooked items For example Note Resources that are put back on the hardware lists show up at the end of the list The first occurrence of special terms is shown in italics Illustrations appear in this manual to clarify text It is important for you to be aware that these illustrations are examples only and do not necessarily represent your actual system configuration test application or software 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 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 Preface 7 Caution notices Other conventions Notes Special terms Illustrations Electronic manual conventions Hypertext links Technical Support Technical Support The manua
52. or panel AC in the current panel view BC Recall A bookmark includes the menu image and the focus status of the menu items When you press the same recall button later in the current or subsequent session the bookmark is recalled For more information see How to change text on page 52 26 Introduction FlexTest SE Front Panel Controls An item may require a numeric value In this case use the numeric buttons or the Dial to enter the number 0 through 9 Types numerals on the screen e Changes the sign of the value being entered e decimal point Types a decimal point e enter Commits the displayed entry e backspace If you make a mistake use the backspace arrow to erase the last digit you have typed e cancel If you change your mind about an entry you have typed press cancel to erase your entire entry The original entry reappears 5 i a iv i Introduction 27 Numeric keypad 9 3 4 1 e IN a enter FlexTest SE Front Panel Controls Program controls Rewind Run Hold Stop Program controls allow you to control the current application typically I lt D O the FG or Tuning FG Program e Run Applies the program signal to the system and lights the Run indicator e Hold Holds the program signal at the current level and lights the Hold indicator e Stop Removes the
53. output of the sensor Gn millivolts to the associated amplified voltage in the conditioner in volts that causes the actuator to move in a compressive direction This value is typically supplied with the calibration information that accompanies the system Sets the gain relationship between the positive output of the sensor Gn millivolts to the associated amplified voltage in the conditioner in volts that causes the actuator to move in a tensile direction This value is typically supplied with the calibration information that accompanies the system Sets the excitation voltage applied to the sensor which is usually specified by the sensor manufacturer AC sensors typically require 10 V AC excitation and DC sensors typically require 10 V DC excitation Adjusts the phase of the feedback signal based on the excitation signal Optimal phase adjustments produce the maximum output signal from the sensor Phase values are usually between 30 45 The conditioner may be configured so that this control behaves like a Coarse Zero or a Bridge Balance Balance Option Course Zero Applies a coarse zero low resolution offset to the sensor s output signal Bridge Balance Typically used with strain gages this control applies a bridge balance to offset any resistance imbalance in the sensor that would saturate the conditioner output at the strain gage s null position Menus Descriptions 145 Cal Type Gain Delta K part 2
54. procedure that should work for most applications However you should consider it a guideline The background information presented in this chapter should help you modify the following procedure for your specific system 1 Select the following settings in the tuning function generator Stand Alone Controllers Tuning gt Manual gt FG Automated Controllers Click on Station Manager CONTROL SETTING Wave Shape Square Frequency 1 Hz Target Setpoint ON Amplitude 10 of full scale 2 Set up the Scope Note You can use an oscilloscope instead of the software scope if you want To do that you must define a Readout channel to connect the oscilloscope Stand Alone Controllers Select Scope and set up scope parameters to display the force feedback signal Automated Controllers A On the Display menu select Scope B Select the Force Absolute Error signal for display C Set the Trace Time to 2 seconds D Ensure Auto Scale is on the default position is ON Note To improve your view of the waveform click the 650816 button to maximize the waveform on the display Common Tasks 95 Procedure FlexTest SE How to Manually Tune the Control Loop AM WARNING Do not place any part of your body in the path of a moving actuator A crush zone exists between the actuator and any equipment in the path of its movement Immediate and unexpected actuator response is possible when you apply hydraulic pressure t
55. program signal from the system and lights the Stop indicator e Rewind Resets counter information when running or resuming programs Interlock controls Hydraulic The Hydraulic Interlock and Program Interlock indicators light to nterloc indicate that an interlock has occurred They will extinguish only after ae a you eliminate the interlock condition and press the reset function button Both types of interlocks stop the test and a hydraulic interlock also turns off the hydraulic power supply The Controller records the cause of the interlock in a log entry 5 Pressing and holding the reset button temporarily overrides the E interlock state 5 E Power controls p m iv The Power controls control the hydraulic power unit HPU and the HPU hydraulic service manifold HSM In practice the functions of these buttons depend upon the hydraulic configuration in software see Off Low page 232 The following are typical functions Power e High Turns on high hydraulic pressure e Low Turns on low hydraulic pressure e Off Turns off hydraulic pressure 28 Introduction FlexTest SE 5 i a iv i Controller Files Controller Files Your FlexTest SE Controller uses the following types of files and attribute sets all of which reside in the Controller s flash disk memory to maintain control and perfo
56. response to a positive command Likewise a servovalve with an inverted polarity retracts the actuator in response to a positive actuator command Before you can set servovalve polarity you must determine if the current servovalve polarity follows the normal convention The procedures that follows determines servovalve polarity by having you observe actuator movement while applying a positive Setpoint command to the actuator Procedures for both stand alone and automated systems are described Stand Alone 1 Get things ready Controllers l l Ensure the actuator can be fully extended without contacting anything You may need to remove any obstructions B Press the Status button twice to display the Status menu and for Control Mode select displacement C For Access Level select Tuning 2 If necessary enter an initial tuning value for P Gain first time only The actuator can not move unless an adequate P Gain value is applied If you already have an adequate P Gain setting for the displacement control mode skip this step Path Tuning gt Manual gt P Gain In P Gain enter 1 No other tuning controls need to be set Note For three stage servovalves the initial maximum P Gain setting is 0 8 so enter an initial value 0 5 3 Set the polarity of the servovalve to Normal Path Setup gt Output gt Polarity Normal o D 0 0 FlexTest SE Common Tasks 63 How to Set Servova
57. system e Vehicles test system e Vehicles component test system e Aero test system Prepare yourself for troubleshooting while on the phone e Call from a telephone close to the system so that you can try implementing suggestions made over the phone e Have the original operating and application software media available gt If you are not familiar with all aspects of the equipment operation have an experienced user nearby to assist you Technical Support Know relevant software information If you contact MTS by phone Identify system type Be prepared to troubleshoot Preface 10 Technical Support Prepare yourself in case we need to call you back Remember to ask for the notification number e Record the name of the person who helped you e Write down any specific instructions to be followed such as data recording or performance monitoring MTS logs and tracks all calls to ensure that you receive assistance and that action is taken regarding your problem or request If you have questions about the status of your problem or have additional information to report please contact MTS again In addition to the Problem Submittal Form on the MTS web site there is also a paper version of this form postage paid in the back of many MTS manuals Use this form to forward problems you are experiencing with your MTS equipment whether it be software hardware manuals or service This form includes check boxes that
58. the Controller boots in the automated mode this field does not apply Access level Configuration FlexTest SE Menus Descriptions 209 Config Config Menu gt Local Settings gt Regional Settings Use this selection to change elements of the configuration file that pertain to localization For instance you can select how the Controller displays the date and the units with which the Controller displays force measurements N i 2 0 0 3 Access level Operator Regional settings Language Decimal separator Unit Assignment Set Date Format Time Format Regional Settings Menu part 1 of 2 ITEM DESCRIPTION Language English is the standard language installed on the Controller and displayed on the interface If available select other languages as desired Decimal Separator Specifies the decimal symbol used in numbers Select Period or Comma Appearance using Period 34678288 00 Appearance using Comma 34678288 00 210 Menus Descriptions FlexTest SE Config Regional Settings Menu part 2 of 2 ITEM DESCRIPTION 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 oO 0 oO 2 T s 0 The following unit assig
59. to calculate the proper Conversion Gain setting assume we are using a Force Displacement dual compensation control mode Method 1 1 Using the function generator excite the specimen in displacement control using a small amplitude sine wave 2 Configure two Peak Valley meters one to measure the force feedback and the other to measure the displacement feedback 3 Calculate specimen stiffness K as K Force Peak Force Valley Displacement Peak Displacement Valley 4 Calculate the Conversion Gain value as Conversion Gain 2 x bid ua Scale Force t K Full Scale Displacemen Note For 8 more conservative estimate use 80 of the calculated Conversion Gain value When using asymmetrical full scale values enter the difference between the values FlexTest SE Setup Conversion Gain Integrator Gain Calculating conversion gain 170 Menus Descriptions 0 i 2 0 0 3 Setup Method 2 1 Select the Force Displacement dual compensation mode and enable the desired compensator on the function generator 2 Set the Conversion Gain to a minimum level 3 Using the function generator excite the specimen in displacement control using a small amplitude sine wave oO 0 oO 2 T i 0 4 Monitor the force feedback with the scope or peak valley meter and gradually increase the Conversion Gain until the force feedback is betwe
60. 0 FlexTest SE Common Tasks 61 B Click the Channel Tuning icon to open the Tuning panel and then click the Adjustments tab gt Station Setup 1 gt ftse cfg gt SE E Station Tuning Ch Disp Channels 2al Adjustments Fiter B Ch PIDF Force 2 6 CLC JI 4 Readouts 0 0010 10 000 Ausiliary Inputs E Gain L In Station Signals 4a FE T T 1 1 T T 1 T 1 1 Digital Inputs 0 0000 1 0000 Detectors D Gain Calculations L Remote Setp 4 1 1 1 1 1 1 1 1 1 4 0 0000 0 1000 CS TT TT Te 0 1000 0 0000 2 1 4 1024 0 1 000 I Show References How To Warm Up Station Hydraulics C Ifthe actuator does not move very well increase the P Gain setting on the Adjustments tab D If you hear a unusual or unexpected sound decrease the P Gain setting on the Adjustments tab 5 After 30 minutes click Stop on the Station Controls panel under Function Generator to stop the command 6 Turn off hydraulic pressure FlexTest SE 62 Common Tasks 0 8 E E i 2 How to Set Servovalve Polarity How to Set Servovalve Polarity Servovalve polarity refers to the direction the servovalve moves the actuator in response to a positive command It can be set to normal or invert By definition a servovalve with a normal polarity extends the actuator in
61. 00kN Disabled t Input Indicator Action Signal Errors Outer Error Inner Error Ch Disp Absolute Error 26 000 mm Disabled 26 000 mm Disabled Ch Force Absolute Error 26 000kN Disabled 26000kN Disabled Ch Force Absolute Error 26 000kN Disabled 26 000 kN Disabled Ch CLC Absolute Error 26 000 mm Disabled 26 000 mm Disabled Menus Descriptions Limit Parameter Limits summary panel Errors summary panel FlexTest SE Log Log Panel The Log panel displays log entries which record station and test events as they occur including file events resource mismatches hydraulic status changes station state changes and detector activity N i 2 0 0 3 Log panel 10 07 44 M Warning Stmar 493 25 5 2 16 is not normalized 10 07 46 AM Error FlesTest SE Internal error detected in file d 10 07 46 4M Error FlexTest SE Internal error detected in file d 10 07 46 AM Error FlexTest SE Internal error detected in file d 10 07 46 4M Error FlexT est SE Internal error detected in file d 10 07 46 AM Error FlexTest SE Internal error detected in file d 10 07 47 AM Information Stmar Initializing view set FTSE Def 10 07 47 4M Information Stmar Successfully initialized view se Time Stamp Severity Level Source Message Menu Use the Log menu to assign display attributes to log entries determine if messages are written to t
62. 3 25 resource Controllers are typically equipped with two consists of a D type connector displacement is typically J4 force is typically J5 and an associated conditioner module in the Controller chassis It is typically used in conjunction with LVDTs linear variable displacement transformers and load cells to condition displacement and force sensor feedback though it can be used to with a variety of other sensors as well The Model 493 47 resource optional consists of a D type connector typically J6 and an associated conditioner module in the Controller chassis It is typically used with an encoder An encoder is a sensor which measures displacement by counting pulses transmitted to it from a device in the actuator Note For more information about hardware resources see Resource naming conventions on page 226 For purposes of creating station configurations analog inputs Model 493 25 conditioners and Model 493 47 encoders are considered input resources which may be used to e Support a control mode e Provide auxiliary outside of the control loop feedback e Receive external command e Augment existing control mode feedback with stabilization feedback The menu that follows shows how the type selected for the each resource affects the menu Note how the Type selection affects the menu items 218 Menus Descriptions FlexTest SE Config Access level Configuration Anlg In 493 25 493 47 Display Na
63. 36 Conditioner For three stage valve drivers displays the Conditioner submenu See Conditioner Menu for Three Stage Valve Drivers on page 136 Service Port Output For three stage valve drivers displays the Service Port Output submenu See Conditioner Menu for Service Port Output Signals on page 137 FlexTest SE Menus Descriptions 135 Setup response of the pilot valve 9 Z Inner Loop Menu for Three Stage Valve Drivers 5 eee 8 ITEM DESCRIPTION a Ss oo_q_X 2 Inner Loop Gain Sets the inner loop s proportional gain which affects the inner loop D Inner Loop Rate Sets the inner loop s derivative gain which affects the servovalve s stability at higher inner loop gain settings Rate Input Selection Spool Position Sets the feedback from the servovalve s spool as the rate input Most systems use this setting Inner Loop Error Sets the inner loop error as the rate input This is the difference between spool position feedback and spool position command Conditioner Menu for Three Stage Valve Drivers ITEM DESCRIPTION Excitation Sets the amount of AC excitation that the conditioner applies to the servovalve s inner spool Phase Sets the phase for the demodulation circuitry that receives the sensor s output The sensor s output rides on the conditioner s excitation signal which is an AC signal An optimal phase shift yields the m
64. B October 2002 100 077 223 C November 2002 Copyright information Trademark information Software verification and validation Publication information Contents Contents Preface 5 Conventions 6 Technical Support 8 Chapter 1 Introduction 13 Basic Description 14 Front Panel Controls 7 Controller Files 29 Specifications 2 Chapter 2 PC Supervised Controllers 35 Basic Description 36 Using the Interfaces 7 PC Supervised Controller Files 43 Locating PC Supervised Documentation 46 Chapter 3 Common Tasks 7 How to Power Up the Controller 49 How to Use the Front Panel Controls 1 How To Warm Up Station Hydraulics 59 How to Set Servovalve Polarity 63 How to Balance the Servovalve 8 How to Adjust Dither 2 How to Perform a Shunt Calibration 79 How to Manually Tune the Control Loop 2 How to Perform Advanced Tuning Techniques 1 FlexTest SE Contents 3 Menus Descriptions 9 Maintenance 243 Menu Summaries 245 Boot Options 247 FlexTest SE Contents Chapter 4 FG 120 Setup 132 Status 178 Scope 181 Meters 187 Tuning 4 Config 207 Limits 238 Log 240 Appendix A Appendix B Appendix C Index 249 Contents 4 Preface Before you attempt to use your MTS equipment in your test system read and understand the Safety manual Like an automobile your test system is very useful but if misused it is capable of deadly force You should not be
65. Compensator Specifies the compensator used by the Function Generator The Compensators that may be available include Null Pacing Peak Valley Control PVC and Peak Valley Phase PVP See About Null Pacing and compensators on page 161 Sweep Type Defines the sweep type Linear Steps the sweep linearly by the Sweep Rate between the Upper and Lower Frequency Logarithmic Steps the sweep logarithmically by the Sweep Rate between Upper and Lower Frequency 128 Menus Descriptions FlexTest SE FG Single Sweeps the frequency until it reaches a frequency limit and then dwells at that limit Sweep Settings Menu part 2 of 2 6 ITEM DESCRIPTION F Sweep Mode Specifies the duration of the sweep 2 5 a Continuous Sweeps the frequency continuously between frequency limits until stopped Sweep Rate Sets the frequency sweep rate Lower Frequency Sets the sweep command s lower frequency limit Upper Frequency Sets the sweep command s upper frequency limit FlexTest SE Menus Descriptions 129 FG 90 About Wave Shapes The Function Generator provides the following wave shapes A 5 quare 4 0000 90 5 2 0000 00000 0 3000 0 9000 1 5000 2 1000 2 7000 3 3000 Time sec Ramp 4 0000 2 0000 0 0000 0 3000 0 9000 1 5000 2 1000 2 7000 3 3000 Time sec Sine 4 0000 2 0000 0 0000 0 3000 0 9000 1 5000 2 1000 2 7000 3 3000 T
66. Controller s composite command to act as a stabilizing factor oO 0 oO 2 T i 0 To create a stabilization resource you must allocate an input resource in the configuration file For more information see page 218 Access Level See submenus Stabilization Calibration gt Offset Zero gt Limits gt Stabilization Menu ITEM DESCRIPTION Calibration See page 138 Offset Zero See page 149 Limits See page 154 FlexTest SE Menus Descriptions 173 Setup Setup Menu gt Digital Input n Use this selection to define each digital input s Trigger and resulting Action A digital input is a signal received by the Controller from another device You can set the Controller to recognize a specific change in state of the digital input or trigger and to perform a specific action when the trigger occurs Access Level Operator Note Channel Low and Channel High trigger modes do not support the following Actions Indicate Program Stop and Program Hold Digital Input n State Trigger Action Digital Input Menu part 1 of 2 DESCRIPTION True The digital input is high False The digital input is low Defines the change in state of the digital input signal needed to trigger an Action High Low Triggers when the input goes from a high state to a low state Low High Triggers when the input goes from a low state to a high state Either Triggers when the input either g
67. Controller uses displacement feedback to maintain closed loop control Compensated Conversion Command Command Gain in Disp i Disp Full Scale Compensator p SP PDF lt Force Full Scale w 1 Integrator A Integrator Gain eo Primary Feedback to PIDF Displacement Secondary Feedback to Compensator Force Dual compensation control modes compensate based on one feedback signal but maintain closed loop control with a second usually less noisy feedback signal FlexTest SE Menus Descriptions 169 The conversion gain controls how the force command from the function generator is converted to a displacement command for the PIDF Controller The output of the compensator is a force signal which is multiplied by the following equation to create the displacement signal used to program the inner PIDF Controller Full Scale oe Conversion Gain Value x Full Scale Force The value you should enter for Conversion Gain depends on the specimen stiffness The Integrator Gain acts the same as the I Gain of the PIDF Controller Its purpose is to improve the static accuracy when the command is paused or stopped Since the Peak Valley Control PVC compensator also corrects the mean the Integrator Gain is disabled when the test is running and this compensator is active The following methods can be used
68. Edit Hardware gt HWI File Use this selection to select open save and delete hardware interface Chwi files Access level Configuration oO 0 oO 2 T i 0 HWI File Select existing name Enter new name lt lt Load gt gt lt lt Save gt gt lt lt Delete gt gt HWI File Menu ITEM DESCRIPTION Select existing name Selects the name of existing hardware interface hwi files saved to the Controller If you select a new file the Controller will create a new hardware interface file Enter new name Allows you to change the name of an existing file and save it as another name similar to a Save As function Use the Dial to add or change letters in the new name lt lt Load gt gt Loads the selected hardware interface file lt lt Save gt gt Saves the selected hardware interface file lt lt Delete gt gt Deletes the selected hardware interface file FlexTest SE Menus Descriptions 229 Config Config Menu gt Edit Hardware gt 493 25 S n J n Use this selection to change the type of excitation provided by the Controller s conditioners Access level Configuration N i 2 0 0 3 493 25 Mode AC 493 25 S n n Menu ITEM DESCRIPTION Mode AC Typically used for displacement sensors such as Linear Variable Displacement Transformers LVDTs DC Typically used for force sensors such as load cells Co
69. Gain as required Balance difference Zero around zero Monitor the error signal then disrupt the system by changing the command by adjusting the Setpoint control with the Dial When you do this the error should return to zero within 5 10 seconds If not increase the reset I Gain setting and repeat the procedure until the error zeros itself within a reasonable time period o D 0 0 Common Tasks 7 Using a ramp Upset recovery method FlexTest SE How to Perform Advanced Tuning Techniques 0 8 E 2 118 Common Tasks FlexTest SE Chapter 4 Menus Descriptions oO 0 oO 2 T i 0 This chapter describes the controls accessed from the front panel menu buttons in detail Note Appendix B Menu Summaries contains fold out displays of each menu Note When the controller is booted in the automated mode and used with PC supervision access to menus and controls changes For more information see PC Supervised Controllers on page 35 Contents FG 120 Setup 132 Status 178 Scope 181 Meters 7 Tuning 194 Config 207 Limits 8 Log 240 FlexTest SE Menus Descriptions 119 FG FG Note This menu is available only when you boot the Controller in the Stand Alone or Stand Alone with Networking mode Config gt Local Settings gt Networking gt Boot Location When booted in the Automated mode and used wi
70. Generator Observe the spool position signal on the Scope If the Spool Position signal is too small to be properly displayed on the Scope window during tuning increase the Function Generator panel s Amplitude If the Amplitude setting does not amplify the spool signal as expected increase the P Gain Stand Alone Controllers Tuning gt P Gain Automated Controllers A In Station Setup window s navigation pane click yY B In the Inputs panel click the Adjustment tab C In the Adjustment tab increase the P Gain FlexTest SE 11 0 8 E E i 2 114 Common Tasks How to Perform Advanced Tuning Techniques 12 Tune the inner loop Stand Alone Controllers Setup gt Output gt Inner Loop Automated Controllers In the Station Setup window s Drive panel click the Inner Loop tab For optimal system response tune the inner loop to be relatively less responsive and more stable than a typical outer loop A For Rate Input Selection select Spool Position B Increase Inner Loop Gain until you see a little overshoot on the oscilloscope V4 Overshoot Ringing C Slightly increase the Inner Loop Rate to eliminate this overshoot When properly tuned the waveform should be a square wave with rounded corners having no overshoot 7 Too Low Correct Too High o D 0 0 Common Tasks 5 FlexTest SE How to Perform Advanced Tuning
71. IPTION Cables for interconnecting Cables required to interconnect multiple Controllers via the Box In multiple Controllers and Box Out rear panel connectors Rack Mounting Kit Hardware necessary for mounting the Controller in a standard size electronics rack Carrying Handle Kit Handle and hardware required to fasten the handle to the Controller i gt 3 b i 16 Introduction FlexTest SE Front Panel Controls Front Panel Controls Control placement Increment Previous Program controls Decrement Next Emergency Up Stop Recall Interlock controls Mrs lexTe SE 6 Fs setup 7 8 9 a 5 6 C Status Program Hydraul C score 1 2 3 C Meters n Program reset C_D Tuning 0 4 Interlock 5 Emergency Stop CD cenfig enter lt gt Limits 9 9 Sun canca Monitori Monitor 2 Menu A Display Screen Numeric keypad Monitor Menu item buttons Connectors Help Power control Note For information about menus and controls when using the Controller with PC supervision see PC Supervised Controllers on page 35 Abbreviations Due to space limitations some of the labels on the face of the Controller as well as text displayed in some of the Controller s menus and prompts contain abbreviated names of the items they represent zi
72. Keep personnel and test equipment clear of the actuator s path when adjusting electrical zero e The shifted electrical zero position is not a calibrated zero position e Your usable range is still limited by the sensor s capacity FlexTest SE Menus Descriptions 151 Setup 9 5 Electrical zero diagram The figure below illustrates the effect electrical offset has on sensor 5 conditioner signals 9 0 5 C ller Applicati Conditioner ontroller Application Sensor Conditioner Digital Voltage Voltage Signal S can gt A D x Electrical Zero Offset Electrical zero adjustments are applied in the conditioner You specify electrical zero adjustments in voltage Applying electrical You can adjust the electrical zero for the active control mode when zero hydraulics are on 152 Menus Descriptions FlexTest SE Setup Using Auto Zero The following steps position the actuator in the new electrical zero location Apply hydraulics Select a displacement control mode and enable the Dial oO 0 oO 2 T i 0 1 2 3 Adjust the Dial to move the actuator to the desired zero position 4 Switch to a different control mode be sure to leave manual command enabled The following steps shift s the selected conditioner s electrical zero 1 In the Setup menu select Displacement 2 In the Dis
