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Model 493.10/793.00 Controller Service Manual

1. Valve Command 10 11 Valve Command 12 13 14 15 e T S Valve VDT Inner Loop _ Feedback i a a See vave X Command 448 16 Command Control Driver sone poseren nnn gt ____y Mode river na A stability Loop Actuator LVDT AEE Feedback Outer Loop Model 493 10 793 00 Controller Service 49 I O Carrier Connections Multiple Universal Driver Connections For special applications the Model 493 79 Multiple Universal Driver MUD board provides up to six drivers that can be used to drive standard 252 servovalves Inputs to this board originate from a Model 493 46 D A board on a Model 493 40 I O Carrier Module A Y cable PN 100116173 connects the I O Carrier module 15 pin D Type to J9 J10 on a MUD board RJ45 aa CHANNEL 493 40 UNIVERSAL VO Carrier DRIVER OUTPUT CS mo lt xmu Shunt Cal SA 5 O 9 00000000 0000000 cal Nn a G ys fo Front Rear 00000000 0000000 C m 5 fo 493 10 Chassis TWanasausasaunasnunasnanasnaausnasaaaaantt Front Rear Cable Conduit humeen maa MTS Cl 00090000 D m S e O MTS D 50 HWI file definition See Multiple Universal Driver on page 300 for detailed information on the hwi file
2. 8 If you do not have transducer ID modules on your sensor cables install the shunt calibration resistor as follows A B C D E 138 Select the appropriate shunt calibration resistor Bend the resistor leads 90 for a 0 3 inch separation Cut the resistor leads 0 12 inch from the bend Insert the resistor into the connector solder cups and solder Complete and attach a shunt calibration label as specified on the 493 40 41 Carrier 028 185 I O Shunt Calibration Kit MTS PN 100 Install the shunt calibration resistor connector assembly into the appropriate SHUNT CAL connector slot on the front panel of the appropriate I O Carrier Module RR SHUNT CAL UA 4 po VO Option Slot 1 Shunt Cal Resistor Location 2 MWh 4 0 Option Slot 2 Shunt Cal Resistor Location 3 VWA 4 0 Option Slot 3 Shunt Cal Resistor Location 4 AA 4 1 0 Option Slot 4 Shunt Cal Resistor Location Model 493 10 793 00 Controller Service Shunt Calibration 9 Verify that force is still zero While it is unlikely it is possible for the force signal to change when the control mode changes If it does click Auto Offset on the Offset Zero tab Inputs panel to zero the force output 10 Perform a shunt calibration Refer to How to Perform a Shunt Calibration in Chapter 3 Station Manager of the Model 793 00 System Software manual for a
3. Servovalve 252 xx single 397083 XX 493 40 J4 J7 N A Servovalve 252 xx dual 397084 XX 493 40 J4 J7 N A Servovalve 256 xx 3 stage N A Valve 554396 XX 493 40 J4 J7 Valve LVDT 397086 XX 493 40 J4 J7 Calibration Cable Package 100 026 213 493 40 J3 Y Adapter Servovalve Valve LVDT 397105 01 493 40 J4 J7 N A required for 256 xx or 257 xx servovalves Servovalve 257 xx 3 stage N A Valve 397019 XX 448 16 to 257 XX 397002 XX 493 40 J4 J7 Valve Velocity 397009 XX 493 40 J4 J7 Valve LVDT 397086 XX 493 40 J3 Calibration Cable Package 100 026 213 N A 493 40 J4 J7 Y Adapter Servovalve Valve LVDT 397105 01 required for 256 xx or 257 xx servovalves System ground console 054023 XX N A System ground floor standing 397092 XX gnd lug E stop 318 Load Unit w crosshead locks 561265 XX 493 74 J29 100 007 947 E stop 318 Load Unit wo crosshead locks 561266 XX 493 74 J29 100 007 947 Emergency Stop 493 73 J24 397132 01 HPU 505 or 24V PLC Pump see Hydraulic 397137 XX 493 73 J25 397133 01 Configurations on page 259 for more information HSM 298 11 on off 397015 XX 493 74 J28 N A HSM Proportional 298 12 561264 XX HSM 290 xx 293 xx 294 xx high low 397014 XX Interlock Test Enclosure 561263 XX 493 74 J43 100 007 948 Interlock Station per system 493 74 J43 100 007 948 Model 493 10 793 00 Controller Service 43 Cable Part Numbers CABLE DESCRIPTION represent custom cable lengths t J
4. Hydraulic Control Hydraulic Control The hydraulic control definition assigns the Hydraulic Power Unit HPU transition board and each Hydraulic Service Manifold HSM transition board to their appropriate rear panel connectors Each of the two HSM transition boards allowed in your system can support up to two HSM stations HPU TRANSITION BOARD For systems without an HSM Setting FIRST ON and LAST change MAIN POWER to OFF to FALSE allows HPU TRANSITION SLOT 9 turn on independent of HSM NAME HPU FALSE to allow HPU 1 to bea power MAN ROR power selection option in Setting FIRST ON and LAST Station Builder OFF to TRUE allows HSM Low selection to activate FIRST ON TRUE HPU High without pressing LAST OFF TRUE the HPU buttons VISIBLE TRUE Changing VISIBLE to FALSE turns off the HPU button display on the CONNECTOR J25 Station Manager Window HSM TRANSITION BOARD The HSM type can be TRANSITION SLOT 8 PROPORTIONAL CHANNEL 1 NAME HSM 1 CONNECTOR J28A CONNECT SOLENOID or TO MAIN TRUE TYPE PROPORTIONAL ON_OFF_SOLENOID HSM RATE SLOW HSM OFF MODE STEP LOW A PERCENT 50 HIGH PERCENT 100 Only the PROPORTIONAL type re uires the Second CHANNEL 2 NAME HSM 2 CONNECTOR J28B CONNECT line It defines the TO MAIN TRUE TYPE SOLENOID characteristics of the V proportional output See RATE SLOW HSM OFF MODE STEP LOW PERCENT 50 J28 HSM on page 61 HIGH RERCENT 100
5. Front Panel with VMEbus Modules What you need to know Related products Rear Panel with Transition Modules MTS Systems Corporation assumes you are familiar with the other components of your system You are expected to know how to perform the following e Ground yourself to the chassis e Handle sensitive electronic components e Connect and secure cables e Plug circuit card modules into chassis guides The Model 493 10 chassis is part of a test system The chassis is controlled by a personal computer and the controller software is Model 493 10 793 00 Controller Service installed on the computer See your controller software documentation for information about the test system use Inappropriate use Before you install the Model 493 10 Chassis read and understand this manual before installing this product Improper installation or operation of this product can result in hazardous conditions that can cause severe personal injury or death and damage your equipment and specimen h i a iv i Model 493 10 793 00 Controller Service 19 i T gz i i pz Functional Description Functional Description VMEbus Transition bus Cable conduit 20 The Model 493 10 Chassis front panel has twelve slots ten VMEbus slots and two slots a and b which are reserved The rear panel of the chassis has twelve transition bus slots Two of these rear panel slots slots
6. Front Rear Cable Conduit 52 Model 493 10 