73. Options ITEM DESCRIPTION Power Type HPU Only This selection applies to systems connected directly to the hydraulic power unit HPU HSM This selection applies to systems equipped with both a hydraulic power unit HPU and a hydraulic service manifold HSM HSM Only This selection applies to systems equipped with a hydraulic service manifold that is connected to house power Auto HPU HSM This selection applies to systems equipped with multiple hydraulic service manifolds HSMs that share a single hydraulic power unit HPU and operate in a first on last off manner Slave HSM This selection applies to systems equipped with multiple hydraulic service manifolds CHSMs configured in a master slave configuration connected to house power HSM Type On Off Solenoid This selection is appropriate if your hydraulic service manifold is equipped with an on off type solenoid Solenoid This selection is appropriate if your hydraulic service manifold is equipped with an off low high type solenoid Proportional This selection is appropriate if your hydraulic service manifold is equipped with an proportional type solenoid 232 Menus Descriptions FlexTest SE Config Front panel hydraulic The Power Type control in this menu and the Power control in the controls and valve driver menu Config gt Edit Configuration gt 493 14 VD 2 J7 indicators determine the functionality of the HPU and HSM controls and indicators on front pane
74. Readjust Gain until the meter reads 10 V DC E Return Polarity to its original setting o D N 0 FlexTest SE Common Tasks 1 How to Perform Advanced Tuning Techniques 7 Produce a Spool Position output signal of 10 V DC with the spool driven into the opposite end cap Stand Alone Controllers A Reverse the Conditioner gt Polarity setting to drive the inner loop spool into the other end cap B Check the Meter It should read 10 V DC 40 5 V DC If the voltage is correct proceed to the next step in this procedure If the voltage is off by more than 0 5 V you may need to mechanically center the pilot spool Refer to Zero the Spool Position Signal in your Controller Service manual for a detailed procedure Complete this procedure then recheck spool position voltages at each endcap before you resume inner loop tuning C Return Conditioner gt Polarity to its original setting Automated Controllers In the Drive panel click the Valve tab In the Valve tab produce a Spool Position output signal of 10 V DC with the spool driven into the opposite end cap A Reverse the Polarity setting to drive the inner loop spool into the other end cap B Check the meter It should read 10 V DC 40 5 V DC If the voltage is correct proceed to the next step in this procedure If the voltage is off by more than 0 5 V you may need to mechanically center the pilot spool Refer t
75. Station Hydraulics It is good practice to warm up station hydraulics before testing by exercising the actuator without a specimen installed for at least 30 minutes Warm up procedures for both stand alone and automated systems are provided here Stand Alone 1 Press the Tuning button then select Manual Controllers 2 For Control Mode select displacement 3 Press FG and enter the following settings in the FG menu CONTROL SETTING Wave Shape Sine Frequency 0 1 Hz Setpoint 0 Amplitude 80 of full scale actuator displacement 4 Press the Back button to return to the Tuning lt Manual gt menu 5 On the front panel press reset to clear interlocks 6 Apply station power 7 On the front panel press Run to start the function generator o D 0 0 FlexTest SE Common Tasks 59 How To Warm Up Station Hydraulics 8 Observe the actuator s response If necessary correct P Gain during warm up A If necessary select the Tuning access level Path Status gt Access Level gt Tuning B Adjust P Gain if required Path Tuning gt Manual gt P Gain If the actuator responds in a sluggish manner increase the P Gain setting If you hear a unusual or unexpected sound decrease the P Gain 9 After 30 minutes click Stop on the controller front panel to stop the command Note Procedures for Automated Controllers assumes the FlexTest SE Controller is equipped wit
76. Station Setup window click z to display the Drive panel In the Drive panel click the Conditioner tab A Set Excitation to 10V Set Phase to between 10 and 30 deg Set Offset to 0 V Set the Gain to 10 m o o w Set the Polarity to Normal o D 0 0 Common Tasks 9 Prerequisites Procedure FlexTest SE How to Perform Advanced Tuning Techniques 5 Configure a Meter to monitor the spool position signal Stand Alone Controllers Path Meters gt Meter 1 A For Meter Type select Timed B For Signal select Spool Position C For Display Mode and Display Units select Volts D Set a Display Resolution Automated Controllers A On the Station Manager window s toolbar select Create Meters on the Meters icon pull down menu B Select Create Meters again to display a second Meters window C Inthe Meters window click the Meter Setup button Use the Meter Setup window to define the meter D For Meter Type select Timed For Signal Selection select the desired Channel name and Spool Position for Signal type F For Display Mode select Volts G Set a Display Resolution 6 Produce a Spool Position output signal of 10 V DC with the spool driven into the end cap Stand Alone Controllers A Reverse the Conditioner gt Polarity setting to drive the inner loop spool into one of the end caps B Adjust Conditioner gt Gain until the Meter reads approximately
77. Techniques How to use error to tune Gain Note This procedure requires the optional Scope or an external oscilloscope This procedure pertains to manually tuning the I Gain control using the Error signal To perform this procedure for the displacement control mode follow the procedure beginning on page 88 then use it as an alternate method to Adjust the I Gain tuning control on page 93 To perform this procedure for the force control mode follow the procedure beginning on page 94 then use it as an alternate method to Adjust the I Gain tuning control on page 100 Setting up the Scope Set up the Scope to view Command and Error and select a Trace Time of 5 seconds Also ensure Auto Scale is on it is on by default Note To improve your view of the waveform click the Rescale button to maximize the waveform on the display Using a square wave Apply the tuning program with a square wave and monitor the amplitude of the settled portion of the error signal The settled portion of the error signal should be the same level for both segments if not adjust I Gain as required en oes Adjust Gain hri Ideal Waveform N 8 E E i 2 116 Common Tasks FlexTest SE How to Perform Advanced Tuning Techniques Apply the tuning program with a ramp and monitor the amplitude of the settled portion of the error signal The settled portion of the error signal should be balanced if not adjust I
78. The purpose of an error detector is to warn you that a specimen is beginning to fail and or to shut down the test before the specimen breaks which can cause equipment damage 0 i 2 0 0 3 e Ifan error exceeds the level you set the digital Controller performs the action you choose disable indicate hydraulics off interlock program interlock e An effective error detector requires the servo loop to be properly tuned e For static or low frequency tests the error detector is typically set to a low level e At high frequencies the error detector is used to detect loss of closed loop control Set the error detector to a high level e Use the minimum error to indicate an approaching failure e Use the maximum error to perform an appropriate action Error Error Feedback Test Command Test Command Feedback At higher frequencies the error level is large The phase lag of the feedback creates a larger error FlexTest SE At lower frequencies the error level is usually small The feedback tracks the command more closely 158 Menus Descriptions Setup Setup Menu gt PIDF Control Mode Tuning Use this selection to adjust the individual PIDF controls of the selected control mode to optimize stability and accurate response to commands oO 0 oO 2 T i 0 The controls in this menu are identical to the controls acce
79. ain EE lGa RES ooo D Gain BE ooo F Gain ME 0 For Control Channel select the channel to be auto tuned For Control Mode select a displacement control mode For Mode to Tune select the displacement mode For Auto Tuning Type select Basic or Advanced Basic provides an adequate level of tuning for most control modes Advanced provides a higher level of tuning based on Tracking values o D 0 0 Common Tasks 3 A m o oO w FlexTest SE How to Perform Advanced Tuning Techniques F For Actuator Type select Normal or Hydrostatic For most cases select Normal If you receive a Feedback is not responding to drive signal message during tuning select Hydrostatic This setting allows more and faster valve movements which results in more actuator movement G For Upper Limit and Lower Limit set the upper and lower limits for actuator travel during auto tuning Basic auto tuning exercises within 80 of these limits Advanced auto tuning function exercises within 20 of these limits If the limits are exceeded the auto tuner will quit and trip an interlock H For Advanced auto tuning Set the Tracking value The 50 default setting is appropriate for most systems I For Advanced auto tuning Set the Sweep Freq The Sweep Freq sets the upper frequency limit of the sine sweep The 20 Hz default setting is a good starting point 0 8
80. al output signals and to define the polarity of digital output signals A digital output is a signal transmitted by the Controller to another device You can set the Controller to recognize specific station events including the reception of specific digital signals which result in the transmission of digital output signals 0 i 2 0 0 3 Access Level Operator Digital Output n Assignment Polarity State Digital Output Menu part 1 of 2 ITEM DESCRIPTION Assignment Defines the change in the state of station events that must occur before the Controller sets the state of the digital output high or if polarity is reversed low Interlock Sets the digital output high when any interlock occurs Run Stop Sets the digital output high when the program is started or stopped This may be caused by the operator pressing the Run and Stop buttons or by the reception of a digital input Hold Sets the digital output high when the program goes into a hold state This may be caused by the operator pressing the Hold buttons or by a digital input Program Interlock Sets the digital output high when a program interlock occurs This may be caused by a limit or error detector or by a digital input Dig In n Sets the digital output high when the Controller receives a specific digital input signal 176 Menus Descriptions FlexTest SE Setup Normal Active High Digital Outp
81. allow you to select when you expect us to respond to your input We guarantee a timely response your feedback is important to us Preface 11 Write down relevant information After you call Problem Submittal Form in MTS manuals Technical Support 12 Preface Chapter 1 Introduction This chapter provides a basic description of the FlexTest SE Controller a detailed description on front panel controls and indicators information about navigation data entry and types of Controller files and specifications Contents Basic Description 14 Standard features 14 Optional features 15 Front Panel Controls 7 Emergency Stop 18 Monitor 1 8 2 connectors 8 Display screen 8 Menu buttons 1 Navigate buttons 25 Dial and Increment Decrement buttons 26 Help button 26 A B Recall buttons 6 Numeric keypad 7 5 4 i a iv i Program controls 28 Interlock controls 28 Power controls 28 Controller Files 29 Specifications 32 FlexTest SE Introduction 13 Basic Description Basic Description The FlexTest Controller is a VME based fully digital PIDF Controller equipped with a multi color display panel Arwind Run Hois stop 44 N e Tuning Stroke Function gene 142 0000 Se MTS FlexTest SE Controller shown with optional carrying handle Standard features Standard features include on board meters with large numeric display full range digital universal conditioner
82. ame Enabled Type Dimension Display Unit Auto Scale Placement gt Trace n Settings Signal Units Div Offset Display Mode Display Unit Display Resolution gt Auto Scale Auto Scale lt lt Rescale gt gt Same Scale Auto Scale Mode gt Panel placement Log Status Scope Meters gt Local Settings HWI File Config File Regional settings gt Passwords gt gt Networking gt gt License Keys gt lt lt Save settings gt gt lt lt Discard changes gt gt gt Regional Settings Language Decimal separator Unit Assignment Set Date Format Time Format gt Passwords Tuning Calibration Configuration gt Networking Controller ID Controller Name Boot location gt gt Licence Keys 793 51 Scope 793 52 Advd FG 793 53 Auto Tuning 793 08 PVP lt lt Reboot gt gt lt lt Save Def Pnis gt gt lt lt Save Panels gt gt lt lt Restore Panels gt gt Placement Config Menu Access Level Panel placement gt Local Settings Edit Configuration gt Edit Hardware gt Set Date gt Set Date Time gt Service Tools gt lt lt Shut down gt gt lt lt Reboot gt gt Appendix 6 Boot Options By pressing specific buttons during the boot process you can prevent the Controller from loading default files as follows PRESS THIS BUTTON To PREVENT LOADING THIS FILE 1 Configuration file as a result only the Config menu will be available
83. ane s Channels locate and select the channel whose servovalve dither you want to adjust 6 In the Station Setup window click xl Three stage valves In the Drive panel click the Valve tab Increase Dither Amplitude until you can hear the dither and then decrease Dither Amplitude until the noise goes away Dither Frequency In addition to Dither Amplitude Flex Test SE Controllers have a Adjustment Dither Frequency control The default dither frequency is 528 Hz which is effective for most applications and should not require adjustment However if the dither frequency begins to resonate with test frequencies adjustment may be necessary 0 8 E E i 2 78 Common Tasks FlexTest SE How to Perform a Shunt Calibration How to Perform a Shunt Calibration Shunt calibration is a method of verifying the calibration accuracy of your system s DC sensor conditioner pairs For a given sensor conditioner pair it does this by shunting a precision resistor across one arm of the sensor s Wheatstone bridge The resulting imbalance provides a reference value which is provided in the calibration sheet that accompanies the sensor The Controller s shunt calibration controls allow you to periodically check this reference value Significant variations between current and reference values may occur if the excitation voltage has drifted or the sensor has been damaged or has changed if some other way Sh
84. anies your system Automated 1 In the Station Manager window s toolbar select an access level Controllers of Calibration 2 In the Station Manager window s Display menu select Station Setup 3 Apply a shunt calibration To apply a shunt calibration to a control mode A In the Station Setup window s navigation pane Channels locate and select the control mode needing a shunt calibration B In the Station Setup window click To apply a shunt calibration to an auxiliary input In the navigation pane s Auxiliary Inputs click the input signal needing shunt calibration 0 8 E E i 2 80 Common Tasks FlexTest SE How to Perform a Shunt Calibration 4 In the Inputs panel click the Shunt tab gt Station Setup 1 gt FTIIM cfg gt iis EF Station Inputs Channel 1 Force Channels Ra Channel v Current Range H Force 2 L Force Displ Vv Sensor Calibration Shunt Offset Zero Limits i Channel 2 Calibration Parameters Channel 3 Gain H Eurotherm Temp ad 1 fico VTA E pote __ Auxiliary Inputs FHF Station Signals 1 1 7 7 7 7 7 1 el Digital Inputs Outputs 0 0000 9 9976 Detectors os Calculations Excitation 10 0000 E Remote Setpoints Do r 0 0000 19 9951 Select Shunt Type Shunt C Shunt Shunt Reference Value r Current Shunt Value
85. annot accept programs that contain mode switches FlexTest SE Menus Descriptions 223 Config Config Menu gt Edit Config gt Monitor n Anlg Out Digital Input n Digital Output n Use the Monitor n Anlg Out Digital Input n and Digital Output n selections to assign attributes to these resources N i 2 0 0 3 The monitor Monitor n resources correspond to the two BNC type connectors Monitor 1 and Monitor 2 on the front panel of the Controller When enabled analog station signals are available on these connectors for external readout devices such as a meter oscilloscope or x y recorder The analog output Anlg Out resource corresponds to a single BNC type connector Analog Out to the rear of the Controller Analog output signals can be used to command an external valve driver or Controller The digital input Digital Input m resource corresponds to a D type connector J54 to the rear of the Controller which can receive digital signals from external devices When the Controller is used in the automated mode with the MultiPurpose TestWare application a digital input can signal your Controller that an external event has occurred 224 Menus Descriptions FlexTest SE Config The digital output Digital Output n resource corresponds to a D type connector J55 to the rear of the Controller which can issue digital signals to exter
86. ase control mode With the associated menu you can e Set up error detector settings and actions to minimize the risk of equipment damage and to manage test events e Adjust Conversion and Integration gain to optimize system performance To create a dual compensation mode you must allocate an input resource to an existing control mode For more information see page 220 Access Level See submenus Note The sample menu shows a Analog In Load dual compensation mode but dual compensation mode can be created from any two input resources Analog In Force Error Detectors gt Null Pacing PVC PVP Dual Compensation gt 168 Menus Descriptions FlexTest SE Setup Dual Compensation Control Mode 2 ITEM DESCRIPTION O Error Detectors Null See Error Detectors on page 157 Null Pacing on page 160 and PVC Pacing PVC PVP PVP on page 163 Dual Compensation Conversion Gain The Conversion Gain controls how the command from the function generator which has a different dimension than the command required by the PIDF Controller is converted to command for the PIDF Controller Integrator Gain The Integrator Gain improves static accuracy when the command is paused or stopped Dual compensation Observe the Force Displacement dual compensation control mode in example the example below Programming and compensation are based on force feedback while the PIDF
87. ation and configuration settings This control also exists in the Config menu To access many of the controls in the Config menu you must be at the Configuration access level oO 0 oO 2 T s i 0 Required access level Operator or higher Note After making higher level changes it is a good idea to always return to the Operator level This is the default user level This level does not need a password and has the fewest privileges Enter this level to make tuning adjustments Enter this level to modify calibration parameters Enter this level to make changes to various controls in the Config menu including all the controls in the Edit Configuration and Edit Hardware submenus This is an optional feature available for PC supervised Controllers This control in conjunction with the Exclusive Control on the interface of the Station Manager program determine whether the Controller or the Station Manager program performs closed loop control of the system For more information see PC Supervised Controllers on page 35 Selects the controlling application that is the application that generates program command and responds to the Controller s Program controls Rewind Run Hold and Stop Function Generator The FG controls provide program command Tuning The Tuning controls provide program command Sets the control mode when using the Dial for manual control Specifies the offset from z
88. ation process Determines how much the feedback signal must change as a percentage of its peak to peak value before a peak or valley is detected This filters out noise and minimizes invalid peak or valley detection Hold Continues to use current values but stops adapting new values Resume Adapts and continuously updates compensation values Clears acquired compensation values and restarts the adaptation process Pressing Reset with compensation applied may produce a spike in the feedback Clicking Reset with hydraulic pressure on can result in unexpected actuator movement A moving actuator can injure anyone in its path Always clear the actuator area before clicking reset FlexTest SE Setup ITEM Convergence Rate Sensitivity Adaptation State lt lt Reset gt gt 164 Menus Descriptions 0 i 2 0 0 Setup About PVC Peak Valley Control PVC compensation monitors cyclic command feedback for any amplitude roll off or mean level divergence PVC performs the following e Increases the command amplitude if it detects amplitude roll off in the feedback signal oO 0 oO 2 T i 0 e Adjusts the mean command level if it detects mean level divergence in the feedback signal Note For best results when using PVC set the I Gain as low as possible on the control mode being compensated 5 4 ge fern 2 1 Mean
89. aximum DC output from the conditioner Offset Sets the offset applied by the conditioner to the sensor s output signal Gain Sets the amount of gain applied by the conditioner to the sensor s output signal Gain values affect tuning settings and the noise sensitivity of the valve command Polarity Sets the polarity of the spool output or inner loop output signal to Normal or Invert Polarity cannot be changed when the station pressure is on 136 Menus Descriptions FlexTest SE Setup a Conditioner Menu for Service Port Output Signals F 9 SIGNAL DESCRIPTION S 5 Valve Current The final output to the servovalve The voltage represents the current output 3 10 V DC 50 mA standard Demod Filter Output The analog output of the demodulator prior to gain Innerloop Command The input signal to the 3 Stage Valve Driver the test program command Spool Position The Conditioner Out signal summed with the Spool Zero signal Spool Offset Signal that is summed with spool position to remove any DC offset 10 V represents 4 V of zero summing Preamp Output The raw AC input from the spool LVDT Conditioner Out The conditioned feedback signal from the servovalve LVDT Voltage Reference 5V Internal board reference test only Monitoring Only the Spool Position signal is available to the Controller on board inner loop signals Scope and Meters To read any of the other inner l
90. back to the upper and lower levels of the test command Any difference should be the same Note You can also use the optional Scope or an external oscilloscope to adjust Gain by monitoring the Error signal For more information see How to use error to tune Gain on page 116 11 Save your tuning settings Stand Alone Controllers Setup gt Open Save Parameters gt lt lt Save gt gt Automated Controllers On the Station Manager File menu select Save Parameters As You can either select an existing parameter set or enter the name of a new parameter set to save It is important that you save your parameter set as you complete the various parts that make up a parameter set Throughout this manual you will be performing discrete procedures while building a single parameter set e Ifyou have already established your default parameter set for the current station and you are creating a new parameter set for a specific test save the parameters with a different name e Different tests and or specimens may require different parameter sets FlexTest SE About saving elements of a parameter set 0 8 E E i 2 100 Common Tasks How to Perform Advanced Tuning Techniques How to Perform Advanced Tuning Techniques The following techniques require product features that are optional for the FlexTest Controller To obtain these features contact your local MTS Sales Representative or refer to
91. cally displacement The second control mode you create is the limiting channel typically force A quick way of determining the type of control modes used for the master and limiting channels is to view the Setup menu The first control mode listed after Output is the master channel the next control mode is the limiting channel The following menu applies to CLC control mode Manual Control Mode FG gt Active P Limiting P Lower Limit Upper Llmit Manual CLC Tuning Menu DESCRIPTION The Channel Limited Channel CLC control mode requires two sensor feedbacks or input channels CLC uses the first input channel master channel to control the servo loop while using the second input channel imiting channel to restrict the master channel The master channel has an Active P Gain control and the limiting channel has a Limiting P Gain control A CLC control mode typically uses displacement as the master channel and force as the limiting channel See FG on page 195 Adjusts the amount of proportional gain for the active control mode Adjusts the amount of proportional gain for the limiting control mode Defines an operating range for the limiting control channel The limiting channel ensures the command does not exceed the upper or lower limits Select limit values based on the modulus of the specimen FlexTest SE ITEM Control Mode FG Active P Gain Limiting P Gain Lower Limit Upper Limit 204 Menus Descr
92. ce in place of the command from the Controller The analog input resource is the input resource typically used to receive external command Dimension Selects the appropriate dimension for the sensor associated with the selected resource Display Unit Selects your preference in units for the selected dimension Channel Specifies the compensator used by the function generator 220 Menus Descriptions FlexTest SE Config control mode specified in the Control Mode field This integrates the feedback into the composite command and helps to stabilize closed loop control It is used primarily in high mass systems equipped with Delta P differential pressure sensors and in high speed systems equipped with accelerometers Anlg In 493 25 493 47 Menus part 3 of 3 ES 5 ITEM DESCRIPTION F 2 Type Stabilization Fdbk Configures the input resource as a stabilization signal for the Q E a Delta P sensors typically use DC conditioners Accelerometers are typically conditioned externally and are cabled to the console through one of the analog input resources Dimension Selects the appropriate dimension for the sensor associated with the selected resource Display Unit Selects your preference in units for the selected dimension Control Mode Specifies the control mode to which the stabilization feedback applies About control modes Control modes use a program command and sensor feedback to
93. ch you can manually control hydraulics and position the actuator not the interface that generates program command When used with PC supervision the Controller cannot generate program command the FG menu is disabled Regardless of whether exclusive control is assigned to the Controller or Station Manager when you select program command you select from various Series 793 applications on the PC When you assign exclusive control to the Controller you choose the desired Series 793 application from the Controller s Status menu Status gt Application The selections are typically Station Manager which is actually the Station Manager s on board function generator Basic TestWare and MPT When you assign exclusive control to Station Manager you choose the desired Series 793 application from the Station Manager interface N 2 p i i oO 3 o 2 gt ar a o oO A 44 PC Supervised Controllers FlexTest SE PC Supervised Controller Files About panel settings for PC supervised Controllers Panel settings consist of the position of the menus on the screen and the associated user settings in each panel including up to two bookmarks you create with the Recall A B buttons When a Controller operates in the stand alone mode panel settings are saved in a panel view set which is not a file in itself but a set of attributes attached to the configuration file both which reside in the Contr
94. ctuator Perform this step to verify that the actuator moves as you want A On the Manual Command window increase the Manual Cmd adjustment for a positive command Note The following conditions assume you want a positive command to retract the actuator 0 8 E E i 2 66 Common Tasks FlexTest SE How to Set Servovalve Polarity Actuator fully retracted B Ifthe actuator is fully retracted and applying a negative or extended Manual Cmd does not extend it zero the command remove hydraulic pressure and change the servovalve polarity Then retry this test If it still does not move return to Step 2 and increase the gain setting e Ifthe actuator is fully extended and applying a positive Manual Cmd does not retract it zero the command remove hydraulic pressure and change the servovalve polarity Then retry this test If it still does not move return to Step 2 and increase the gain setting Actuator not fully e Ifthe actuator does not move at all return to Step 2 and retracted or extended increase the gain setting e Ifthe actuator retracts the servovalve polarity is correct e Ifthe actuator extends the servovalve polarity must be reversed Check the Polarity setting on the Valve tab of the Drive panel and change it from Normal to Inverted or vice versa C Check the movement of the actuator Adjust the Manual Cmd slider to extend the actuator and then adjust the Manual Cmd slider to retrac
95. d I Gain increases system response during static or low frequency operation and maintains the mean level during high frequency operation It can offset a DC or steady state error such as that caused by valve imbalance 198 Menus Descriptions FlexTest SE Tuning The following ramp and hold waveforms illustrate different levels of reset The I Gain determines how much time it takes to improve the mean level accuracy Overshoot Hunting Gain Too Low Optimum Gain Gain Too High Excessive Gain oO 0 oO 2 T i 0 e I Gain improves the mean level response during dynamic operations e IGain corrects the feedback droop caused by servovalve spring characteristics during static and very low frequency tests e I Gain minimizes the amount of time that the system needs to recover from transitions or transients e For best performance set I Gain as low as possible when using compensation methods that provide mean correction These methods include Peak Valley Phase PVP and Peak Valley Control compensation PVC e Higher I Gain settings increase system response e Excessive I Gain can cause a slow oscillation or hunting e Readings in the Max Min Meter window can be useful when adjusting I Gain FlexTest SE Menus Descriptions 199 Tuning Derivative Gain Derivative gain D Gain is used with dynamic test programs It D Gain introduces a derivative of the feedback signal This mea
96. d Fatal Error messages does not write Diagnostic and Information messages e Error Writes Error and Fatal Error messages does not write Diagnostic Information and Warning messages e Fatal Error Writes only Fatal Error messages does not write Diagnostic Information Warning and Error messages lt lt Clear Log gt gt Clears all messages from the Log Placement Moves the Log around the screen FlexTest SE Menus Descriptions 241 Log 0 i 2 0 A 0 242 Menus Descriptions FlexTest SE Appendix A Maintenance This section describes how to maintain the Model 493 02 Chassis Cleaning the chassis Remove any dust from the chassis or front panel with a damp cloth Air Filter removal and The Controller is equipped with an air filter which can be accessed installation from the rear of the chassis Clean or replace the filter as required To remove the filter pull the filter handle straight out from the chassis Note Filter orientation is important Ensure you re install the filter in the proper orientation Clean the air filter with soapy water and then rinse well and dry it completely before reinstalling 2 4 oO 2 ix D 3 e lt 9 oe 5 9 9 Air Filter Ensure the element is oriented as shown so that the Air Flow arrow points to the right while you are facing the rear of the cha
97. d mode While in the automated mode several of the Controller s menus are disabled as described in the table below To compensate for the disabled Controller menus you use the Station Manager s interface which replaces the functionality of the disabled Controller menus You run the Station Manager program on the PC whenever using the Controller in the PC supervised mode Controller interface functions in the automated mode The table that follows describes how the various Controller menus are affected while the Controller is in the automated mode Controller interface in the automated mode part 1 of 3 MENU CONTROL FUNCTION FG menu Disabled To create simple program command use Station Manager s Function Generator which has similar capabilities to the FG menu of the Controller when used in the stand alone mode If exclusive control see page 39 is assigned to the Controller and the Function Generator is not selected as the current application you can select the Function Generator by selecting Station Manager in the Application list of the Status menu Setup menu Disabled Use the Station Manager interface to perform setup activities Status panel Controller counters are disabled To use counters select an application that uses counters such as Basic TestWare Test Counters or MPT Sequence Counters and Channel Counters and view counter information on the application panel of Station Manager The Applicatio
98. de that is maintained while auto tuning takes place Mode to Tune Selects the control mode to auto tune Auto tuning is available only for PIDF control modes Actuator Type Normal Uses tuning algorithms for non hydrostatic actuators Hydrostatic Uses tuning algorithms for hydrostatic actuators Lower Limit Upper Sets the limits in which the actuator moves during auto tuning i If the actuator exceeds these limits during auto tuning the Controller will trip an interlock and auto tuning will cease lt lt Accept gt gt Transfers Reference PIDF values to Current PIDF values 206 Menus Descriptions FlexTest SE 0 oO 2 T s i 0 Config Use this menu to create and modify configuration files modify hardware settings and to perform a variety of other tasks such as e Entering license keys for Controller options e Setting regional and local settings e Changing network settings e Setting the time and date for the Controller e Selecting screen positions for the various panel displays Access level See submenus Config Access Level Panel Placement gt Local Settings gt Edit Configuration gt Edit Hardware gt Set Date Time gt Service Tools gt lt lt Shut down gt gt lt lt Reboot gt gt Access Level part 1 of 2 DESCRIPTION This control determines your ability to access and change tuning calibration and configuration settings This con
99. ditional presses scroll through the list Navigate Down button In a menu the Down button scrolls down through menu items in a panel it scrolls down through the panel 5 i a iv i FlexTest SE Introduction 25 Front Panel Controls Dial and Increment Decrement buttons Dial The Dial is a high resolution rotary input device that is especially useful for making small adjustments in numerical values You can also use it to select from lists enter text and scroll through file names Ns Increment Note To change the unit of resolution used by the Increment Decrement buttons Decrement or the range available to the Dial see page 54 Co Enabled Enable button and indicator The enabled state will automatically turn off after 30 seconds of inactivity Dial Press the Enable button to use the Dial Enabled indicator must be lit The Dial is velocity sensitive so fast rotations change values at a proportionally higher velocity than slow rotations Increment Decrement The Increment Decrement buttons change numerical values by one buttons point of resolution You can also use them to select from lists Help button C2 The Help button displays information about the currently selected item Pressing it a second time returns to the original display i gt cs ih A B Recall buttons The A B Recall buttons store a bookmark to a selected menu
100. down the current displacement I Gain B Zero the I Gain 0 8 m E E i o 68 Common Tasks FlexTest SE How to Balance the Servovalve 7 Setup a meter to view displacement error A Select Meters B Select an existing meter such as Meter 1 or select lt lt Add Meters gt gt to create a new meter and select it C For Meter Type select Timed D For Signal select Ch Error 8 Zero displacement error with the Valve Balance control Path Setup gt Output gt Valve Balance A Enable the Dial B While observing Ch Error on the Meters panel adjust the Valve Balance control by rotating the Dial until Ch Error is zero 9 Return displacement I Gain to its original setting Path Tuning gt Manual gt I Gain Note Procedures for Automated Controllers assumes the FlexTest SE Controller is equipped with the PC Supervision option and that Exclusive Control is assigned to Station Manager For more information about Station Manager see the Model 793 00 System Software manual that accompanies your system Automated 1 In the Station Manager window s toolbar select an access level Controllers of Calibration 2 Remove any specimen 3 Apply hydraulic pressure A WARNING Selecting the Enable Manual Command allows you to manually position actuators A moving actuator can injure anyone in its path Always clear the actuator area before selecting Enable Manual Command o
101. duction 29 Hardware interface files hwi Configuration files cfg FlexTest SE A parameter set is a set of attributes attached to a configuration file Though not a separate file you can create up to four different parameter sets for a configuration file A parameter set defines the operational characteristics of the resources in the configuration For instance you can define the PIDF tuning settings for a specific conditioner sensor pair When complete a parameter set contains all of the settings needed by a configuration to run a test such as calibration tuning limit and compensator settings A parameter set adapts the way your station resources operate to suit your test requirements The Controller s Setup menu lets you define and edit parameter sets which are saved with the configuration file A panel view set is another set of attributes attached to the configuration file You can create up to two panel view sets for a configuration file one with default panel settings and another with saved panel settings Each panel view set is independent of each other and includes e The position of the menus on the screen e Associated user settings in each panel e Up to two bookmarks created with the Recall A B buttons each of which captures menu images and the focus status of menu items Default panel settings are saved when you press the lt lt Save Def Pnls gt gt button The Controller also automa
102. e Controller Standalone with Networking Use to operate the Controller in the standalone mode when a network cable is attached to the Controller for purposes of file transfers etc Service Use to perform service activities typically involving file transfers between the PC and the Controller Automation Use to operate the Controller with a PC equipped with MTS Series 793 software Access level Operator FlexTest SE Menus Descriptions 213 Config Config Menu gt Local Settings gt License Keys Use this selection to add and remove optional Controller features To add enable a feature you must enter a license key provided by MTS A license key is an alphanumeric password that enables an optional product Note The 793 54 Automation feature does not require a license key To remove a feature use the backspace button to clear the license key save Config gt Local Settings gt lt lt Save Settings gt gt then reboot The optional resource will still be displayed in menu without the license key but the feature will be removed from the Controller Access level Operator License Keys 793 51 Scope 793 52 Advanced FG 793 53 Auto Tuning 793 08 PVP Compensator The following options are available for the Controller e 793 51 Scope The Scope option is a full featured on board oscilloscope that allows you to view time and X Y plots optimize the display with auto scaling and pan trace history By d
103. e Status e Log FlexTest SE Monitor 1 Monitor 2 Display screen Information panels 18 Introduction i gt cs ih 5 i a iv i Front Panel Controls By default the Meters Status and Log panels are displayed on the screen Cf the optional Scope is purchased it is displayed in front of Default panel positions the Log Each panel is associated with a Menu button You can change the position of each panel on the screen as desired refer to How to change numbers on page 53 4 Status Introduction 19 Waring Stmar 493 25 5 2 15 is not normalized 3 00 23 PM PM Warning Stmar 493 25 5 2 16 is not normalized 3 00 23 PM Error FlexT est SE Internal error detected in file d 5 3 00 25 PM Error FlexTest SE Internal error detected in file d 5 3 00 25 3 00 25 PM Error FlexT est SE Internal error detected in file d 5 3 00 25 PM Error FlexT est SE Internal error detected in file d 5 3 00 25 PM Information FlexTest SE Initializing view set FTSE 3 00 25 PM Information FlexT est SE Successfully initialized vie default Calibration FG Disp 9020 Sec Parameter Set Access Level Application Control Mode Running Time Preset Count Current Count Total Count vi Disp 0 00 mm vA Force 0 00 kN vA Force2 0 00 kN vi Anig In 0 00 mm Log gt Meters gt Defaul
104. e found in the servovalve product literature The natural frequency can be approximated with the following formula Actuator Frequency CA WV Where C constant for English 2500 or metric units 1060 A actuator piston area expressed as 2 cm W any directly coupled mass including the actuator piston mass expressed in 05 kg V hydraulic fluid volume contained inside the actuator and manifold expressed as in cm e Ifthe system response deteriorates when adding delta P then change the polarity of the signal e Check all amplitudes for overshoot Do not allow more than 10 overshoot preferably none at any amplitude of a square wave response Delta P will not compensate for additional compliance from swivels linkages test tables etc Test systems with specimens affected by acceleration resonances can use a mass accelerometer signal for stabilization Acceleration stabilization dampens the resonances vibrations affecting the specimen Typical systems that benefit from acceleration stabilization include e Load units that operate at high frequencies with massive grips e Test systems that employ swivels linkages test tables etc Sensor feedback is provided by an accelerometer attached to or near the specimen The Controller converts this feedback into a stabilization signal which is combined with the composite command signal post PIDF correction The stabilized command signal is then sent t
105. ectly linear uncompensated state Linearization Data Displays the Linearization Data table in which you can manually enter sensor calibration data The table has three columns e The left column contains incremental range values that span the full range of the selected sensor e The middle column labeled Standard contains the actual force or displacement values applied to the sensor during the calibration process e The right column labeled Conditioner contains the conditioner s output in response to the applied Standard values The Controller uses the difference between the Standard and Conditioner values at each range increment to compensate for sensor non linearity Excitation Sets the excitation voltage applied to the sensor which is usually specified by the sensor manufacturer AC sensors typically require 10 V AC excitation and DC sensors typical require 10 V DC excitation 142 Menus Descriptions FlexTest SE 0 oO 2 T i 0 Setup Cal Type Gain Linearization part 2 of 2 DESCRIPTION Adjusts the phase or lag of the sensor signal in relation to the excitation signal Optimal phase adjustments produce the maximum output signal from the sensor Phase values are typically between 30 45 The conditioner may be configured so that this control behaves like a Coarse Zero or a Bridge Balance Balance Option Course Zero Pe
106. ed activities 46 Down button 25 Index 249 Index Symbols cfg file 29 hwi file 29 Numerics 493 15 3 Stage Valve Driver 15 493 25 Digital Universal Conditioner DUC 15 493 40 I O Carrier 15 493 45 A D 15 493 46 D A 15 493 47 Encoder 15 793 software 36 793 01 System Software 15 793 08 PVP Compensator 15 793 10 MultiPurpose TestWare 15 793 51 Scope 15 793 52 Advanced FG 15 793 53 Auto Tuning 15 A A B Recall buttons 26 abbreviations 17 acceleration stabilization 202 accelerometers stabilizing with 221 additional model 493 40 I O Carrier 15 air filter installing 243 Amplitude 127 auto tuning how to 101 Back button 25 basic capabilities 14 Basic TestWare 36 Block n of a block cyclic program 125 BNC connectors front panel 18 FlexTest SE hwi file hwi See hardware interface file Hydraulic Interlock 28 hydraulics warm up 59 79 Increment Decrement buttons 26 information panels 18 information on screen 26 Inner Loop 135 Inner Loop Menu for Three Stage Valve Drivers 136 Inner Loop Rate 136 inner loop tuning three stage valves 108 Integral gain about 198 Interlock controls 17 28 interlock defined 28 L Level Type of a block cyclic program 125 Limits description 24 Limits table 22 Locating 46 locating documentation for PC Supervised activities 46 location of Exclusive Control in the Station Manager 40 location of Exclusive Control on t
107. eep on the internal or external scope C Increase the P Gain adjustment until you see a little Overshoot ae a overshoot and a little ringing D Increase the D Gain adjustment to reduce the overshoot and ringing Ringing E Repeat C and D until you achieve a optimum waveform High The middle waveform is a optimum waveform In some cases the optimum YW waveform will have no Rate D overshoot or ringing and the waveform will look more like a square waveform with rounded corners Vo Low Gain P High Unstable sounds For actual testing if your system goes unstable it will sound unstable that is it will emit an annoying high pitched sound that is quite different from the usual tuning sound ka chunk ka chunk If your system begins to go unstable quickly readjust the control that caused the instability to return the control to its previous setting N 8 E E i 2 92 Common Tasks FlexTest SE How to Manually Tune the Control Loop 9 Adjust the I Gain tuning control Set up a peak valley meter to monitor the peaks and valleys of the sensor signal The peaks and valleys should be balanced Before adjusting reset I Gain be sure the feedback signal is repeatable that is the same peaks and valleys are achieved For example assume the test command is centered on zero and the meter displays 3 mm and 5 mm You want to adjust the reset I Gain control to achieve 4
108. efault the Controller includes a simplified scope designed to assist with tuning e 793 52 Adv FG The Advanced Function Generator Adv FG option includes features advanced programming features such as Sweeps and Block Cyclic waveforms e 793 53 Auto Tuning The Auto Tuning option allows you to quickly tune your Controller to new specimens or changing specimen characteristics without having to make individual PIDF control adjustments e 793 08 PVP Compensator The Peak Valley Phase PVP compensator option optimizes command by altering command phase to correct for phase lag and increasing the command amplitude to correct for amplitude rolloff FlexTest SE 214 Menus Descriptions N i 2 0 0 3 0 oO 2 T i 0 Config Config Menu gt Edit Config Use this menu to edit configuration files cfg by adding or removing resources listed in the Controller s hardware interface hwi file For instance suppose you want to add a readout channel for use by an external meter With the Edit Config menu you could add a readout channel to your Controller by enabling a Monitor resource and you can name it Meter or whatever you wish You can modify any configuration file including the file that is currently running If you are modifying the currently running configuration file you must save your changes Edit Configuration gt lt lt Sa
109. eforms 87 prerequisites 85 Proportional gain about 198 specimens changing 82 three stage valves 108 valve balance 68 waveforms 86 when to tune 84 Tuning menu 22 U Up button 25 Upset recovery method 117 V Valve Balance 135 valve balance adjusting 68 valves polarity check 64 67 252 Index
110. el gt Tuning 2 Remove any specimen 72 Common Tasks FlexTest SE 0 8 E E i 2 How Adjust Dither 3 Select FG from the front panel and create a program as follows CONTROL SETTING Type Cyclic Wave Shape Ramp Control Mode displacement Target Setpoint 0 mm Amplitude 5 mm Frequency 0 001 Hz Compensator None 4 Select Scope and set up scope parameters to display the channel s command and feedback signals A WARNING Applying station hydraulic pressure can put actuators in motion A moving actuator can injure anyone in its path Always clear the actuator area before applying hydraulic pressure 5 Apply station hydraulic power 6 Press Run to start the displacement command 7 Use the Scope to observe the feedback signal If the feedback signal shows a smooth ramp you do not need to adjust the dither amplitude If the feedback signal shows a jagged ramp caused by the actuator sticking before moving continue on to the next step to adjust the dither amplitude o D 0 0 FlexTest SE Common Tasks 73 Increase Dither Amplitude until the feedback is smooth Path Setup gt Output gt Dither Amplitude If you hear an unusual sound coming from the servovalve the dither amplitude is set too high How to Adjust Dither 8 Method 2 Select an access level of Tuning Path Config gt Access Level gt Tuning Re
111. en breaks The best input signal for this purpose is from the LVDT sensor 156 Menus Descriptions FlexTest SE Setup Setup Menu gt PIDF Control Mode Error Detectors Use Error Detectors to set control mode error values and specify the Controller s response if these limits are exceeded You can use error detectors to warn you when the specimen is beginning to fail and to trigger an action to record data and or halt the test oO 0 oO 2 T i 0 Access Level Operator control mode Calibration gt Offset Zero gt Limits gt Error Detectors gt Error Detectors Inner Limit Inner Action Outer Limit Outer Action Error Detectors Menu ITEM DESCRIPTION Inner Limit Displays the error signal s inner limit A detector action can occur if the signal exceeds this limit New values can be entered in the display boxes Indicator colors show each detector s status Inner Action Outer Action See Actions on page 155 Outer Limit Displays the error signal s outer limit A detector action can occur if the signal exceeds this limit FlexTest SE Menus Descriptions 157 Setup How error detectors The error detector monitors the difference between the test command work and a feedback signal The amount of error indicates how closely the system tracks the test command As a specimen changes approaching failure the amount of error will likely increase
112. en 80 100 of the commanded value FlexTest SE Menus Descriptions 1 Setup Setup Menu gt Monitor n Use this selection to assign attributes to station signals for optimal display by external readout devices such as oscilloscopes or meters To create a readout channel you must allocate a readout channel resource in the configuration file For more information see page 224 0 i 2 0 0 3 Access Level Operator Readout n Readout Polarity Gain Offset Readout Menu ITEM DESCRIPTION Readout Signal Selects the signal you wish to make available for monitoring The signals are available on the selected Monitor 1 or 2 BNC connector on the front panel of the Controller For information of the list of available station signals see Station signals on page 191 Gain Sets the amplification applied to the readout signal The default is 1 which means that the full scale of the selected signal is scaled to 10 V Polarity Allows you to invert the readout signal Offset Adjusts the zero reference point of the readout signal The default setting is 0 which references the signal to 0 volts The offset is applied to the converted value in volts 172 Menus Descriptions FlexTest SE Setup Setup Menu gt Stabilization Use this selection to assign attributes to the stabilization input A stabilization input is an input resource that is integrated into the
113. en Limits o D 0 0 FlexTest SE Common Tasks 1 How to Perform Advanced Tuning Techniques 4 Set up auto tuning parameters Stand Alone Controllers A Select Tuning gt Auto Tuning B For Control Mode select displacement C For Mode to Tune select displacement D For Actuator Type select the type you have The actuator is typically equipped with a label that identifies whether or not it is hydrostatic Note Ifyou receive a Feedback is not responding to drive signal message during tuning select Hydrostatic This setting allows more and faster valve movements which results in more actuator movement E For Upper Limit and Lower Limit set the upper and lower limits for actuator travel during auto tuning Auto tuning exercises the actuator within 80 of these limits 0 8 m E E i o 102 Common Tasks FlexTest SE How to Perform Advanced Tuning Techniques Automated Controllers In the Station Manager window click to open the Auto Tuning control panel Auto Tuning Control Channel Channel A Control Mode Displacement A Mode to Tune Displacement A Active Mode Displacement o e Auto Tuning Type 6 A Actuator Type Noma A ae 1 1 14 1 10 0000 10 0000 Lower Limit 10 0000 Tracking 1 0 0000 100 0000 Al p 1 1 0 45000 100 0000 m Results New Values Current PG
114. enabled or not Once the waveform is scaled to fit enable Auto Scale to continue adjusting the units division and offset automatically Note These controls affect the display not the waveform When you select a signal the scope scaling defaults to 100 of the signal range To change the scaling for the selected trace enter the desired values in the Units Div and Offset controls in the individual Trace Settings menus Signal prior to auto scaling peaks are off scale Signal after auto scaling grid is scaled peaks fit FlexTest SE Scaling traces Scope 184 Menus Descriptions 0 i 2 0 0 3 oO 0 oO 2 T i 0 Scope The Offset control in the Trace Settings menu defines the grid s midpoints Applying an Offset shifts where zero is on the display For example suppose your scope is set up so that the upper scale is 8 mm the lower scale is 8 mm and Offset is set to 0 mm Changing the Offset to 1 0 mm shifts the upper range to 9 mm and the lower range to 7 mm Changing the Offset also shifts the signal trace down on the display grid to reflect the new zero position No Offset 1 0 mm Offset The X Y plot mode displays one signal on the horizontal axis and another signal on the vertical axis Menus Descriptions 185 Offsetting traces Zero reference at midpoint 1 0 mm now at midpoint
115. ero Setpoint is the static portion of the program command that is the base from which the program command s Status Menu part 1 of 2 ITEM Access Level This control determines your ability to access and change tuning Operator Tuning Calibration Configuration Exclusive Control Application Control Mode Setpoint amplitude content centers on Menus Descriptions 179 FlexTest SE Status Menu part 2 of 2 DESCRIPTION Changes the amplitude span of the program command Saves panel changes to the configuration file automatically prompts you to save parameter set changes if any have been made then closes all applications and prompts you to remove power from the Controller Saves panel changes to the configuration file automatically prompts you to save parameter set changes if any have been made then closes all applications and restarts the Controller Default panel settings are the settings of the FG Scope Meters and Log menus and the Recall buttons Default panel settings are stored in the configuration file in an attribute set Pressing lt lt Save Def Pnls gt gt saves the default panel settings The Controller also automatically saves default panel settings when you e Shut down e Reboot e Runa test press Program Run after changing the FG Type Cyclic Preset Count Block Cyclic Control Mode or Block Cyclic Count Pressing lt lt Save Def Pnls gt gt al
116. ers gt lt lt Save gt gt You may save auto tuning values to an existing parameter set or to a new parameter set o D 0 0 Common Tasks 7 FlexTest SE How to Perform Advanced Tuning Techniques How to manually tune three stage servovalves Note This procedure requires the optional Scope or an external oscilloscope About the inner loop Systems equipped with Model 493 15 Valve Drivers and three stage servovalves have an inner control loop inside the test system s primary or outer control loop 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 The inner loop is similar to a displacement control mode for the outer loop The Model 493 15 Three Stage Valve Driver includes the electronics necessary to support the inner control loop The innerloop Feedback proportional gain and rate Gates derivative adjustments Loop are the same types of adjustments as the proportional and derivative gain adjustments of the gt outerloop tuning controls Control Hydraulic oe eras Power Signal Supply Program Command 493 15 Valve Driver Important Always tune the inner loop without the hydraulics applied to the actuator Perform the inner loop gain adjustments with hydraulic pressure removed fr
117. essage to the log Disabled No action occurs This setting disables the Limit indicator Indicate This setting turns the Limit indicator white Station Power Off Clamps the servovalve turns off pressure at the hydraulic service manifold HSM and stops any program Interlock Turns off pressure at both the HSM and hydraulic power unit HPU and stops any program command Program Interlock Stops any program command but does not turn off station hydraulic pressure Program Stop Stops any program command Produces the same action as Clicking the Program Stop button on the Station Controls panel Program Hold Holds all program command Produces the same action as Clicking the Hold button on the Program panel Upper Limit Sets the upper limit that the feedback signal must cross to trigger the Upper Action The adjustment range equals 130 of the selected range s full scale FlexTest SE Menus Descriptions 155 Setup Signal limits The upper limit defines the most positive or least negative level for the limit detector The lower limit defines the least positive or most negative level of the limit detector The difference between the upper and lower limits represents the normal operating range of the sensor When set correctly a sensor output beyond this range represents a change in the test that deserves attention Limits can also protect your equipment if a specimen breaks If the sensor output exceeds either
118. feedback signal Encoder Temposonics only For encoder resolution the resolution value is supplied in the encoder documentation For Temposonics III refer to the product literature For Temposonics II resolution use the following formula to determine the resolution value 1 Recirculations AMS i Gradient x Frequency x Recirculations Gradient Unique value supplied with the Temposonics sensor documentation Gradient refers to the propagation speed of the wave in the waveguide Frequency Speed of the internal clock typically 8 MHz 140 Menus Descriptions FlexTest SE Setup Calibration Menu part 2 of 2 ITEM DESCRIPTION Recirculations Unique value supplied with the Temposonics sensor documentation Recirculation is the number of times the position of the magnet is checked before it is reported You may have to adjust the recirculation numbers on the control dials in the sensor head to comply with the number supplied oO 0 oO 2 T i 0 Cal Type Sets the type of calibration used for the feedback signal The calibration types displayed depend on the conditioner type selected e Gain Linearization Select to use linearization data for calibration of sensors with full range conditioners This type of calibration allows use of the Advanced Sensor Data window to precisely edit range data points See Cal Type Gain Linearization on page 142 e Gain Delta K Se
119. g imbalance provides a reference value which is provided in the calibration sheet that accompanies the sensor 0 i 2 0 0 3 To perform a shunt calibration see How to Perform a Shunt Calibration on page 79 Access level Tuning Shunt Calibration Controls ITEM DESCRIPTION Shunt Display Selects whether the shunt values are displayed in engineering units or volts Shunt Reference Displays the saved shunt reference value in engineering units Initially you enter this value from the calibration sheet that accompanies the sensor When performing a shunt calibration you compare the shunt value displayed on the meters using the same units to the value stored here To update the shunt reference value enter the values as desired lt lt Update gt gt Makes the current shunt value the new Shunt Reference value Shunt State On Shunts voltage across the Controller s shunt resistor and displays the results in engineering units on the meter panel Off Removes voltage from the shunt resistor 148 Menus Descriptions FlexTest SE 0 oO 2 T i 0 149 Setup Setup Menu gt PIDF Control Mode Offset Zero With this menu you can apply a software offset to the conditioner s output changing its apparent zero reference You can also adjust the conditioner s electrical zero changing its actual zero refere
120. h the PC Supervision option and that Exclusive Control is assigned to Station Manager For more information about Station Manager see the Model 793 00 System Software manual that accompanies your system Automated 1 In the Station Manager navigation pane click the Function Controllers Generator icon to display the Function Generator panel LFunction Generator Channel Channel 1 he Ig Control Mode Displacement Se H Command Type ie A Target Set Point 4 1 1 1 EE O 1 1 0000 1 0000 21 1 1 1 1 1 1 1 7 0 0000 1 0000 Frequency 1 1 1 1 1 1 1 4 100 0000 0 0000 Wave Shape Compensator SIE E 0 8 E E i 2 60 Common Tasks FlexTest SE How To Warm Up Station Hydraulics 2 Enter the following settings in the Function Generator panel CONTROL SETTING Control Channel The control channel associated with the valve you are adjusting Control Mode Displacement Adaptive None Compensator Target Setpoint 0 Amplitude 80 of the full scale actuator displacement Frequency 0 1 Hz Wave Shape Sine 3 In the Station Manager window s Station Controls panel A Click Reset to clear interlocks B Apply station power C Click Program Run to start the function generator 4 If necessary correct P Gain during warm up A On the Station Manager window s Display menu select Station Setup o D 0
121. hard drive in which the application resides Example 11 2 GB free space or 72 free space e Current status of hard drive fragmentation Example 3 total fragmentation Preface 9 Know information from prior technical assistance Identify the problem Know relevant computer information For MTS software application problems have the following information available e The software application s name version number build number and if available software patch number This information is displayed briefly when you launch the application and can typically be found in the About selection in the Help menu Example Station Manager Version 3 3A Build 1190 Patch 4 e The same information for other MTS software included with your system e Names of other non MTS applications that are running on your computer such as screen savers keyboard enhancers print spoolers and so forth Your call will be registered by a HELPLine agent if you are calling within the United States or Canada Before connecting you with a technical support specialist your agent will ask you for your site number name company company address and the phone number where you can normally be reached To assist your HELPLine agent with connecting you to the most qualified technical support specialist available identify your system as one of the following types e Electromechanical materials test system e Hydromechanical materials test
122. he Controller How to Power Up the Controller Stand alone power up Apply power to the Controller with the I O button on the Controller s rear panel and allow the software to fully boot The boot process typically requires a few minutes during which the Controller loads the default configuration file associated parameter set and any saved panel views While booting the screen displays various messages including the MTS logo When the boot process is complete the screen typically displays the Scope or Log Status and Meters panels PC supervised power up For PC supervised systems complete the following power up procedure 1 Ensure that the network cable PN 519968 xx is connected from the PC to the Controller 2 Ensure that the PC is on preferably with the Desktop displayed 3 Apply power to the Controller with the I O button on the Controller s rear panel 4 Allow the software to boot When the initial boot process is complete the Controller will display the message Waiting for System Load If Waiting for System Load does not appear but the Scope Status and Meters panels are displayed you must set the Controller to boot in Automation mode Select the Automation mode with this path Config gt Local Settings gt Networking gt Boot Location gt Automation Next if desired save your settings lt lt Save Settings gt gt then reboot the Controller 5 Launch System Manager from your PC
123. he Controller 40 Log menu 22 Log panel 22 Master slave power up 50 max min meters 189 194 mean amplitude meters 189 194 Menu buttons 21 Menu Item button 25 meters mean amplitude 189 194 peak valley 194 running max min 189 194 Meters menu 22 Meters panel 22 Model 493 15 3 Stage Valve Driver 15 Model 493 25 Digital Universal Conditioner DUC 15 Model 493 45 A D 15 Model 493 46 D A 15 Model 493 47 Encoder 15 Model 793 08 PVP Compensator 15 FlexTest SE dual compensation control mode 223 conversion gain 169 integrator gain 169 E electrical zero conditioner 151 Emergency Stop 17 18 enabling Exclusive Control in Station Manager 43 Exclusive Control control 179 External Command 124 F Feed Forward gain 201 FG menu 21 120 force tuning prerequisites 94 procedure 95 forward loop filter about 203 Frequency 127 front panel controls 17 G gain Derivative 200 Feed Forward 201 Integral gain about 198 Proportional about 198 stabilization S gain 201 hardware interface file 226 hardware interface file hwi 29 Help button 26 how to change numbers 53 how to change panel positions 51 how to change text 52 how to change the display resolution of controls 54 how to change the range of controls 54 how to power up the controller 49 how to select files and items from lists 57 how to use error to tune I Gain 116 how To warm up station hydraulics 59 HPU 17 HSM 17 250 Index
124. he end level type cannot Test Time Rate Specifies whether the ramp is defined in terms of Time or Rate When Time is selected Test Time allows you to enter the ramp time The longest test time permitted is 120 minutes 7200 seconds When Rate is selected Test Rate allows you to enter the ramp rate End Level Type Specifies the end level of the command as Absolute or Relative The End Level value depends on the end level Type selection Absolute or Relative End Level value Absolute values are relative to zero Relative values are relative to the current output The end level value can be changed while a test is running but the end level type can not Compensator Specifies the compensator used by the Function Generator The Compensators that may be available include Null Pacing Peak Valley Control PVC and Peak Valley Phase PVP See About Null Pacing and compensators on page 161 FlexTest SE Menus Descriptions 121 Use the Cyclic selection to define a cyclic program Cyclic Wave Shape Control Mode Target Setpoint Amplitude Frequency Compensator Preset Count Current Count Total Count Cyclic Menu part 1 of 2 DESCRIPTION Specifies the program signal s wave shape as Square Ramp Sine Square Tapered Ramp Tapered or Sine Tapered Tapered shapes will ramp from zero to amplitude when starting and from amplitude to zero when stopping or holding See About Wave Shapes on page 130
125. he log based on severity level clear log entries and position the Log panel on the screen Access level Operator Log Show Time Stamp Show Source Show Severity Minimum Severity lt lt Clear Log gt gt Placement 240 Menus Descriptions FlexTest SE Log information on the format of the time and date in timestamp entries see Date Format and Time Format on page 211 Log Menu 6 i ITEM DESCRIPTION O Show Time Stamp Determines if and how the time stamp is displayed in log entries For z a Show Source Determines whether or not log entries display their source For stand alone operation two internal Controller components may write messages to the log FlexTest SE and Stmgr For automated operation additional applications such as Station Manager also Stmgr MultiPurpose TestWare MPT and Basic TestWare BTW may also write messages to the log Show Severity Determines whether or not log entries display their severity level Minimum Severity Sets the severity level that must be reached before the Controller writes a message to the Log The Controller writes messages to the log according to the following minimum severity levels e Diagnostic Writes Diagnostic Information Warning Error and Fatal Error messages e Information Writes Information Warning Error and Fatal Error messages does not write Diagnostic messages e Warning Writes Warning Error an
126. he station and disabling control in the other In general you perform all setup operations including calibration tuning zeroing setting errors and limits and all program command definition with Station Manager regardless of the interface you assign exclusive control These functions are disabled on the Controller interface when the Controller is booted in the automated mode For other activities such as applying hydraulic power manually positioning the actuator Span and Setpoint and starting the test you may assign exclusive control to which ever device you wish Some controls which are included in both interfaces are always functional regardless of which interface has exclusive control These are Emergency Stop HPU Off HSM Off interlock Reset and Program Stop and Program Hold for Basic TestWare and MPT only the Function Generator does not have the Program Hold function D 74 a D 5 O 2 gt 0 FlexTest SE PC Supervised Controllers 39 In Station Manager the Exclusive Control feature is located below the Station Controls panel as shown Exclusive Control in the Station Tl Exclusive Control Manager program s interface MPT gt i On the Controller the Exclusive Control feature is located on the Status panel and Status menu as shown Exclusive Control in the Controller s Status panel Access Level Operato
127. hed in your station parameter set are appropriate for the test you are about to run To do this you will e Create and apply a simple tuning program e Evaluate the current force tuning values by comparing command and feedback signals Once established displacement tuning values are unlikely to require adjustment in contrast optimal force tuning values are a function of your specimen s compliance and often change over time or even from test to test You should also tune force whenever you make any change to the force train such as changing fixtures Note Procedures for Automated Controllers assumes the FlexTest SE Controller is equipped with the PC Supervision option and that Exclusive Control is assigned to Station Manager For more information about Station Manager see the Model 793 00 System Software manual that accompanies your system Prerequisites Be sure the following conditions are present before you begin tuning the force control mode Stand Alone Controller and Automated Controllers e Hydraulic pressure is off e The specimen is not installed Automated Controllers Only e You have created a station configuration file e You have created a station parameter set 0 8 m E E i o 94 Common Tasks FlexTest SE o D 0 0 How to Manually Tune the Control Loop The following is a step by step tuning procedure for a force control mode It is a basic
128. hen testing a soft specimen in force control and helps the servo control loop react quickly to abrupt changes in command Stabilization S gain allows a second signal to be integrated into the control mode as a stabilizing factor The S Gain enhances stability for systems that move large masses at high speeds Note This feature is available only if the control mode being tuned includes a stabilization input Forward Loop FL filter adjustments compensate for noise in the servo loop which usually comes from sensor feedback FL filter adjustments establish a frequency bandwidth for the servo loop command signal Some systems experience mechanical resonances that limit the amount of gain you can use before the system becomes unstable A filter may be used in the forward path of the Controller to reduce the system response at the resonance frequency This makes it possible to increase the Controller gain while maintaining system stability Two types of filters are available e A lowpass filter attenuates signals above a specified frequency e lt A bandstop filter attenuates signals in a specified band around a specified frequency For low pass filters enter a frequency above which the filter will attenuate For bandstop filters enter a frequency to define the center of the attenuation band FlexTest SE Tuning ITEM D Gain F Gain S Gain FL Filter Filter Type Frequency 196 Menus Descriptions 0
129. iles that can be saved is limited to four Enter new name Allows you to save the file as another name similar to a Save As function Use the Dial to add or change letters in the new name lt lt New gt gt Creates a new configuration file To create the new configuration file the Controller initializes all the hardware resources in the current d hwi file lt lt Load gt gt Loads the selected configuration file lt lt Save gt gt Saves the selected configuration file If the selected configuration file includes user defined attributes referred to as a parameter set you will be prompted whether you want to save the configuration file with or without the parameter set lt lt Delete gt gt Deletes the selected configuration file 216 Menus Descriptions FlexTest SE Config s gt 77 i The Model 493 15 SV S2 J7 resource is a two stage valve driver three D stage valve drivers are also available listed in the Controller s HWI file Q The valve driver is an electronic module that controls a servovalve in a control channel 493 15 VD S2 J7 Display Name Enabled Include CLC Power 493 15 VD S2 J7 Menu DESCRIPTION Allows you to customize the default resource name for display purposes For instance the internal name of the valve driver resource is 493 15 VD 52 7 you can assign a display name that is meaningful to your test system such as 10 KN
130. ime sec 130 Menus Descriptions FlexTest SE FG Tapered square waves taper from 0 to 100 amplitude when starting and from 100 to 0 when stopping or holding oO 0 oO 2 T i 0 20000 4 0000 Time sec Tapered triangle waves taper from 0 to 100 amplitude when starting and from 100 to 0 when stopping or holding 4 0000 2 0000 4 0000 Time sec Sine waves taper from 0 to 100 amplitude when starting and from 100 to 0 when stopping or holding 2 0000 2 0000 4 0000 Time sec Menus Descriptions 131 Square tapered Ramp tapered Sine tapered FlexTest SE Setup Setup Note This menu is available only when you boot the Controller in the Stand Alone mode Config gt Local Settings gt Networking N i 2 0 0 3 Overview Use the Setup menu to assign attributes to the parameter set associated with the loaded configuration and to manage parameter sets A parameter set defines the operational characteristics of the resources in the configuration such as calibration tuning and limit settings You can save up to four parameter sets in the Controller Access Level See submenus Typical Setup Menu Setup For a more complete Open Save Parms Open Save Parms Monitor n listing see Appendix B Output gt Select existing name Readout Signal Menu Summaries Se
131. ing About PIDF tuning controls Tuning affects how the servoloop responds to the error between a command and its resulting feedback The goal of tuning is to get the error to be as low as possible at all times Over tuning the servoloop causes instability as the Controller overcompensates for the error Under tuning the servoloop causes the system response to be sluggish N i 2 0 0 3 You can monitor the error on the scope it allows you to view the command and sensor signals in real time As you monitor the signals you can continually adjust the tuning controls to optimize the Controller response to the error Proportional Gain Proportional gain P Gain increases the effect of the error signal on P Gain the servovalve to improve system response Proportional gain is used in all tuning situations The following figures show the tuning command in grey and the feedback in black IN P Gain Too Low Optimum P Gain P Gain Too High e As P Gain increases the error decreases and the feedback signal tracks the command signal more closely e Higher P Gain increases the speed of the system response e Too high a P Gain can cause the system to become unstable e Too low a P Gain can cause the system to become sluggish Integral Gain Integral gain 1 Gain introduces an integral of the error signal that I Gain gradually over time boosts the low frequency response of the servovalve comman
132. ion describes how the amplitude frequency and waveform type of a tuning program can be selected to reflect the capabilities of the testing system or the testing requirements Command A tuning program produces a cyclic program command to exercise the waveforms system while you make the initial tuning adjustments A square wave is best because it demands the maximum response of the servo hydraulic system but it may not be suitable for all systems The following describe the different waveform characteristics Square Tapered Square A square waveform requires the servovalve to open and close rapidly It is the most demanding waveform because it requires the maximum response from the servoloop system It also places a large acceleration on the test system and specimen Tapered square waves taper from 0 to 100 amplitude at the beginning of execution and from 100 to 0 at the end of execution e A square waveform is most useful for tuning displacement e A square waveform has an infinite velocity command e Do not use a square waveform when tuning a control mode that uses an extensometer The large accelerations can cause the extensometer to move or fall off the specimen which can cause the system to go unstable 0 8 E E i 2 86 Common Tasks FlexTest SE How to Manually Tune the Control Loop A ramp waveform also called a triangle waveform requires the actuator to move at a constant rate This req
133. ion for specific activities related to using your Controller in the PC supervised mode WHERE TO FIND DOCUMENTATION See PC supervised power up on page 49 in this manual For MultiPurpose TestWare see the Model 793 10 MultiPurpose TestWare manual that accompanies your system This manual also describes how to set up Sequence Counters and Channel Counters For Basic TestWare and the Station Manager s function generator see the Model 793 00 System Software manual that accompanies your system This manual also describes how to set up Test Counters When you assign Exclusive Control to the Controller see this manual When you assign Exclusive Control to Station Manager see the System Software manual that accompanies your system See the Station Manager manual that accompanies your system When booted in the automated mode the Controller cannot apply a software offset or adjust electrical zero regardless of its Exclusive Control status See Appendix C Service Tools in the FlexTest SE Service manual ACTIVITY Powering Up Using Program Command Applications Using Counters Using Manual Control specimen installation Using Compensators Using Auto Zero Moving Files between the Controller and the PC 46 PC Supervised Controllers FlexTest SE N 2 f i i oO 3 o 2 gt ar a 0 gt A Chapter 3 Common Tasks This chapter describes how to perform com
134. iptions N i 2 0 0 3 Tuning How CLC works A CLC control mode uses one input channel to control the servo loop Active P gain while using a second input channel Limiting P gain to restrict the active channel CLC example Suppose you have a 3 cm displacement sensor LVDT an 11 kN force sensor and phasing that produces tension with a positive command oO 0 oO 2 T s i 0 A typical CLC control mode uses displacement as the master channel and force as the limiting channel The upper limit is set to 1 KN and the lower limit is set to 2 kN The specimen is installed in one of the grips As you position the actuator manually with the Dial the specimen moves towards the other grip compression in displacement control When the specimen starts to contact the grip the force increases When force reaches 2 kN and you continue to adjust the control nothing happens The displacement value that caused the force limit is maintained and will not increase After the specimen is gripped and you adjust the Dial for tension the lower limit value ensures the tension does not go beyond 1 KN Guidelines for tuning Command the CLC control mode with the Dial A typical CLC control a CLC mode mode uses displacement as the active channel and force as the limiting channel Note The easiest way to tune a CLC mode is to begin by assigning the proportional gain P
135. is selection to change passwords for tuning calibration and configuration access levels By default passwords are not assigned and you will not be prompted for password validation when changing from one access level to another N i 2 0 0 3 To set passwords use the numeric buttons and enter numbers as desired Access level Operator Passwords Tuning Calibration Configuration 212 Menus Descriptions FlexTest SE Config Config Menu gt Local Settings gt Networking Use this selection to define networking options such as Controller D identification and boot location Networking is necessary for servicing Q the Controller and for operating the Controller in the automated mode i Access level See individual controls Networking Controller ID Controller Name Boot Location Networking Menu ITEM DESCRIPTION Controller ID Specifies the Controller s network identification number Important This setting must be 0 in order for the Controller to operate properly with MTS service tools Access level Configuration Controller Name Specifies the Controller s name By default this value will be the serial number of the Model 493 42 System I O board in the Controller You can change this name as desired Access level Configuration Boot Location Standalone Use to operate the Controller in the standalone mode ensure no network cables are attached to th
136. isplays Log Status Scope and Meters on the Controller screen Note You can also set the position of each panel display in its equivalent menu For instance you can also set the position of the Log panel display in Log gt Placement Access level Operator Panel Placement Log Top Status Bottom right Scope Top Meters Bottom left Selections are Top Right Bottom Left Top Left Top Right Bottom Right Bottom Left 208 Menus Descriptions FlexTest SE Config Config Menu gt Local Settings Use this menu to specify settings that are specific to the Controller and independent of the currently selected hardware interface hwi and configuration file cfg For instance when you select passwords for access levels they apply to any configuration file you load in the Controller oO 0 oO 2 T i 0 When making changes you must save Local Settings gt Save Settings and reboot the Controller before the changes will take effect Access level See submenus and individual controls Local Settings HWI File Config File Regional settings gt Passwords gt Networking gt License Keys gt lt lt Save Settings gt gt lt lt Discard Changes gt gt Local Settings Menu ITEM DESCRIPTION HWI File Config File Specifies the hardware interface file hwi or configuration file cfg that is loaded when the Controller boots in the standalone mode When
137. l is only available for Timed meters Displays the command signal in engineering units This signal can be internally generated by the Controller or externally generated by an analog input Menus Descriptions 191 Station signals ITEM Time Hourly Rollover Time Running Time Output Sensor signals Segment Count Command FlexTest SE Station Signals part 2 of 2 DESCRIPTION Displays the command signal after going through a compensator e Adaptive Compensator in engineering units This does not apply to null pacing If null pacing is used this signal is the same as the command signal Displays the control mode error signal in engineering units This signal shows the difference between the Channel Name Command and the Channel Name Control Mode Name signals Displays the sensor feedback of the active control mode Displays the absolute value of the Error signal in engineering units Absolute means negative becomes positive and positive remains positive This signal is always positive Displays the signal present at the Controller analog input connector Anlg In Displays the signals currently selected by Controller s monitor connectors Monitor 1 2 Displays the signal present at the Controller s analog output connector Meters ITEM Compensated Command Error Active Feedback Absolute Error Anlg In Monitor 1 2 Anlg Out Anlg Out FlexTest SE
138. l of the Controller as shown in the following oO 0 oO 2 T i 0 HWI FILE CFG FILE HPU INDICATOR amp HSM INDICATOR amp POWER TYPE POWER BUTTON FUNCTION BUTTON FUNCTION SELECTION SELECTION HPU Only HPU On Off None Off Off HSM N A N A HPU HSM HSM On On None On Off HSM Only HSM On On None On Off Auto HPU HSM On On HSM None On Off Slave HSM HSM Off Off 1 This selection is available but invalid 2 HPU must be on before HSM can be turned on 3 HSM can be turned on before HPU is turned on Note For more information about hydraulic interconnection see the FlexTest SE Service manual FlexTest SE Menus Descriptions 233 Config Config Menu gt Edit Hardware gt System Options If desired use this selection to enable the velocity limiter option a safety feature designed for CE compliance Access level Configuration N i 2 0 0 3 System Options Velocity Limiter CE System Options ITEM DESCRIPTION Velocity Limiter CE Enables or disables the velocity limiter feature When enabled the velocity limiter feature restricts the rate of actuator movement to 10 mm sec when actuator positioning is performed with the Dial as is typical during specimen installation 234 Menus Descriptions FlexTest SE Config Config Menu gt Set Date Time Use this selection to set the Controller s date and time acc
139. lect to use delta K for calibration of sensors Allows you to specify the amount of delta K applied to the sensor s output signal Equally negative and positive inputs cause asymmetry in the sensor s output signal Delta K compensates for this asymmetry See Cal Type Gain Delta K on page 144 e mwv v Pos Tension Select when a sensor has been calibrated so that a positive output represents actuator retraction tension See Cal Type mv v Pos Tension on page 145 e mv v Pos Comp Select when a sensor has been calibrated so that a positive output represents actuator extension compression See Cal Type mv v Pos Compression on page 147 FlexTest SE Menus Descriptions 1 Setup 9 5 Cal Type Gain Linearization part 1 of 2 A ITEM DESCRIPTION a Pre amp Applies coarse gain to the pre amp element of the conditioner s gain function Post amp Applies fine gain to the post amp element of the conditioner s gain function Total Gain Displays the total gain applied This value is a function of Pre Amp and Post Amp values Entering a total gain value here causes the Controller to enter the Pre amp and Post amp values required to achieve this value Data Range From To Sets the operating range over which the linearization values apply Range is expressed as a percentage of the transducer s fullscale value lt lt Reset gt gt Resets the conditioner and standard values to an perf
140. lows you to update the default panel settings at any time without shutting down or rebooting or changing function generator parameters Default panel settings are automatically restored when you load or reboot the Controller Pressing lt lt Save Panels gt gt saves the current panel settings in an attribute set in the configuration file that is independent of default panel settings Saved panel settings like default panel settings are the settings of the FG Scope Meters and Log menus and the Recall buttons stored in the configuration file Saved panel settings are restored only when you press the lt lt Restore Panels gt gt in the current or subsequent sessions Restores the panel settings that are saved with the lt lt Save Panels gt gt control Moves the Status panel around the display FlexTest SE Status ITEM Span lt lt Shut down gt gt lt lt Reboot gt gt lt lt Save Def Pnis gt gt lt lt Save Panels gt gt lt lt Restore Panels gt gt Placement 180 Menus Descriptions 0 i 2 0 0 3 Scope Note The Scope is an optional feature for the FlexTest SE Controller To obtain this feature contact your local MTS Sales Representative or refer to Technical Support on page 71 oO 0 oO 2 T i 0 processed by the Controller The scope has two formats one for Time and another
141. ls supplied by MTS provide most of the information you will need to use and maintain your equipment If your equipment includes MTS software you should look for README files for additional product information If you cannot find answers to your technical questions from these sources you can use the internet telephone or fax to contact MTS for assistance You can also fill out the Problem Submittal Form that is available on the MTS web site and in the back of many MTS manuals that are distributed in paper form MTS provides a full range of support services after your system is installed If you have any questions about a system or product contact MTS in one of the following ways The MTS web site gives you access to our technical support staff by means of a Problem Submittal Form and a Technical Support link e Problem Submittal Form www mts com gt Contact MTS gt Problem Submittal Form e Technical Support www mts com gt Contact MTS gt Technical Support info mts com HELPLine 800 328 2255 Weekdays 7 00 A M to 6 00 P M Central Time 952 937 4515 Please include an MTS contact name if possible MTS can help you more efficiently if you have the following information available when you contact us for support The site number contains your company number and identifies your equipment type material testing simulation and so forth The number is usually written on a label on your MTS equipment before the system leaves
142. ltage in which the 493 02 chassis can operate is 90 to 264 V AC 32 Introduction FlexTest SE Specifications Rack mounting The Controller can be mounted in an equipment rack When doing so requirements allow a minimum of 2 in 5 1 cm on either side of the Controller for air flow There are no spacing requirements for the top or bottom of the Controller If the equipment rack is equipped with doors allow adequate clearance for the front and rear of the Controller The rear of the Controller requires a minimum clearance of 6 in 15 24 cm to accommodate cables 5 i a iv i FlexTest SE Introduction 33 Specifications i cs i 34 Introduction FlexTest SE Chapter 2 PC Supervised Controllers Contents This chapter describes the PC supervision option for the FlexTest SE Controller With this option the Controller includes a PC equipped with Model 793 00 System Software Basic Description 36 Using the Interfaces 37 Controller interface functions in the automated mode 7 About Exclusive Control 39 PC Supervised Controller Files 43 About passwords and PC supervised controllers 44 About selecting applications for PC supervised controllers 44 About panel settings for PC supervised Controllers 45 About sensor files in PC supervised Controllers 5 Locating PC Supervised Documentation 46 U D 74
143. lve Polarity 4 If necessary clear hydraulic interlocks If the Hydraulic Interlock indicator is lit determine the cause correct it and then press reset If an interlock indicator lights again you will need to determine the cause and correct it before proceeding 5 Apply hydraulic power 6 Check the movement of the actuator to determine servovalve polarity A Enable the front panel Dial B Press the Status button twice to display the Status menu and select Setpoint While observing the actuator use the Dial to slowly apply a positive Setpoint command to the actuator e Ifthe actuator extends when a positive command is applied the servovalve polarity is correct e Ifthe actuator retracts when a positive command is applied and the polarity setting is Normal some electrical element that affects the servovalve such as conditioner polarity or cable orientation has been reversed and should be remedied e Ifthe actuator begins in full retraction and applying a positive Setpoint does not extend it zero the command remove hydraulic pressure and change the servovalve polarity Then retry this test If it still does not move return to Step 2 and increase the gain setting e Ifthe actuator begins in full extension and applying a negative Setpoint does not retract it zero the Setpoint command remove hydraulic pressure and change the servovalve polarity Then retry this test If it still does not move return to Step 2
144. m in a particular block is defined in terms of amplitude and mean or in terms of end level values Block n Specifies the cyclic program that will play out from a particular block See Block n Menu on page 126 FlexTest SE Menus Descriptions 125 Block n Menu DESCRIPTION Specifies the program signal s wave shape as Square Ramp Sine Square Tapered Ramp Tapered or Sine Tapered Tapered shapes will ramp from zero to amplitude when starting and from amplitude to zero when stopping or holding See About Wave Shapes on page 130 Specifies the control mode used when the Function Generator starts Typical selections are force and displacement Absolute The program is relative to zero Relative The program is relative to the starting command value the value when the block begins Mean Specifies the mean value around which the block s cyclic program centers End Level 1 Specifies one of the end levels of the block s cyclic program Amplitude Specifies the amplitude that operates around the specified mean of the block s cyclic program End Level 2 Specifies the remaining end level of the block s cyclic program Sets the frequency of the block s cyclic program Specifies the compensator used by the Function Generator The Compensators that may be available include Null Pacing PVC and PVP See About Null Pacing and compensators on page 161 Specifies the number of segmen
145. me Enabled Type Control Mode Dimension Display Unit Channe lt lt Add Dual Comp gt gt Type Aux Input Dimension Display Unit Type External Command Dimension Display Unit Channe Type Stabilization Fdbk Dimension Display Unit Mode oO 0 oO 2 T s i 0 Anlg In 493 25 493 47 Menus part 1 of 3 DESCRIPTION ITEM Display Name Allows you to customize the default resource name for display purposes True Enables the resource in the current configuration file False Disables the resource in the current configuration file Allocates the selected input resource for the control channel Specifically the feedback from the input resource a 493 25 conditioner 493 47 encoder or an analog input that receives externally conditioned feedback is summed with a command source to drive a servovalve which applies the command to the specimen Selects the appropriate dimension for the sensor associated with the selected input resource Selects your preference in units for the selected dimension Enabled Type Control Mode Dimension Display Unit Channel Selects the valve driver allocated to the control channel Menus Descriptions 219 FlexTest SE Config Use the Dual Comp menu to add a sensor input to the selected control mode for purposes of command compensation This creates a dual compensation control mode in which the compensa
146. menu Saved Panel Settings To CREATE To RESTORE BENEFITS COMMENTS e Press lt lt Save Panels gt gt Press lt lt Restore Panels gt gt This feature allows you to save alternate panel settings that are independent of default panel settings i a iv i Also the saved panel set can be recovered any time in any subsequent session by pressing the lt lt Restore Panels gt gt button In contrast default panel settings are recovered only when you load or reboot the Controller FlexTest SE Introduction 31 Specifications Specifications MTS FlexTest SE Specifications PARAMETER SPECIFICATION Physical Height 13 cm 5 2 in Width 43 cm 17 in Depth 43 cm 17 in Weight 8 6 kg 19 lbs in stand alone configuration Rack mount Compatibility see Rack mounting Standard 48 cm 19 in chassis requirements on page 33 Environmental Ambient temperature 5 C 41 F to 40 C 104 F Relative humidity 10 to 85 non condensing Altitude For use at altitudes up to 2000 m 6500 ft Power Input Power Factor Corrected universal input 5 Input voltage 100 to 240 V AC startup E Input frequency 47 to 63 Hz Input surge lt 50A Operating power V AC 4 2 A gt 360 W Insulation over voltage Category II Pollution degree 2 The specification shown conforms to the CE Low Voltage Directive requirements The specification allows for 10 of the values stated The actual vo
147. mize the risk of equipment damage and to manage test events e Adjust Active and Limiting P gain and associated limits and compensator tuning values to optimize system performance e Note Compensators are typically not used for CLC control modes To create a CLC control mode you must define at least two PIDF control modes and enable the CLC control on the valve driver resource For more information see page 217 Access Level See submenus CLC Error Detectors gt Tuning gt Null Pacing PVC gt PVP gt CLC Control Mode ITEM DESCRIPTION Error Detectors Null See Error Detectors on page 157 Null Pacing on page 160 and PVC Pacing PVC PVP PVP on page 163 Tuning See Tuning controls for a CLC control mode on page 204 FlexTest SE Menus Descriptions 167 Setup Setup Menu gt Dual Compensation Mode This selection is a dual compensation control mode which uses two control modes that operate simultaneously A compensator control mode and a base control mode 0 i 2 0 0 3 The compensator control mode uses secondary feedback from a sensor not typically suitable for PIDF control to provide command compensation and has two tuning controls Conversion Gain and Integration Gain The base control mode receives primary feedback from a sensor that is suitable to maintain PIDF control The naming convention is Compensator control mode B
148. mm If the command is not centered on zero monitor the difference between peaks and valleys of the sensor feedback to the upper and lower levels of the test command Any difference should be the same Note You can also use the optional Scope or an external oscilloscope to adjust Gain by monitoring the Error signal For more information see How to use error to tune Gain on page 116 10 Save your tuning settings Stand Alone Controllers Setup gt Open Save Parameters gt lt lt Save gt gt Automated Controllers On the Station Manger File menu select Save Parameters As You can either select an existing parameter set or enter the name of a new parameter set to save About saving elements It is important that you save your parameter set as you complete of a parameter set the various parts that make up a parameter set Throughout this manual you will be performing discrete procedures while building a single parameter set e Ifyou have already established your default parameter set for the current station and you are creating a new parameter set for a specific test save the parameters with a different name e Different tests and or specimens may require different parameter sets o D 0 0 FlexTest SE Common Tasks 93 How to Manually Tune the Control Loop How to manually tune the force control mode To complete this task you will make sure the force tuning values establis
149. mon tasks such as powering up the Controller warming up hydraulics and tuning the servoloop For each task instructions are provided for stand alone and PC supervised Controllers If you are using a PC supervised Controller read PC Supervised Controllers on page 35 before beginning Also for more information about specific menus and controls refer to Chapter 4 Menus Descriptions How to Power Up the Controller 49 Stand alone power up 9 PC supervised power up 49 Master slave power up 50 How to Use the Front Panel Controls 1 How to change panel positions 1 How to change text 52 How to change numbers 3 How to change the range and display resolution of controls 4 How to select files and items from lists 57 How to use bookmarks 58 How To Warm Up Station Hydraulics 59 How to Set Servovalve Polarity 63 How to Balance the Servovalve 68 How to Adjust Dither 72 How to Perform a Shunt Calibration 79 o D 0 0 Common Tasks 47 Contents FlexTest SE How to Manually Tune the Control Loop 2 About tuning programs 6 Monitoring tuning waveforms 87 How to manually tune the displacement control mode 8 How to manually tune the force control mode 94 How to Perform Advanced Tuning Techniques 1 How to auto tune 1 How to manually tune three stage servovalves 108 How to use error to tune Gain 116 0 8 m E E i o 48 Common Tasks FlexTest SE How to Power Up t
150. move any specimen Apply station hydraulic power Increase Dither Amplitude until you can hear the dither and then decrease Dither Amplitude until the noise goes away Path Setup gt Output gt Dither Amplitude 1 Note Procedures for Automated Controllers assumes the FlexTest SE Controller is equipped with the PC Supervision option and that Exclusive Control is assigned to Station Manager For more information about Station Manager see the Model 793 00 System Software manual that accompanies your system Automated Method 1 In the Station Manager window s toolbar select an access level of Tuning Remove any specimen In the Station Manager window s navigation pane click 4 FlexTest SE Controllers 1 N 8 E E i 2 74 Common Tasks How Adjust Dither 4 In the Function Generator panel set up a tuning program These are typical Function Generator settings For Channel select a channel whose dither needs checking For Control Mode select a displacement mode For Target Setpoint select 0 mm For Amplitude select 5 mm moo gt For Frequency select 0 001 Hz 2 For Wave Shape select Ramp G For Compensator select None Function Generator a 3 Control Mode Displacement Command Type fi Target Setpoint ooooomm EES SSS 5 an d 150 0000 150 0000 1 TT eT 0 0000 150 0000 1 1 1 1 1 4
151. n control displays the current application selected to provide program control To select a different application use the Application control in the Status menu 0 6 74 a 5 O i 2 0 FlexTest SE PC Supervised Controllers 37 Using the Interfaces Controller interface in the automated mode part 2 of 3 MENU CONTROL FUNCTION Status menu Fully functional The Application control lists the applications available from Station Manager which can provide program command for the Controller Typical applications that are available include Station Manager function generator Basic TestWare and MPT MultiPurpose TestWare e The Station Manager selection chooses the Station Manager s on board function generator The function generator allows you to create simple program command without data acquisition The function generator is suitable for simple programs and exercising the actuator prior to testing This selection is similar to the FlexTest SE s FG menu e The Basic TestWare application allows you to create more complex program command with basic data acquisition e The MPT application allows you to create very complex program command with sophisticated data acquisition options Scope panel and menu Fully functional Meters panel and menu Fully functional Tuning panel and menu Disabled To change tuning parameters of the current configuration file use the S
152. nal devices When the Controller is used in the automated mode with the MultiPurpose TestWare application a digital output can signal an external device that an event has occurred in your test oO 0 oO 2 T i 0 Access level Configuration Monitor Anlg Out Dig In Dig Out Display Name Enabled Mon n Anlg Out Digital Input n Digital Output n Menus ITEM DESCRIPTION Display Name Sets the display name of the resource Enter as desired Enabled Enables or disables the resource in the current configuration FlexTest SE Menus Descriptions 225 Config Config Menu gt Edit Hardware Use this menu to modify hardware settings by changing resource attributes in the hardware interface hwi file For instance with the Edit Hardware menu you can change the sensor excitation of Model 493 25 conditioners from DC which is used by force sensors such as load cells to AC which is used by displacement sensors such as LVDTs When you make changes to the controls in this menu you are literally editing the equivalent portion of the associated hwi file If you change the conditioner mode with this control and save your changes you would see the same change if you opened up and examined the associated hwii file You can modify any hardware interface file hwi including the file that is currently running If you are modifying the currently running hardware interface file you must save your
153. nce Access Level See individual controls Offset Zero lt lt Auto Offset gt gt Manual Offset lt lt Auto Zero gt gt Electrical Zero Electrical Zero Lock Offset Zero DESCRIPTION Automatically zeroes the conditioner s output to the current value by applying a software offset Access Level Operator Permits manual application of a software offset to the conditioner s output Access Level Operator Automatically zeroes the conditioner s output to the current value by adjusting the conditioner s electrical zero Access Level Operator Note The Auto Zero and Electrical Zero controls are not available for the active control mode when hydraulic pressure is on Permits manual adjustment of the conditioner s electrical zero Access Level Operator Lock Disables the Auto Zero and Electrical Zero controls preventing changes to the conditioner s electrical zero Unlock Enables the Auto Zero and Electrical Zero controls allowing changes to the conditioner s electrical zero Access Level Calibration Menus Descriptions ITEM lt lt Auto Offset gt gt Manual Offset lt lt Auto Zero gt gt Electrical Zero Electrical Zero Lock FlexTest SE Setup About software offset With the software offset controls Auto Offset and Manual Offset you can zero the conditioner s output without shifting the conditioner s electrical zero reference You can apply the soft
154. ncy e The frequency decreases to the minimum frequency value 20 of the original frequency The command is then held at this frequency as long as the error remains out of tolerance This condition is also known as low cycle 162 Menus Descriptions FlexTest SE 0 i 2 0 0 3 Setup Setup Menu gt PIDF Control Mode PVC PVP PVC Use this selection to define Peak Valley Control PVC compensation parameters See About PVC on page 165 for more information PVP Note Peak Valley Phase compensation PVP an optional feature for the FlexTest SE Controller To obtain this feature contact your local MTS Sales Representative or refer to Technical Support on page 11 0 oO 2 T i 0 Use this selection to define Peak Valley Phase PVP compensation parameters See About PVP on page 166 for more information Access Level Tuning control mode Calibration gt Offset Zero gt Limits Error Detectors Tuning gt Null Pacing PVC gt PVC PVP PVP gt Convergence Rate Sensitivity Adaptation State lt lt Reset gt gt FlexTest SE Menus Descriptions 163 PVC PVP Menu DESCRIPTION Sets how quickly compensation values are applied to converge the feedback and command signals Larger values cause faster adaptation but values that are too large result in instability and failure of the adapt
155. nds accurately to the command and improves the performance of your test system You can tune PIDF and CLC control modes manually from the Manual submenu and PIDF control modes automatically from the Auto submenu For information about how to tune a PIDF control mode see How to auto tune on page 101 and How to Manually Tune the Control Loop on page 82 Access level Tuning Tuning Manual gt Auto gt Tuning gt Manual This menu contains controls that can be manually adjusted when tuning PIDF and CLC control modes The controls available depend on the control mode selected for instance PIDF control modes have different tuning controls than CLC control modes 194 Menus Descriptions FlexTest SE Tuning Tuning controls for a PIDF control mode The following menu applies to PIDF control modes with typical labels such as Force Displacement or Strain For information about tuning a CLC control mode see Tuning controls for a CLC control mode on page 204 oO 0 o oO 2 T i 0 Manual Base Control Mode FG gt P Gain Gain F Gain FL Filter Filter Type Frequency Bandwidth Stabilization Filter Manual PIDF Tuning Controls part 1 of 3 ITEM DESCRIPTION Control Mode Selects the control mode to tune A Proportional Integral Derivative Feed Forward PIDF control mode uses one input channel such as force or displacement t
156. ne select force A WARNING Pressing the Run button will put the actuator in motion A moving actuator can injure anyone in its path Always clear the actuator area before pressing the Run button 4 Press Run to start auto tuning The Controller displays the following The Mode to Tune Force is not the control mode which will be active during auto tuning Ensure that the lt lt OK lt lt active Control Mode is tuned prior to proceeding If the selected Modeto lt lt Cancel gt gt Tune requires feedback from a specimen ex Force T orque Strain ensure that 3 specimen is mounted Press lt lt OK gt gt to continue auto tuning or lt lt Cancel gt gt to abort auto tuning Press lt lt OK gt gt if you have tuned the channel s displacement mode and installed a specimen 0 8 m E E i o 106 Common Tasks FlexTest SE How to Perform Advanced Tuning Techniques Then the Controller starts auto tuning and displays the following Auto Tuning in Progress To terminate auto tuning before completion press lt Stop gt When auto tuning is complete the Controller displays Auto Tuning for this mode has completed successfully Also when auto tuning is complete the results are displayed showing Current tuning values and Reference values Press Accept to apply the Reference values Save the auto tuning values Path Setup gt Open Save Paramet
157. nfig Menu gt Edit Hardware gt 493 47 S n J n Use this selection to match the type of encoder supplied with your test system to the types supported by Model 493 47 encoders Access level Configuration 493 47 Mode Incremental 493 47 S n n Menu ITEM DESCRIPTION Mode Select the type of encoder supplied with your test system from the following e Teledyne e Incremental e Tempo III 24 Bit e Tempo III 25 Bit 230 Menus Descriptions FlexTest SE Config Config Menu gt Edit Hardware gt 493 14 VD S n J7 Use this selection to set the Model 493 14 valve driver to support a single or dual servovalves Note Model 493 15 three stage valve driver resources do not have editable attributes and are not displayed in the Edit Hardware menu oO 0 oO 2 T i 0 Access level Configuration 493 14 Mode Single 493 14 VD S n J7 Menu ITEM DESCRIPTION Mode Sets the type of servovalve support provided by the valve driver Single Supports a single servovalve configuration Dual Supports a dual servovalve configuration FlexTest SE Menus Descriptions 231 Config 9 z Config Menu gt Edit Hardware gt Power Options 5 Use this selection to choose appropriate hydraulic power unit HPU and hydraulic service manifold HSM options for your Controller 9 5 T Access level Configuration Power Options Power Type HPU HSM HSM Type Solenoid Power
158. ng the next session Once in the next session the panel view saved when you pressed lt lt Save Panels gt gt in the previous session can be restored by pressing the lt lt Restore Panels gt gt FlexTest SE Front Panel Controls Panel views Introduction 20 i gt 3 b 5 i a iv i Front Panel Controls Menu buttons Each menu button pertains to an activity you perform with the Controller or to a general function as described below Note The FG Setup Tuning and Limits menus are not available for Controllers in the automated mode For more information see PC Supervised Controllers on page 35 Note For menu displays that pertain to stand alone Controllers refer to Appendix B Menu Summaries Menu Function part 1 of 2 DESCRIPTION The FG menu defines program command You can select from monotonic cyclic and external command program types With the Advanced FG option Sweep and Block cyclic programs types are also available For a description of FG menu controls see page 120 The Setup menu assigns attributes to the parameter set associated with the loaded configuration and manages parameter sets A parameter set defines the operational characteristics of the resources in the configuration such as calibration tuning and limit settings For a description of Setup menu controls see page 132 The Status panel displays general
159. nment 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 Date Format Selects the format in which the date stamp is displayed on the message log Select M D Y D M Y or D M Y Appearance examples M D Y 4 24 2002 D M Y 24 4 2002 D M Y 24 4 2002 Time Format Selects the format in which the time stamp is displayed on the message log Select 12 hour or 24 hour Appearance examples 12 hour 6 31 23 AM 24 hour 18 21 23 FlexTest SE Menus Descriptions 211 Config Config Menu gt Local Settings Passwords Use th
160. ns that it anticipates the feedback signal s rate of change and slows the system s response at high rates of change 0 i 2 0 0 3 pe Overshoot a Ringing Needs D Gain Optimum D Gain Too Much D Gain Excessive D Gain e D Gain reduces ringing e D Gain provides stability and reduces noise at higher P Gain settings e D Gain tends to amplify noise from sensors e D Gain tends to decrease system response when set too high e Too much D Gain can create instability at high frequencies e Excessive D Gain may cause a ringing or screeching sound e Too little D Gain can make a rumbling sound The correct amount of D Gain results in the system running quietly e Series 256 and 257 Servovalves require D Gain on both inner and outer control loops 200 Menus Descriptions FlexTest SE Tuning Feed Forward Gain Feed forward F Gain introduces a derivative of the command signal F Gain It anticipates how large a valve opening is needed to reach the required response and adds that to the valve command like compensating for phase lag Adjusting F Gain causes the command signal to start sooner This causes the Original Command feedback signal to track the original 4 command signal more closely Command with F Gain oO 0 oO 2 T i 0 N Original Feedback e F Gain does not compensate for normal changes during testing such as tempe
161. nsor Enter new name Polarity Dual Mode Sensor gt lt lt Open gt gt Gain Monitor n gt lt lt Save gt gt Offset Aux Input 1 gt lt lt Delete gt gt Analog Out gt Aux Input n Stabilization gt Output single valve Calibration Digital Input n Polarity Offset Zero gt Digital Output n Valve Balance Limits gt Dither Amplitude Dither Frequency Stabilization Calibration gt Sensor Offset Zero gt Calibration Limits gt Offset Zero Limits Digital Input n Error Detectors gt State Tuning gt Trigger Null Pacing gt Action PVC gt PVP gt Digital Output n State FlexTest SE Dual Mode Sensor Error Detectors gt Null Pacing PVC gt PVP gt Dual compensation gt 132 Menus Descriptions 0 oO 2 T s i 0 Setup Setup Menu gt Open Save Parameters Use this menu to create load save and delete parameter sets Select an existing or new parameter set with the Select Existing Name or Enter New Name controls then choose the desired operation with the appropriate trigger lt lt gt gt control Note After entering a new name for an existing parameter set be sure to press the Enter button on the face of the Controller Access Level Operator Open Save Parameters Select existing name Enter new name lt lt Open gt gt lt lt Save gt gt lt lt Delete gt gt File Menu DESCRIPTION Allow
162. ntrollers 45 panel view sets 30 panel views 20 parameter set 30 parameter sets 30 Passes in a block cyclic program 125 passwords and PC supervised controllers 44 PC supervised power up 49 PC supervision 35 Peak Valley Control PVC compensation 165 Peak Valley Phase PVP compensation 166 Peak Valley Compensation PVC about 165 peak valley meters 194 PIDF 17 Polarity 135 Power controls 28 prerequisites creating a parameter set 30 Preset Count 122 pressure differential 202 Previous button 25 Previous Next 17 Program controls 28 Program Interlock 28 Proportional gain about 198 FlexTest SE FlexTest SE W warm up procedure 59 79 Wave shapes ramp 130 ramp tapered 131 sine 130 sine tapered 131 square 130 square tapered 131 waveforms 86 87 areas of interest 87 monitoring 87 Z zero offset conditioner zero 150 shift conditioner electrical zero 151 station parameter set creating 30 overview 30 Status menu 21 Sweep Settings of a sweep program 127 switching Exclusive Control between interfaces 40 system hydraulics warm up 59 79 T tapered wave shapes 131 Target Setpoint 122 127 Total Count 123 tuning auto tuning 101 compensation 82 creating a program 86 Derivative gain about 200 displacement 88 dither about 72 Feed Forward gain about 201 force control modes 94 forward loop filter about 203 guidelines 83 inner loop 108 Integral gain about 198 monitoring wav
163. o Zero the Spool Position Signal in your Controller Service manual for a detailed procedure Complete this procedure then recheck spool position voltages at each endcap before you resume inner loop tuning C Return Polarity to its original setting 0 8 E E i 2 112 Common Tasks FlexTest SE How to Perform Advanced Tuning Techniques 8 Monitor the spool position signal with a scope Stand Alone Controllers Press Scope to monitor the spool position signal Automated Controllers A In the Station Manager window s toolbar click S once to display a single Scope window to open the Setup B Inthe Scope window s toolbar click 5 for Scope window 9 Open the function generator application Stand Alone Controllers Select FG and select the following settings to set up a tuning program Automated Controllers In the Station Manager window s navigation pane click SETTING Cyclic Square displacement 0 mm 50 of full scale 1 Hz None o D 0 0 Common Tasks 3 CONTROL Type Wave Shape Control Mode Target Setpoint Amplitude Frequency Compensator FlexTest SE How to Perform Advanced Tuning Techniques 10 Start the function generator Stand Alone Controllers Press Run to start the displacement command Automated Controllers In the Station Controls panel click to start the Function
164. o control the servo loop For detailed information about individual PIDF controls see About PIDF tuning controls on page 198 FG Displays the various Tuning FG controls you use to create simple command waveforms required for manual tuning P Gain Proportional P gain is used for all tuning situations It introduces a control factor that is proportional to the error signal Proportional gain increases system response by boosting the effect of the error signal on the servovalve Gain Integral D gain introduces an integral of the error signal that gradually over time boosts the low frequency response of the servovalve command Integral gain improves mean level response during dynamic operation and corrects feedback droop caused by the spring characteristic of the servovalve in static and very low frequency test programs FlexTest SE Menus Descriptions 195 Manual PIDF Tuning Controls part 2 of 3 DESCRIPTION Derivative D gain is used with dynamic test programs It anticipates the rate of change of the feedback and slows the system response at high rates of change Derivative gain reduces ringing and provides stability and reduces noise at higher proportional gain settings Feed forward F gain is like derivative gain except that it anticipates how much valve opening is needed to reach the required response and augments the valve command like compensating for phase lag Feed forward gain is needed w
165. o the valve driver Note Acceleration stabilization works to minimize compliances from swivels linkages test tables etc FlexTest SE Tuning Delta P AP stabilization Acceleration stabilization 202 Menus Descriptions N i 2 0 0 3 Tuning Forward Loop Filter Forward loop filter FL Filter adjustments compensate for noise in the FL Filter setvoloop which usually comes from sensor feedback FL Filter adjustments establish a frequency bandwidth for the servoloop command signal oO 0 oO 2 T s i 0 Needs FL Filter D Gain Amplifies Noise FL Filter Removes Most Noise By default the FL Filter is set to one half the system rate e The minimum FL Filter setting is 0 01 e Ensure the FL Filter is set higher than any frequency in the test program e Systems with moving load cells or heavy grips can produce a noisy force signal e Ifyou observe a noisy sensor feedback signal reduce the FL Filter setting to about 100 provided your test does not reach 100 Hz If additional adjustment is needed reduce the setting in five to ten Hz increments FlexTest SE Menus Descriptions 203 Tuning Tuning controls for a CLC control mode The following menu applies to CLC control modes Note The CLC control mode uses the first two contro modes you create in the configuration file The first control mode you create becomes the master channel typi
166. o your system Stay clear of the actuators when applying hydraulic pressure 3 Turn on hydraulic pressure Stand Alone Controllers A Inthe Power section press Low and then High for the HPU If an HPU is not listed start the HPU at the pump Note The HPU can be configured for first on If this is the case start the appropriate HSM B If an HSM is present click Low and then High for the HSM Automated Controllers A In the power selection box click Low and then High for the HPU If an HPU is not listed start the HPU at the pump Note The HPU can be configured for first on If this is the case start the appropriate HSM B Ifan HSM is present click Low and then High for the appropriate HSM 4 Ensure that the displacement control mode is selected Stand Alone Controllers Press the Back button or select Tuning gt Manual gt Control Mode Automated Controllers On the Manual Command window ensure that displacement is selected for Control Mode 0 8 m E E i o 96 Common Tasks FlexTest SE How to Manually Tune the Control Loop 5 Install a dummy specimen Stand Alone Controllers A Enable the Dial B Adjust the Dial to position the actuator during specimen installation Automated Controllers A On the Manual Command window Click Enable Manual Command B Adjust the Manual Command window slider to position the actuator during specimen in
167. oes from a low state to a high state or from a high state to a low state Channel Low Triggers when the channel goes low and remains triggered as long as the channel stays low Channel High Triggers when the channel goes high and remains triggered as long as the channel stays high None Disables the Action FlexTest SE ITEM State Trigger 174 Menus Descriptions 0 i 2 0 0 3 Setup Note All Actions except Disabled write a message to the Log Digital Input Menu part 2 of 2 0 ITEM DESCRIPTION 2 9 Action Sets a trigger response S e Disabled No action occurs e Indicate Writes a message to the Log e Station Power Off Clamps the servovalve turns off pressure at the hydraulic service manifold HSM and stops any program e Interlock Turns off pressure at both the HSM and hydraulic power supply HPS and stops any program command e Program Interlock Stops any program command but does not turn off station hydraulic pressure e Program Stop Stops any program command Produces the same action as clicking the Stop button on the Program panel e Program Hold Places a hold on any program command Produces the same action as clicking the Hold button on the Program panel FlexTest SE Menus Descriptions 175 Setup Setup Menu gt Digital Output n Use this selection to define when the Controller transmits digit
168. oller s flash disk memory When a Controller operates in the automated mode panel settings are saved in a separate view set file View set files have the same name as the associated configuration file but have a cfv extension instead of a cfg extension View set files are stored in the flash disk memory of the Controller When you use the save or restore panel controls in the Status menu the view set file updates the associated configuration file which is stored in the PC About sensor files in PC supervised Controllers A sensor files stores calibration data that pertains to a sensor conditioner pair and has an scf extension You create sensor files with Station Manager when calibrating your system and sensor files are stored with the associated configuration file When you boot the Controller in the automation mode and use it with PC supervision it can open configuration files that include sensor files When you boot the Controller in the stand alone mode you cannot open configuration files that include sensor files If you attempt to open a configuration file that includes sensor files the Controller will display an error message FlexTest SE PC Supervised Controllers 45 D 7e a D 5 O 2 gt 0 Locating PC Supervised Documentation Locating PC Supervised Documentation The following table describes where to find documentat
169. olution number or digits and dimension To adjust these parameters you must access the control s Display Parameters menu by pressing and holding the Menu Item button next to the control For instance to change the display parameters for the Setpoint control 1 Press the Status button twice to display the Status menu 2 Press and hold the Menu Item button next to Setpoint to bring focus to it 3 Note the Setpoint value 4 Press and hold the Menu Item button next to Setpoint to display the Display Parameters menu See the figure below for an explanation of each control in the menu For more information see More about the Display Parameters menu on page 55 5 Change the values as desired 0 8 m E E i o 54 Common Tasks FlexTest SE How to Use the Front Panel Controls Minimum and Maximum These values determine the control s range of adjustment Status Setpoint Minimum 10 5 mm Maximum 70 5 mm Resolution 0 00 mm Formatting lt Formatting Determines the number of digits used to display the range and control Display Unit a T values Display Unit Defines the dimension in which the control value is displayed Resolution Defines the smallest unit with p which you may adjustments to the control Access Level Calibration Application FG Control Mode Disp _ 2 6 mm Span 100 00 gt lt lt Shut down gt
170. om the main spool while maintaining pressure at the pilot stage This prevents interaction between the inner and outer loops 108 Common Tasks FlexTest SE 0 8 m E E i o How to Perform Advanced Tuning Techniques The hydraulic fluid and the servovalve should be at operating temperature See How To Warm Up Station Hydraulics on page 59 Command compensators should be turned off The specimen should be removed Remove hydraulic pressure from the main spool A Remove hydraulic pressure B Disconnect the HSM control cable at the back of the FT SE Controller chassis from connector J28 Disconnecting this cable disables pressure to the main spool but leaves pressure applied to the pilot stage of the servovalve 1 2 Apply hydraulic pressure Note Procedures for Automated Controllers assumes the FlexTest SE Controller is equipped with the PC Supervision option and that Exclusive Control is assigned to Station Manager For more information about Station Manager see the Model 793 00 System Software manual that accompanies your system 3 Select an access level of Tuning Stand Alone Controllers Config gt Access Level gt Tuning Automated Controllers In the Station Manager window s toolbar select an access level of Tuning Set the following valve drive conditioner parameters Stand Alone Controllers Setup gt Output gt Conditioner Automated Controllers In the
171. on Tasks 87 What to monitor You do not need to monitor the entire waveform Instead zoom in on the area of interest FlexTest SE How to Manually Tune the Control Loop How to manually tune the displacement control mode A displacement control mode uses the feedback signal from an LVDT dinear variable differential transformer You do not need a specimen to tune a displacement control mode When to tune A displacement control mode typically needs to be tuned only when recalibrated However you may want to retune the displacement control mode if e The fixtures attached to the actuator have changed such as grips The main tuning factor is a change in the mass attached to the actuator e Any time hydraulic system potential has changed such as after servovalve hose or pump replacement e You want to fine tune the control mode e The sensor range has changed e You feel system response should be improved or reduced Prerequisites Be sure the following conditions are present before you begin tuning the displacement control mode e Hydraulic pressure is off e The specimen is not installed 0 8 E E i 2 88 Common Tasks FlexTest SE How to Manually Tune the Control Loop Procedure This basic displacement tuning procedure should work for most applications consider it a guideline You should be familiar with the background information presented in this chapter so you can modify the
172. on to display the Config menu 2 Press the Menu Item button next to the Panel Placement control to display its submenu which lists all the panels and position settings 3 Change each position as desired FlexTest SE Common Tasks 51 How to Use the Front Panel Controls How to change text Some tasks such as entering license keys and parameter set names require that you enter text To do this 1 Press the Menu Item button next to the field in which you wish to enter text to select it 2 Press the Dial s Enable button this will highlight the text field 3 Slowly rotate the Dial until the desired letter is displayed 4 Press the Increment button to the upper left of the Dial to enter the desired letter or number 5 Repeat steps 3 and 4 as required 6 Press enter Controls used to enter and edit text CONTROL EFFECT ON TEXT Dial Scrolls through characters Backspace Deletes one character to the left Increment Shifts the text entry cursor one position to the right Decrement Shifts the text entry cursor one position to the left cancel Reverts to the saved text string Menu Item button Once the text entry field is highlighted pressing the Menu Item button next the field toggles the character display from lowercase to uppercase for instance a to A 0 8 E E i 2 52 Common Tasks FlexTest SE How to Use the Front Panel Controls How to change
173. oop signals 1 Connect a service calibration cable package MTS part number 100 026 213 to connector J3 Service on the I O carrier module 2 Connect a DVM or oscilloscope to the appropriate BNC Output Channel on the service cable depending on which slot the valve driver occupies in the I O Carrier module 3 Select Setup gt Output gt Service Port Output 4 From Service Port Output select one of signals described in the Service Port Output Signals list FlexTest SE Menus Descriptions 137 Setup Setup Menu gt PIDF Control Mode This selection with labels such as Displacement Force or Strain is a PIDF control mode which is the typical control mode used for testing With the associated menu you can e Adjust the calibration settings of the control mode s sensor conditioner pair to ensure measured and actual variables are the same e Adjust the software zero for convenience and the electrical zero to compensate for changes in sensor s calibrated output e Set up limits error detectors and limit detectors and actions to minimize the risk of equipment damage and to manage test events e Adjust PIDF and compensator tuning values to optimize system performance To create a PIDF control mode you must allocate an input resource to receive sensor feedback For more information see page 218 Access Level See submenus control mode Calibration gt Offset Zero gt
174. opping Disable Uses 100 of the external command to be applied and removed when starting and stopping Note You cannot vary the taper times of soft start and stop ramps created with the Controller However when operating in the automated mode the Controller will accept customized taper times created by other applications Specifies the compensator used by the Function Generator The Compensators that may be available include PVC and PVP FlexTest SE ITEM Control Mode Target Setpoint Soft Start Stop Compensator 124 Menus Descriptions 0 i 2 0 0 3 FG FG Menu gt Block Cyclic Note Block Cyclic and Sweep programming capabilities are included in the optional Advanced FG feature for the FlexTest SE Controller To obtain this feature contact your local MTS Sales Representative or refer to Technical Support on page 71 oO 0 oO 2 T i 0 Use the Block cyclic selection to create repeating blocks of program command Block Cyclic Passes Level Type Block 1 gt Block n Block 2 Wave Shape Block 3 Control Mode Block 4 gt Mean End Level 1 Amplitude End Level 2 Frequency Compensator Count Block Cyclic Menu ITEM DESCRIPTION Passes Specifies the number of times in which all of the blocks will play out in series To repeat continuously enter 0 Level Type Specifies whether the cyclic progra
175. ording to the format selected in Config Menu gt Local Settings gt Regional Settings See Date Format and Time Format on page 211 oO 0 oO 2 T i 0 Access level Operator Set Date Time Month Day Year Hour Minute Second lt lt Set gt gt Set Date Time Menu ITEM DESCRIPTION Date Month Selects the month of the year Day Selects the day of the month Year Selects the year Time Hour Selects the hour of the day 24 hour format Minute Selects the minute of the hour 0 59 Second Selects the second of the minute 0 59 lt lt Set gt gt Sets the date entries in the Controller s memory Config Menu gt Service Tools This menu contains tools to assist MTS service personnel with updating troubleshooting and calibrating the Controller Access level Operator Service Tools Automated Calibration Service View Files gt FlexTest SE Menus Descriptions 235 Config Config Menu gt Service Tools Automated Calibration Service This selection is for MTS service personnel to assist with calibrating the Controller with MTS proprietary software tools Access level Operator N i 2 0 0 3 Automated Calibration Service Activate Serial Port Control Mode Automated Calibration Service Menu ITEM DESCRIPTION Activate Serial Port Enables the Controller s serial port to communicate with a PC equip
176. ou do not need to adjust the dither amplitude If the feedback signal shows a jagged ramp caused by the actuator sticking before moving continue on to the next step to adjust the dither amplitude 9 In the Station Manager window s Display menu select Station Setup 10 In the Station Setup window navigation pane s Channels locate and select the channel whose servovalve dither you want to adjust 11 In the Station Setup window click Three stage valves In the Drive panel click the Valve tab Increase Dither Amplitude until the feedback is smooth If you hear an unusual sound coming from the servovalve the dither amplitude is set too high gt Station Setup 1 gt ftse cfg gt OP x Station Drive Ch Disp E Channels 493 14 2 Stage Valve Er Ch Fullscale Min Max 2 E a Force a E ae Y Polarity H Readouts 6 Normal C Invert EF Ausiliary Inputs ad Station Signals 42 C TE E Digital Inputs 10 000 10 000 Detectors A Remote Setp J r a o D 0 0 FlexTest SE Common Tasks 77 How to Adjust Dither Method 2 1 In the Station Manager window s toolbar select an access level of Tuning 2 Remove any specimen 3 Apply station hydraulic power 4 In the Station Manager window s Display menu select Station Setup 5 In the Station Setup window navigation p
177. own An unstable system produces humming or screeching sound A system shutdown displays an error e Ifan adjustment causes the system to go unstable quickly readjust the control until the noise stops If you cannot eliminate the sound shut down the system by pressing the Emergency Stop button e Ifan adjustment causes the system to shut down readjust the control to the level where the system was last stable Then reset the system and continue tuning Saving tuning The tuning values are saved as part of the parameter set The parameters parameter set can save one set of tuning values for each control mode o D 0 0 FlexTest SE Common Tasks 83 How to Manually Tune the Control Loop Recognizing when Tuning is needed whenever any of the following events occurs tuning is necessary e A gross change in the compliance or size of the test specimen For example you were testing steel and change to rubber e The servohydraulic configuration has changed For example a servovalve is replaced or changed to a different capacity e The system is sluggish slow to react or not reaching the desired peaks However this is not always a tuning problem it could be insufficient velocity capability such as a low capacity servovalve e Ifa control channel or sensor is recalibrated e The system is unstable indicated by a humming or screeching sound e When you observe poorly controlled accuracy e
178. ped with MTS service tools Control Mode When the serial port is enabled allows MTS service personnel to switch control modes to facilitate automated calibration 236 Menus Descriptions FlexTest SE Config Config Menu gt Service Tools gt View Files This selection is for MTS service personnel to view the content of system files used by the Controller including hardware interface files Chwi unit definition files udf unit assignment sets uas and configuration files cfg oO 0 oO 2 T s i 0 Access level Operator View Files ftse hwi gt sysunit udf gt siset uas gt ftse3 cfg gt 5 d ftim ftse hwi Both processor entries are needed for single processor systems PROCESSOR ADDRESS 0xC8000000 SLOT 1 FUNCTION SUPERVISOR PROCESSOR NUMBER 0 INTERRUPT LEVEL 2 FILENAME sup o PORT ETHERNET IP ADDRESS 148 150 203 8 PROCESSOR ADDRESS 000000 SLOT 1 FUNCTION CONTROL View File Example FlexTest SE Menus Descriptions 237 Note This menu is available only when you boot the Controller in the Stand Alone mode Config gt Local Settings gt Networking gt Boot Location When booted in the Automated mode and used with PC supervision this menu is disabled Use Station Manager to set limit and error parameters The Limits button toggles between two types of limit summary panels Limits and Errors Each panel displays
179. peration may require a level of detuning to accommodate specimen changes during a test e A highly tuned system provides the greatest level of response but this places the system near the point of oscillation or instability e As a specimen changes characteristics during testing the response of the system also changes This can cause unstable operation e You may need to retune the system response when the characteristics of the specimen change during a test e For the greatest control accuracy use a control compensator N 8 E E i 2 82 Common Tasks FlexTest SE How to Manually Tune the Control Loop If you ve never If you are unfamiliar with the tuning controls review the following tuned before guidelines Before you start tuning your system manually you should e If your Controller is equipped with the optional auto tuning feature auto tune your system before manually tune it e Define upper and lower limits for the displacement and force sensors before you start tuning e Tune the displacement control mode first since no specimen is needed e Note the value of the tuning control before adjusting it so you can return it to that value if necessary e Make small initial tuning adjustments If the waveform does not appear to change increase the adjustments What If you adjust If you make an inappropriate adjustment the system will go unstable y pprop y 8 something wrong or shut d
180. placement menu select Offset Zero 3 If necessary in the Offset Zero menu set the Electrical Zero Lock control to Unlock 4 In the Offset Zero menu click lt lt Auto Zero gt gt Using Electrical Zero If you want to shift the conditioner s electrical zero manually use the Electrical Zero control FlexTest SE Menus Descriptions 153 Setup Setup Menu gt PIDF Control Mode Limits Use Limits to set the feedback signal s limit values and specify the Controller s response if these limits are exceeded You can use limits to 0 i 2 0 0 3 e Minimize the risk of injury to yourself and damage to the specimen and test equipment while installing the specimen e Indicate when sensor levels that you define are detected e Stop the test automatically when defined sensor levels are detected Access Level Operator control mode Calibration gt Offset Zero gt Limits Limits Lower Limit Lower Action Upper Limit Upper Action 154 Menus Descriptions FlexTest SE Setup Lower Action Limits Menu 0 SSS eee ITEM DESCRIPTION fz Lower Limit Sets the lower limit that the feedback signal must cross to trigger the 5 a The adjustment range equals 130 of the selected range s full scale Actions Adjusts the Controller s response when a Limit trips Note All actions except Disabled write a m
181. pressing the Increment button once would result in a Setpoint display of 1 50 because even though the value was increased by one point of resolution the displayed value will not reflect that increase until pressed ten times Unless the Formatting number is less than the number of digits required to express the whole numbers in those values For instance if the maximum range is 100 and you enter a formatting number of 1 the maximum range is still displayed as 100 0 8 E E i 2 56 Common Tasks FlexTest SE How to Use the Front Panel Controls How to select files and items from lists Many menu items contain a list of selections and some menu items serve as file viewers allowing you to browse file names In both cases you can scroll through the available items with the Dial Increment Decrement and Menu Item buttons as follows Using the Dial 1 Press the Menu Item button next to the desired menu item to bring focus to it 2 Press the Enable button to enable the Dial The Enabled indicator lights 3 While observing the menu item rotate the Dial to scroll through the list as desired Using the Increment 1 Press the Menu Item button next to the desired menu item to Decrement buttons bring focus to it 2 Press the Increment Decrement buttons to scroll through the list as desired Using the Menu Item 1 Press the Menu Item button next to the desired menu item to buttons bring focus to it
182. r Exclusive Control Exclusive Control in the Disabled 1 Controller s Status menu Application Control Mode Disp Setpoint 0 0000 cm lt lt Save Def Pris 4 To perform some activities you may have to switch from one interface to another For instance suppose you have assigned exclusive control to the Controller and use it to apply hydraulic pressure to the station and position the actuator with the Dial to install the specimen In this case to zero out the tare weight of the specimen you would have to switch to the Station Manager interface where zero controls are always active and perform zeroing there In general if you assign exclusive control to Station Manager you will switch between interfaces less often than if you assign exclusive control to the Controller FlexTest SE PC Supervised Controllers Using the Interfaces Location of Exclusive Control in the Station Manager Location of Exclusive Control on the Controller Switching between interfaces 40 N ES 5 2 gt a 6 A Using the Interfaces How exclusive control The table below describes how assigning exclusive control to either affects the interface interface affects the controls on both interfaces Effects of Exclusive Control on Program and Power Controls part 1 of 2 MENU CONTROL FUNCTION Program Control buttons When exclusive cont
183. rature changes and servovalve droop e F Gain can be used to minimize phase lag e F Gain should be used like D Gain However F Gain applies to the test command signal while D Gain applies to the feedback signal e F Gain gain helps the servocontrol loop react quickly to an abrupt change in the command signal e F Gain is needed when testing a soft specimen in force control Stabilization gain S Stabilization gain allows a second signal to be integrated into the control mode as a stabilizing factor The S Gain enhances stability for systems that move large masses at high speeds The input to the stabilization gain is usually a dynamic input signal such as e AP differential pressure e Acceleration Note This control will be available only if a stabilization resource was added when the station configuration file was created Most systems do not need stabilization gain FlexTest SE Menus Descriptions 201 Delta P is a differential pressure sensor that measures the difference in pressure at each end of the actuator It compensates for hydraulic compliance compressed hydraulic fluid acts like a spring Delta P improves displacement control of heavy mass loaded systems Delta P is typically used on systems with large hydraulic fluid flow rates This adjustment is usually needed when the natural frequency of the actuator is less than the 90 phase lag frequency of the servovalve The servovalve 90 phase lag frequency can b
184. rforms fine high resolution changes to conditioner s zero reference Bridge Balance Typically used with strain gages this control applies a bridge balance to offset any resistance imbalance in the sensor that would saturate the conditioner output at the strain gage s null position Zeroes the sensor signal and makes the current output the new zero reference Applies a fine zero high resolution offset to the sensor s output signal See Shunt Calibration on page 148 Menus Descriptions 143 ITEM Phase AC only Balance Option Coarse Zero DC only lt lt Auto Zero gt gt Fine Zero Shunt Display Shunt Reference lt lt Update gt gt Shunt State FlexTest SE Cal Type Gain Delta K part 1 of 2 DESCRIPTION Applies coarse gain to the pre amp element of the conditioner s gain function Applies fine gain to the post amp element of the conditioner s gain function Displays the total gain applied This value is a function of Pre Amp and Post Amp values Entering a total gain value here causes the Controller to enter the Pre Amp and Post Amp values required to achieve this value Applies Delta K to the sensor s output signal Delta K is a gain control affecting only the positive side of the sensor s output which is necessary because of inherent asymmetry in the output Delta K compensates for this asymmetry Sets the excitation voltage applied to the
185. rm a Shunt Calibration on page 79 e Ifyou have a three stage Series 256 or 257 servovalve tune the inner loop gain and rate before tuning the outer loop The rules for inner loop tuning are similar to those of the outer loop Refer to How to Perform a Shunt Calibration on page 79 e If your Controller is equipped with the optional auto tuning feature it is best to run auto tuning first Auto tuning establishes reasonable tuning levels that will be adequate for most control modes If the results from auto tuning are not satisfactory you should manually tune each control mode Refer to How to Perform Advanced Tuning Techniques on page 101 o D 0 0 FlexTest SE Common Tasks 85 How to Manually Tune the Control Loop About tuning programs The Tuning menu includes a built in function generator provided specifically for creating tuning programs Tuning gt Manual gt FG The purpose of a tuning program is to produce a command that reflects the most demanding system response expected from a test Initial tuning is best done with a waveform that has abrupt changes This excites the system at frequencies likely to be unstable with excessive gain Square and ramp waveforms are preferred Final tuning can be done with the actual program command for the test A typical tuning program is a low amplitude 5 to 10 of full scale low frequency 1 Hz to 2 Hz square waveform This sect
186. rm tests e Hardware Interface files hwi e Configuration files cfg e Station Parameter sets e Panel View sets The hardware interface file extension hwi is an inventory of the conditioners valve drivers and other physical resources that are available to the Controller for creating configuration files MTS creates the hardware interface for you at the factory The Controller s Config menu has an Edit Hardware control that lets you change attributes of the resources listed in the hardware interface file For instance you can change the excitation of one of the universal conditioner s from DC to AC to accommodate a sensor that requires AC excitation For more information about editing hardware interface files see page 229 The configuration file extension cfg defines how the resources listed in the hardware interface file are allocated For instance you can allocate a valve driver resource and a sensor resource for a control channel When complete a configuration file allocates all of the station resources needed for a specific test station including valve drivers conditioners analog inputs and outputs digital inputs and outputs and readouts You can store up to four configuration files in the Controller The Controllers Config menu has an Edit Configuration control that lets you change the allocation of resources in configuration files For more information about editing configuration files see page 215 Intro
187. rol is assigned to the Controller Run Stop and Hold if available are functional on the Controller e Rewind is disabled on the Controller e Run is disabled on Station Manager When exclusive control is assigned to Station Manager Run Hold if available and Stop are functional on Station Manager Run and Rewind are disabled on the Controller When exclusive control is assigned to either interface e Hold for Basic TestWare and MPT and Stop are functional on both interfaces D 74 a D 5 O 2 0 FlexTest SE PC Supervised Controllers 41 Using the Interfaces Effects of Exclusive Control on Program and Power Controls part 2 of 2 MENU CONTROL FUNCTION Hydraulic Power and When exclusive control is assigned to the Controller Interlock Reset buttons e HPU Off Low and High are functional on the Controller e If available HSM Off Low and High are functional on the Controller e HPU Low and High are disabled on Station Manager If available HSM Low and High are disabled on Station Manager When exclusive control is assigned to Station Manager e HPU Off Low and High are functional on Station Manager gt If available All Off HSM Off Low and High are functional on Station Manager e HPU Low and High are disabled on the Controller If available HSM Low and High are disabled on the Controller When exclusive
188. s front panel monitor connectors dedicated menu buttons for direct access to grouped functions and instant recall of panel displays Basic capabilities include station configuration editing the creation of up to four parameter sets per configuration auto zeroing control mode switching with hydraulics on and adaptive control The Controller provides fully self contained single channel control and can be linked to other Controllers for multi channel testing It supports cyclic and monotonic programming without data acquisition 14 Introduction FlexTest SE i gt ih i 5 i a iv i Basic Description The following options are available for the Controller Optional features FlexTest Controller Options part 1 of 2 DESCRIPTION Personal Computer equipped with a high speed Ethernet connection PC to Controller and MTS Model 793 software including Model 793 01 System Software with Basic TestWare and Model 793 10 MultiPurpose TestWare For more information see PC Supervised Controllers on page 35 Full featured on board oscilloscope that allows you to view time and X Y plots optimize the display with auto scaling and pan trace history Enhancement to the standard FG menu that includes sine sweeps and block cyclic programming Enhancement to the standard Tuning menu that allows you to quickly tune your Controller without having to make indi
189. s you select an existing parameter set by entering its name Allows you to enter a new name for the current parameter set Allows you to select an existing parameter set by means of a browser Allows you to save the current parameter set Deletes the specified parameter set Menus Descriptions 133 ITEM Select Existing Name Enter New Name lt lt Open gt gt lt lt Save gt gt lt lt Delete gt gt FlexTest SE Use this menu to assign attributes to the drive signal analog output which is typically used to drive a servovalve The controls and menus vary according to the type of valve driver with which your Controller is equipped Both two stage and three stage valve driver menus are shown For information about how perform servovalve adjustments see How to Set Servovalve Polarity on page 63 and How to Balance the Servovalve on page 68 How to Adjust Dither on page 72 and How to Perform Advanced Tuning Techniques on page 101 Access Level Tuning Output Single Valve Driver Polarity Valve Balance Dither Amplitude Dither Frequency Output Dual Valve Driver Polarity Valve Balance1 Valve Balance 2 Dither Amplitude Dither Frequency Output 3 Stage Valve Driver Polarity Valve Balance Dither Amplitude Dither Frequency Inner Loop Inner Loop Conditioner gt Inner Loop Gain Service Port Output Inner Loop Rate Rate Input Selection Conditioner
190. sensor which is usually specified by the sensor manufacturer AC sensors typically require 10 V AC excitation and DC sensors typically require 10 V DC excitation Adjusts the phase of the feedback signal based on the excitation signal Optimal phase adjustments produce the maximum output signal from the sensor Phase values are usually between 30 45 The conditioner may be configured so that this control behaves like a Coarse Zero or a Bridge Balance Balance Option Course Zero Applies a coarse zero low resolution offset to the sensor s output signal Bridge Balance Typically used with strain gages this control applies a bridge balance to offset any resistance imbalance in the sensor that would saturate the conditioner output at the strain gage s null position Zeroes the sensor signal and makes the current output the new zero reference FlexTest SE Setup ITEM Pre amp Post amp Total Gain Delta K Excitation Phase AC only Balance Option DC only lt lt Auto Zero gt gt 144 Menus Descriptions 0 i 2 0 0 3 Setup DESCRIPTION Applies a fine zero high resolution offset to the sensor s output signal oO 0 oO 2 T 0 See Shunt Calibration on page 8 Cal Type mv v Pos Tension part 1 of 2 DESCRIPTION Sets the gain relationship between the negative
191. sensor manufacturer AC sensors typically require 10 V AC excitation and DC sensors typically require 10 V DC excitation Adjusts the phase of the feedback signal based on the excitation signal Optimal phase adjustments produce the maximum output signal from the sensor Phase values are usually between 30 45 The conditioner may be configured so that this control behaves like a Coarse Zero or a Bridge Balance Balance Option Course Zero Applies a coarse zero low resolution offset to the sensor s output signal Bridge Balance Typically used with strain gages this control applies a bridge balance to offset any resistance imbalance in the sensor that would saturate the conditioner output at the strain gage s null position Zeroes the sensor signal and makes the current output the new zero reference Performs high resolution changes to conditioner s zero reference See Shunt Calibration on page 148 Menus Descriptions 147 ITEM Neg Tension Pos Compression Excitation Phase AC only Balance Option DC only lt lt Auto Zero gt gt Fine Zero Shunt Display Shunt Reference lt lt Update gt gt Shunt State FlexTest SE Setup Shunt Calibration Shunt calibration is a method of verifying the calibration accuracy of dc sensor conditioner pairs by shunting a precision resistor across one arm of the sensor s Wheatstone bridge The resultin
192. set file View set files have the same name as the associated configuration file but have a cfv extension instead of a cfg extension View set files are stored in the flash disk memory of the Controller When you use the save or restore panel controls in the Status menu the view set file updates the associated configuration file which is stored in the PC D 74 a D 5 O 2 0 FlexTest SE PC Supervised Controllers 43 PC Supervised Controller Files About passwords and PC supervised controllers The user level passwords for the Controller and Station Manager are independent of each other Because of this it s likely that you will need to know both sets of passwords when using the Controller in the PC supervised mode For instance if you assign exclusive control to the Controller you are still required to perform setup activities with the Station Manager Some of the setup activities such as shifting electrical zero tuning and calibration require entering Station Manager passwords to gain access to higher user levels Keep both sets of passwords handy when using your PC supervised Controller About selecting applications for PC supervised controllers While you can assign exclusive control to either the Controller or Station Manager the term exclusive control refers to the interface that controls the station the interface with whi
193. splay ref E Shunt Ref lt lt Update gt gt Shunt State gt Stabilization Calibration gt Offset Zero Limits ref A gt Calibration Minimum Maximum Display Unit Polarity Gain Null Pacing gt PVC gt gt APC gt gt PVP gt gt Readout n Readout Signal Polarity Gain Offset Valve Balance 1 Valve Balance 2 Dual Only Dither Amplitude Dither Frequency gt Output 3 Stage Valve Polarity Valve Balance Dither Amplitude Dither Frequency Inner Loop gt Conditioner gt gt Service Port Output gt gt Inner Loop Inner Loop Gain Inner Loop Rate Rate Input Selection gt Conditioner Excitation Phase Offset Gain Polarity gt Force Displacement Error Detectors ref B Null Pacing ref C PVC ref D PVP ref D Dual compensation gt gt gt gt Dual Compensation Conversion Gain Integrator Gain DC only Readout n gt Stabilization Digital Input n Digital Output n gt CLC Error Detectors ref B Tuning gt gt Null Pacing ref C PVC gt ref D PVP ref D gt gt Tuning Active P Gain Limiting P Gain 5 Gain ref F Lower Limit FL Filter Upper Limit Filter Type ref F lt lt Accept gt gt Frequency ref F Bandwidth ref F Stabilization Filter lt gt Edit Hardware HWI file 493 25 DC Slot 1 493 25 AC Slot 2 gt
194. ss the Limits button a table of signal limit information is displayed z i gt b 24 Introduction FlexTest SE Front Panel Controls Navigate buttons The Navigate buttons include Menu Item buttons Up and Down buttons the Back Button and the Previous and Next buttons You use the Navigate buttons to select menus bring focus to specific menu items select from lists in menu items and scroll within logs and tables Note You can also perform some navigation functions with the Dial and Increment Decrement buttons Up button In a menu the Up button scrolls up through menu items in a panel it scrolls up through the panel gt CAD gt The Back button goes back to the previous layer in gt gt nested menus When in the root layer of a menu pressing the Back button removes the menu from the screen in a panel it removes focus Previous and Next buttons When in a submenu that contains related submenus pressing these buttons scrolls through the submenus In the Log pressing these buttons scrolls through the log entries horizontally In the Limits and Linearization table pressing these buttons scrolls through the table values horizontally Amplitude 6 000 mm Frequency 4 00 Hz Compensator 0 0 6 6 86 Hone 0 Menu Item buttons bring focus to the menu items directly across from them If the menu item contains a list ad
195. ssed by pressing the Tuning button on front panel they are in both places for the sake of convenience For detailed information about tuning controls see Tuning on page 194 For information about how to tune a PIDF control mode see How to auto tune on page 101 and How to Manually Tune the Control Loop on page 82 Access Level Tuning control mode Calibration gt Offset Zero gt Limits Error Detectors Tuning gt Tuning P Gain Gain D Gain F Gain S Gain FL Filter Filter Type Frequency Bandwidth Stabilization Filter Stabilization Filter Filter Type Filter Min Filter Max FlexTest SE Menus Descriptions 159 Setup Setup Menu PIDF Control Mode Null Pacing Use this selection to define the null compensation parameters that can be applied to the command signal e Static null pacing holds the command at a steady state until the feedback reaches its target peak if the error becomes too large 0 i 2 0 0 3 e Dynamic null pacing slows the command frequency to allow the feedback more time to track the command if the error becomes too large See About Null Pacing and compensators on page 161 for more about this compensation method Access Level Tuning control mode Calibration gt Offset Zero gt Limits Error Detectors gt Tuning gt Null Pacing gt Null Pacing SNP Error Tolerance SNP Timeout SNP
196. ssis FlexTest SE Maintenance 243 FlexTest SE 244 Maintenance gt Appendix 8 Menu Summaries This appendix contains fold out summaries of FlexTest SE menus for ready reference Note When used with PC supervision access to menus and controls is restricted For more information see PC Supervised Controllers on page 35 n 3 3 6 FlexTest SE Menu Summaries 245 FlexTest SE 246 Menu Summaries 9 4 5 Frequency Compensator Preset count Current count Total count lt lt Sweep Up gt gt End Level lt lt Sweep Dwell gt gt Compensator lt lt Sweep Down gt gt gt Sweep Settings Control mode Wave Shape Compensator Sweep Type Sweep Mode Sweep Rate Lower Frequency Upper Frequency Cal Type Gaii Pre amp Post amp Gain Delta K Excitation pea Balance option Phase lt lt Auto Zero gt Fine Zero Shunt Display 1 Shunt Ref lt lt Update gt gt Shunt State gt gt Offset lt lt Auto Offs Manual Offs Resolution ref H Cal Type Gain Linearization Gain Delta K mv V Pos Tension mv v Pos Comp Cal Type Gain Linearization Pre amp Post amp Gain Data Range From Data Range To lt lt Reset gt gt Linearization Data ref G Excitation peak AC only Balance option Phase lt lt Auto Zero gt gt Fine Zero Shunt Di
197. stallation 6 Switch to the force control mode 7 Check system interlocks Stand Alone Controllers If the Hydraulic Interlock or Program Interlock indicator is lit determine the cause correct it and then click Reset If either interlock indicator lights again you will need to determine the cause of the interlock and correct it before proceeding Automated Controllers If the Interlock indicator is lit click Reset If the indicator lights again you must determine the cause and correct it before proceeding o D 0 0 FlexTest SE Common Tasks 97 How to Manually Tune the Control Loop 8 Open the Tuning submenu or panel Stand Alone Controllers Tuning gt Manual Automated Controllers A Click yY to display the Tuning panel B In the Tuning panel click the Adjustments tab C Select the Show References check box Notice the Reference column on the right side of the window This column shows the current set of tuning parameters Use the buttons to update reference settings with new values or replace the current values with the last set that worked properly Note The Reference settings are saved with the parameter set 0 8 m E E i o 98 Common Tasks FlexTest SE How to Manually Tune the Control Loop 9 Adjust the P Gain and D Gain tuning controls Stand Alone and Automated Controllers A Start the function generator B On the Scope menu
198. t Auto Zero gt gt Fine Zero Shunt Display DC only Shunt Ref DC only lt lt Update gt gt DC only Shunt State DC only Cal Type Gain Delta K Pre amp Post amp Gain Total Gain Delta K Excitation Balance Option DC only lt lt Auto Zero gt gt Fine Zero Shunt Display DC only Shunt Ref DC only lt lt Update gt gt DC only Shunt State DC only Cal Type Gain Linear Pre amp Post amp Total Gain Data Range From Data Range To lt lt Reset gt gt Linearization Data Excitation Phase AC only lt lt Auto Zero gt gt Fine Zero Shunt Display DC only Shunt Ref DC only lt lt Update gt gt DC only Shunt State DC only FlexTest SE Setup units which determines the range of the sensor i Calibration Menu part 1 of 2 5 4 ITEM DESCRIPTION 2 Minimum Maximum Sets the sensor s fullscale minimum and maximum values in engineering Display Unit Selects the engineering units in which the sensor signal is displayed The selected display unit will be used as the default display unit for the Scope and Meters Polarity Sets the polarity of the feedback signal to change how the actuator responds to commands Normal A positive command can extend or retract the actuator depending on system conventions Invert Reverses the actuator s normal response Resolution Sets the resolution of the sensor
199. t positions of the Log Meters and Status panels on standard Controllers 0 20 Secidiv Parameter Set Access Level Application Control Made Running Time Preset Count Current Count Total Count Disp 3 28 mm A Force 3 28 kN vA Force2 3 28 kN vA Anig In 13 00 mm Ch Command 2 00 mmidi 1 00 mm Ch Active Fegfiback 003 2 Scope optional gt When the Scope is displayed the Log is behind the Scope To display the Log press the Log Menu button Default positions of the Scope Meters and Status panels on Controllers equipped with the optional Scope FlexTest SE When you shutdown or reboot the Controller saves the information displayed on the screen or panel view present at the time of the operation The panel view includes the position of the panels on the screen and the associated user settings in each panel Note A panel view does not include menu images or the focus status of menu items as is the case with the Recall buttons see A B Recall buttons on page 26 The Controller also saves the current panel view when you press the lt lt Save Panels gt gt button in the Status menu and restores that panel view when you press lt lt Restore Panels gt gt So at any given time the Controller can store two different panel views for later recall The panel view saved when you shutdown or reboot is automatically restored when you power up the Controller duri
200. t the actuator 6 Disable manual command A On the Station Controls Toolbar click the Manual Command button to open the Manual Command window B Click on the Enable Manual Command check box to disable manual command o D 0 0 FlexTest SE Common Tasks 67 How to Balance the Servovalve How to Balance the Servovalve The act of balancing the servovalve adjusts the electrical input to the servovalve so that the feedback and command signals are equal The Controller s valve balance control electrically compensates for minor electrical and mechanical imbalances in the servoloop Procedures for both stand alone and automated systems are described Stand Alone 1 Select the Calibration access level Controllers Path Config gt Access Level gt Calibration 2 Remove any specimen 3 Apply hydraulic pressure A WARNING Enabling the front panel Dial for Setpoint control allows you to manually position actuators A moving actuator can injure anyone in its path Always clear the actuator area before manually adjusting actuator position 4 Select the displacement control mode Path Status gt Control Mode gt displacement 5 Position the actuator at or near its midstroke position Path Status gt Setpoint A Enable the Dial B Use the Dial to adjust the Setpoint to position the actuator 6 Record and zero displacement I Gain Path Tuning gt Manual gt I Gain A Write
201. tation Manager s tuning controls Display gt Station Setup gt Tuning Config menu Fully Functional Changes to the Access Level and Panel Placement controls respond immediately in the current session Changes to all other Config menu controls take effect only after the Controller is rebooted Limits menu Disabled To set and view limit and error detectors use Station Manager s Detector controls Display gt Station Setup gt Detectors 0 ES 2 i g D 42 D 2 A 38 PC Supervised Controllers FlexTest SE Using the Interfaces Controller interface in the automated mode part 3 of 3 MENU CONTROL FUNCTION Log panel and menu Fully functional Program Controls See Effects of Exclusive Control on Program and Power Controls on page 41 Hydraulic Power Controls Interlock Reset Controls Emergency Stop Control About Exclusive Control When used in the PC supervised mode you use the Controller in tandem with Station Manager which provides an additional interface with which you can perform test activities For safety reasons you cannot control apply hydraulic power and manually position the actuator your station from both interfaces at the same time To prevent this each interface is equipped with a control labeled Exclusive Control You assign exclusive control to one interface or the other giving that interface exclusive control of t
202. ters panel on the screen focus to the Meters menu FlexTest SE Introduction 23 Front Panel Controls Limits When you press the Limits button once the Controller displays a table of signal limit values and actions when you press the Limits button again the Controller displays a table of signal error values and actions pressing the button a third time dismisses the table The information in these tables is identical to the Limits information in the Setup menu Errors Upper Limit Lower Limit Outer Error Inner Error Anig In Ch Disp Absolute Error 1 3000 cm Disabled 1 3000 Disabled 26 000 mm Disabled 26 000 mm Disabled Disp Ch Force Absolute Error 43 000 mm Disabled 73 000 mm Disabled 26 000 kN Disabled 26 000kN Disabled Force Ch Force2 Absolute Error 73 000kN Disabled 73 000kN Disabled 26 000kN Disabled 26 000kN Disabled Force2 Ch CLC Absolute Error 73 000kN Disabled 73 000kN Disabled 26 000 mm Disabled 26 000 mm Disabled Control Mode Disp Running Time 9517 Sec Preset Count Current Count Total Count 3 28 kN Control Mode Disp Running Time 9484 Sec Preset Count Current Count Total Count 13 00 mm 13 00 mm the next time you press the Limits button a table of signal error information is displayed Pressing the Limits button does not display a menu it displays a table The first time you pre
203. th PC supervision this menu is disabled Use Station Manager to create program command N i 2 0 0 3 Menu Use the FG menu to define program command To begin select a program type Each program type has a unique set of parameters which is reflected on the FG menu Access Level Operator FG Type Monotonic Cyclic External Command Block Cyclic Sweep FG Types TYPE DESCRIPTION Monotonic The function generator ramps the command signal to the specified amplitude at the specified rate Cyclic The function generator cycles the command signal at the specified amplitude and frequency External command The Controller accepts program generation from an external source Block cyclic The function generator plays out predefined blocks of cyclic commands Sweep The function generator sweeps the command signal between specified frequency limits 120 Menus Descriptions FlexTest SE FG s lt FG Menu gt Monotonic i Use the Monotonic selection to define a ramp program 2 2 Monotonic Ei Control Mode o Rate Type a Test Time End Level Type End Level Compensator Monotonic Menu ITEM DESCRIPTION Control Mode Specifies the control mode for the ramp Rate Type Defines the command ramp in terms of Time or Rate The ramp starts at the current actuator position and ends at the specified end level The time rate value can be changed while a test is running but t
204. the limit setting status and action for all associated input signals in the station Detector color key e Grey appears when the limit is Disabled e White appears when the limit is set to Indicate and has not tripped e Green appears when the limit is set to Interlock Program Interlock Program Stop or Program Hold and has not tripped e Red appears when the limit is set to Interlock Program Interlock Program Stop or Program Hold and has tripped You can edit limit settings in summary panels To edit a setting select the setting row by pressing the navigate button next to the row then use the lt gt previous next buttons to select the setting field When the desired field has focus use the navigate button to toggle through the selections You can also edit limit settings for individual input signals at Settings gt input signal gt Limits Changes made there are reflected in the limit summary panels and visa versa Access level Operator Note For more information see Limits page 154 FlexTest SE Overview Limits Limits 238 Menus Descriptions 0 i 2 0 0 3 0 oO 2 T s i 0 Limits 239 Upper Limit Lower Limit Anig In 1 30 cm Disabled 1 30 Disabled Disp 43 000 mm Disabled 73 000 mm Disabled Force 73 00 kN Disabled 13 00kN deteriock Force2 73 000 kN Disabled 73 0
205. tically offset the feedback signal 1 In the Setup menu select Displacement 2 In the Displacement menu select Offset Zero 3 In the Offset Zero menu click lt lt Auto Offset gt gt oO 0 oO 2 T i 0 The output will zero the conditioner s current output at the current actuator position Note Since your range is centered around the sensor s calibrated electrical zero offset limits the usable range in the direction you shift it For example if you are in a 1 cm range offsetting the signal 0 5 cm results in 0 5 cm of control range on the positive side and 1 5 cm on the negative side Using Manual Offset If the desired amount of offset is known enter the value manually with the Manual Offset control About electrical zero With the electrical zero controls you can shift the sensor s electrical zero reference Displacement sensors and corresponding conditioners are typically calibrated so the conditioner s feedback is zero volts at the middle of the actuator s operating range This position is known as the conditioner s electrical zero In some situations you may want to shift the conditioner s electrical zero Electrical zero Consider the following items before adjusting the electrical zero considerations e Electrical zero adjustments can be made on the current feedback when hydraulics are active A WARNING Actuator movement is possible when adjust electrical zero
206. tically saves default panel settings whenever you shut down or reboot and whenever you run a test after making changes to the FG Type Cyclic Preset Count Block Cyclic Control Mode or Block Cyclic Count FG menu controls FlexTest SE Controller Files Parameter sets Panel view sets Default Panel Settings Introduction 30 i gt cs ih Controller Files The Controller automatically restores default panel settings whenever you load or reboot the Controller Default Panel Settings To CREATE To RESTORE BENEFITS COMMENTS e Press lt lt Save Def Pnis gt gt e Load Controller This feature may be a benefit when performing unsupervised long e Press lt lt Shut Down gt gt e Reboot Controller duration tests e Press lt lt Reboot gt gt Pressing lt lt Save Def Pnls gt gt before beginning a test ensures that when e Press Program Run after rebooting after an uncontrolled making changes to shutdown or power failure the Controller will recover the settings FG Type present while the test was in Cyclic Preset Count progress Block Cyclic Control Mode Block Cyclic Count Saved Panel Settings The Controller creates a panel view set independent of the default panel view set when you press lt lt Save Panels gt gt in the Status menu The Controller restores this panel view set only when you press the lt lt Restore Settings gt gt control in the Status
207. tomated Controllers A On the Manual Command window Click Enable Manual Command B Adjust the Manual Command window slider to position the actuator during specimen installation 6 Check system interlocks Stand Alone Controllers If the Hydraulic Interlock or Program Interlock indicator is lit determine the cause correct it and then click Reset If either interlock indicator lights again you will need to determine the cause of the interlock and correct it before proceeding Automated Controllers If the Interlock indicator is lit click Reset If the indicator lights again you must determine the cause and correct it before proceeding 7 Open the Tuning submenu or panel Stand Alone Controllers Path Tuning gt Manual Automated Controllers A Click yY to display the Tuning panel B In the Tuning panel click the Adjustments tab C Select the Show References check box Notice the Reference column on the right side of the window This column shows the current set of tuning parameters Use the buttons to update reference settings with new values or replace the current values with the last set that worked properly Note The Reference settings are saved with the parameter set o D 0 0 FlexTest SE Common Tasks 91 How to Manually Tune the Control Loop 8 Adjust the P Gain and D Gain tuning controls A Start the tuning function generator B Select Continuous Sw
208. tor uses a sensor input with a different dimension than the sensor input used by the Controller to maintain PIDF control See Types of control modes and More about dual compensation on page 223 9 Anlg In 493 25 493 47 Menus part 2 of 3 E ITEM DESCRIPTION a lt lt Add Dual Comp gt gt Creates a Dual Comp 7 menu item Display Name Allows you to edit the default name The default naming convention for a dual compensation control mode is Signal compensator feedback signal name control mode name Arig n Type Signal Selects the resource whose feedback signal will be used by Amp Controi On the compensator been Type Sets the type of control the compensator provides You can select Amplitude Control Only or Mean and Amplitude Control lt lt Delete gt gt Deletes the current instance of the Dual Comp m submenu Type Aux Input Configures the input resource to receive sensor feedback not used for PIDF control When the Controller is used in the stand alone mode auxiliary input signals can be monitored When the Controller is used in the automated mode they can also be used for data acquisition Dimension Selects the appropriate dimension for the sensor associated with the selected resource Display Unit Selects your preference in units for the selected dimension Type External Command Configures the input resource to receive command from an external sour
209. trol also exists in the Status menu it is repeated on the Config menu for convenience To access many of the controls in the Config menu you must be at the Configuration access level Required access level Operator or higher Note After making higher level changes it is a good idea to always return to the Operator level This is the default user level This level does not need a password and has the fewest privileges Menus Descriptions 207 Config Overview ITEM Access Level Operator FlexTest SE Config 0 Access Level part 2 of 2 5 ITEM DESCRIPTION 0 Tuning Enter this level to make tuning adjustments i l ae 5 Calibration Enter this level to modify calibration parameters Configuration Enter this level to make changes to various controls in the Config menu including all the controls in the Edit Configuration and Edit Hardware submenus lt lt Shut down gt gt Saves panel changes to the configuration file automatically prompts you to save parameter set changes if any have been made then closes all applications and removes power from the Controller lt lt Reboot gt gt Saves panel changes to the configuration file automatically prompts you to save parameter set changes if any have been made then closes all applications and starts them up again Config Menu gt Panel Placement Use this selection to specify the position of all of the panel d
210. ts between the actuator and any equipment in the path of its movement Immediate and unexpected actuator response is possible when you apply hydraulic pressure to your system Stay clear of the actuators when applying hydraulic pressure 3 If necessary turn on hydraulic pressure Stand Alone Controllers A Inthe Power section press Low and then High for the HPU If an HPU is not listed start the HPU at the pump Note The HPU can be configured for first on If this is the case start the appropriate HSM B If an HSM is present click Low and then High for the HSM Automated Controllers A Inthe power selection box click Low and then High for the HPU If an HPU is not listed start the HPU at the pump Note The HPU can be configured for first on If this is the case start the appropriate HSM B Ifan HSM is present click Low and then High for the appropriate HSM 4 Ensure that the displacement control mode is selected Stand Alone Controllers Press the Back button or select Tuning gt Manual gt Control Mode Automated Controllers On the Manual Command window ensure that displacement is selected for Control Mode 5 Install a dummy specimen Stand Alone Controllers A Enable the Dial 0 8 E E i 2 90 Common Tasks FlexTest SE How to Manually Tune the Control Loop B Adjust the Dial to position the actuator during specimen installation Au
211. ts or cycles the current block will repeat before the next block is played out To skip the current block enter 0 FlexTest SE FG ITEM Wave Shape Control mode End Level Type Mean End Level 1 Amplitude End Level 2 Frequency Compensator Count 126 Menus Descriptions 0 i 2 0 0 FG Note Block Cyclic and Sweep programming capabilities are included in the optional Advanced FG feature for the FlexTest SE Controller To obtain this feature contact your local MTS Sales Representative or refer to Technical Support on page 11 oO 0 oO 2 T i 0 Use the Sweep selection to define a sweep program Sweep Sweep Settings gt Sweep Settings Target Setpoint Control Mode Amplitude Wave Shape Frequency Compensator lt lt Sweep Up gt gt Sweep Type lt lt Sweep Dwell gt gt Sweep Mode lt lt Sweep Down gt gt Sweep Rate Lower Frequency Upper Frequency Changes in Function Generator values made with hydraulic pressure on can result in unexpected actuator movement Unexpected actuator movement can injure personnel and damage equipment Always clear the actuator area before changing values Sweep Menu part 1 of 2 DESCRIPTION Defines the sweep parameters See the Sweep Settings Menu table below Specifies the setpoint or mean level at which the program signal s amplitude centers
212. tup window click Three stage valves In the Drive panel click the Valve tab B While observing Displacement Absolute Error on the Meters panel adjust the Valve Balance control until Displacement Absolute Error is zero 10 In the Station Setup window click Vv In the Tuning panel click the Adjustments tab In this tab return I Gain to its original setting o D 0 0 FlexTest SE Common Tasks 71 How to Adjust Dither Dither is a small high frequency sine wave applied to a servovalve s spool to improve the valve s response to low amplitude signals by reducing sticking Dither exaggerated Test Waveform The following are signs of an improper dither adjustment e Dither amplitude is too low While running a sinusoidal test on a properly tuned system you notice that the waveform distorts at its maximum and minimum points This will normally be more apparent during a test that has either a low frequency or a low amplitude test waveform e Dither amplitude is too high You hear unusual sounds such as hammering squealing or pounding coming from the test system There are two methods for checking and adjusting dither Method 1 uses an oscilloscope Method 2 uses your hearing Procedures for both stand alone and automated FT SE systems are described Stand Alone Method 1 Controllers 1 Select an access level of Tuning Path Config gt Access Lev
213. ual compensation control modes are configurations in which the compensation compensator uses a feedback signal with a different dimension than the feedback signal used by the Controller This is also known as mixed mode compensation Suppose you want to program an actuator in the strain control mode but the strain feedback is too noisy to provide adequate control You can create a dual compensation control mode that compensates the command signal based on strain feedback while the PIDF Controller uses displacement feedback to close the loop oO 0 oO 2 T i 0 Function Strain Displacement e Compensator A NDE Generator Controller h Displacement Strain Dual compensation Control Mode Strain Displacement Controller receives displacement feedback for PIDF control Compensator receives strain feedback and strain based programming For a dual compensation control mode the feedback signals available to the compensator are the auxiliary input signals and feedback signals already assigned to the channel The default naming convention for a dual compensation control mode is compensator feedback name control mode name About external You can configure the Controller to accept commands from an external command device while the Controller performs all other closed loop control functions The Controller can only accept programs that contain a single control mode The Controller c
214. uires the servovalve to move quickly between two discrete openings Cycling a ramp waveform produces a triangle waveform Tapered ramp waves taper from 0 to 100 amplitude at the beginning of execution and from 100 to 0 at the end of execution e A ramp waveform is useful for all levels of tuning e Use a ramp waveform if a square waveform creates excessive velocities or acceleration for the type of specimen being tested A sine waveform also called sinusoidal or haversine requires the servovalve to move at a variety of rates Tapered sine waves taper from 0 to 100 amplitude at the beginning of execution and from 100 to 0 at the end of execution Ramp Tapered Ramp Sine Tapered Sine Monitoring tuning waveforms On standard Controllers whenever you select the manual tuning menu Tuning gt Manual the Controller also displays a panel on which you can monitor tuning waveforms referred to as the Tuning Panel The Tuning Panel automatically scales and displays command tuning program and feedback waveforms to facilitate tuning The accuracy of the waveform represents how well it reaches the amplitude of the command or how repeatable the end levels are The peaks and valleys of triangle and sine waveforms should be consistent Use the area of the square wave after the ringing settles to monitor the end levels These are the areas of interest on these waveforms J Saa o D 0 0 Comm
215. units desired Otherwise the display units are shown as volts Sets the number of digits used to display the meter output from one to ten Specifies the amount the signal must change before the data signal is updated Peak Valley and Mean Amplitude meters only Adds a new meter below the currently selected meter This control is disabled if 16 meters already exist Deletes the current meter This control is disabled if there is only one meter Moves the selected meter up one row in the meter panel where Meter 1 is at the top of the display Moves the selected meter down one row in the meter panel where Meter 16 Gif created is at the bottom of the display Moves the meter panel around the display Toggles the size of the meter font display between small or large fonts Small font is the default FlexTest SE Meters ITEM Signal Display Mode Display Unit Display Resolution Sensitivity lt lt Add Meter After gt gt lt lt Delete Meter gt gt lt lt Shift Meter Up gt gt lt lt Shift Meter Down gt gt Placement Font Size 190 Menus Descriptions N i 2 0 0 3 Meters The following table lists station signals that are typically available to the on board Scope and Meters These signals may also be available to the front panel Monitor 1 and 2 connectors provided they have been configured as readout channels
216. unt calibration procedures for both stand alone and automated FT SE systems are described here Stand Alone 1 Select a control mode to which shunt calibration applies Controllers Path Setup gt force gt Calibration 2 Locate the shunt calibration controls toward the bottom of the calibration menu 3 Apply the shunt by setting the Shunt State control to On 4 Compare the output of the selected feedback as displayed on the Meter panel to the Shunt Reference Value You may find it necessary to recalibrate the sensor conditioner pair if the two values differ by more than your standards permit for example gt 20 mV 5 To make the output of the current feedback the new Shunt Reference Value A Attain the calibration access level Path Status gt Access Level Calibration B Return to the force calibration menu Path Setup gt force gt Calibration C Press lt lt Update gt gt 6 Remove the shunt by setting the Shunt State control to Off Note Leaving the calibration menu automatically removes the shunt o D 0 0 FlexTest SE Common Tasks 79 How to Perform a Shunt Calibration Note Procedures for Automated Controllers assumes the FlexTest SE Controller is equipped with the PC Supervision option and that Exclusive Control is assigned to Station Manager For more information about Station Manager see the Model 793 00 System Software manual that accomp
217. ut Menu part 2 of 2 a 5 ITEM DESCRIPTION F 9 Polarity Sets the polarity of the selected Digital Output when assigned Q E 5 7 Invert Active Low State Displays the current state of the selected Digital Output If the Digital Output is not assigned and not in use by another application such as MultiPurpose TestWare you can change its state True The digital output is high False The digital output is low FlexTest SE Menus Descriptions 177 Status Status Panel The Status panel displays general information about what is currently loaded into the Controller including the parameter set an attribute of the configuration file the user access state the active application the current running time and if available counter information N i 2 0 0 3 Sample Status Panel Stand alone Controller Menu Use this menu for ready access to many frequently used Controller features such as e Changing access levels e Selecting a control mode and controlling application e Adjusting Set Point and Span e Shutting Down Rebooting Access level Operator Status Access Level Application gt Control Mode gt Setpoint Span lt lt Shut Down gt gt lt lt Reboot gt gt lt lt Save Def Pnis gt gt lt lt Save Panels gt gt lt lt Restore Panels gt gt Placement 178 Menus Descriptions FlexTest SE Status DESCRIPTION calibr
218. values from any tuned PIDF control mode of the same signal type to the Active P gain and Limiting P gain values The following procedure is a tuning guideline assuming the Active feedback is displacement and the Limiting channel is force 1 Adjust the Active P control for adequate actuator response when adjusting the Dial 2 Monitor the force output and adjust the limiting channel control to minimize any delay to stop actuator movement when it reaches the specified limit FlexTest SE Menus Descriptions 205 Tuning Tuning gt Auto Note Auto Tuning is an optional feature for the FlexTest SE Controller To obtain this feature contact your local MTS Sales Representative or refer to Technical Support on page 71 N i 2 0 0 3 The auto tuning feature automatically calculates tuning values for PIDF control modes To do this the auto tuner disregards your current PIDF gain settings and applies the minimum required drive signal to ramp the feedback to 80 of the auto tuning limits It then measures the relationship between the feedback velocity and the valve opening and derives the minimum PIDF gains required to track the command Auto tuning provides a modest level of tuning for PIDF control modes Auto Control Mode Mode to Tune Actuator Type Lower Limit Upper Limit lt lt Accept gt gt Auto Tuning Menu ITEM DESCRIPTION Control Mode Selects the active control mo
219. ve for a 10 cm displacement the LVDT feedback only achieves 9 cm A Peak Valley Control compensator will monitor the feedback and automatically boost the initial command to ensure that the LVDT feedback reaches the commanded 10 cm You can view the compensated command with the Controller s Scope and Meters Each type of compensator uses a different technique to achieve the commanded levels Certain compensators work more effectively than others for specific applications Types of There are two types of null pacing Null Pacing e Static null pacing e Dynamic null pacing FlexTest SE Menus Descriptions 161 Setup How static null If the error is too large static null pacing holds the command at its pacing works segment boundaries allowing the sensor feedback more time to reach its target peak As the error comes within the user specified Error Tolerance static null pacing resumes the command Amplitude i SNP starts at end Amplitude of Segment 1 Feedback Time Segment 1 SNP Hold Segment 2 Static Null Pacing SNP How dynamic If the error is too large dynamic null pacing reduces the command null pacing works frequency allowing the sensor feedback more time to track the command The frequency decreases until either of the following occurs e The error comes within the user specified Error Tolerance at which time the command frequency starts increasing towards the command freque
220. ve gt gt and reboot before the changes take effect Note The FlexTest SE Controller can store up to four station configuration files on board Store additional station configuration files on a PC and download as required Access level Configuration Edit Configuration Configuration File Ex cfg 493 15 VD S2 J7 Ch 1 gt Anlg In Stabilization gt 493 25 S2 J4 Disp 493 25 S2 J5 Force gt Monitor 1 gt Monitor 2 gt Anlg Out gt Dig In 1 D I 1 Dig In 2 D I 2 Dig In 3 D I 3 Dig Out 1 D O 1 Dig Out 2 D O 2 Dig Out 3 D O 3 The resources you allocate to create station configuration files include valve drivers conditioners analog inputs and outputs digital inputs and outputs readouts and so forth You also configure control modes feedback signals and readout signals that will be available during your test Menus Descriptions 215 FlexTest SE Config Config Menu gt Edit Config gt Configuration File This selection allows you to select open save and delete configuration files Configuration File Select existing name Enter new name lt lt New gt gt lt lt Load gt gt lt lt Save gt gt lt lt Delete gt gt N i 2 0 0 3 Configuration File Menu ITEM DESCRIPTION Selecting existing Selects the name of existing configuration cfg files saved to the name Controller The number of configuration f
221. vidual PIDF control adjustments Compensator that optimizes command by altering command phase to correct for phase lag and increasing the command amplitude to correct for amplitude rolloff Additional I O carrier can be accommodated in special models Support for the additional I O carrier must be configured in the factory when the Controller is manufactured Note This is not an add on option For more information contact MTS Heavy duty valve driver required to support three stage servovalves MTS Series 256 and 257 Servovalves Sensor conditioning electronics that can accommodate both AC and DC coupled sensors Sensor conditioning electronics that can accommodate encoder type sensors incremental and Temposonics III SSD Electronics that convert up to six channels of analog signals to digital signals for use by the Controller Electronics that convert up to six channels of digital signals from the Controller to analog signals for use by external devices Introduction 15 ITEM PC Supervision Model 793 51 Scope Model 793 52 Advanced FG Model 793 53 Auto Tuning Model 793 08 PVP Compensator Additional Model 493 40 I O Carrier Model 493 15 3 Stage Valve Driver Additional Model 493 25 Digital Universal Conditioner DUC Model 493 47 Encoder Model 493 45 A D Model 493 46 D A FlexTest SE Basic Description FlexTest Controller Options part 2 of 2 ITEM DESCR
222. ware offset to accommodate specimen size forces from test components extensometers cable length resistance environmental factors and so forth 0 i 2 0 0 3 Software offset Consider the following items before using the software offset controls considerations e Offset can be used on the current control mode when hydraulic pressure is on e Since offset alters the feedback signal used by the Controller any offset will be included in the closed loop control calculations e Applying offset to a saturated signal will not remove interlocks tripped by saturation e Your usable range is limited in the direction you offset zero Offset diagram The following figure illustrates the effect offset has on sensor conditioner signals Conditioner Controller Application Sensor Conditioner Digital Voltage Voltage Signal 6077 S can A D Electrical Zero Offset Offset is applied to the digital signal in the software You specify offset in engineering units Applying offsets You can apply a software offset to the feedback signal of the current control mode while hydraulic pressure is on For instance suppose you are in displacement control and you use manual command to position the actuator away from midstroke where the sensor output is not zero 150 Menus Descriptions FlexTest SE Setup Using Auto Offset To automa
223. will have cables attached to both the Box In and Box Out connectors The end of run slave will have a cable attached to the Box In connector and a jumper plug attached to its Box Out connector For more information see the FlexTest SE Service manual Interlock function If you have more than one Controller connected to each other power must be applied to all of the Controllers for proper operation If power is not applied to any one of the Controllers you will not be able to clear an interlock condition in any of the Controllers 0 8 E E i 2 50 Common Tasks FlexTest SE o D 0 0 How to Use the Front Panel Controls How to Use the Front Panel Controls How to change panel positions Changing the position of You can change the position of any panel on the screen To do this for an individual panel a specific panel press the Menu button associated with the panel and change the setting of the Placement control For instance to change the position of the Log from the lower half of the screen to the upper half 1 Press the Log button twice to display the Log menu 2 Press the Menu Item button next to the Placement control to bring focus to it 3 Press the Menu Item button additional times to select Bottom Changing the position of You can also change the positions of all the panels on the screen with all the panels one control as follows 1 Press the Config butt

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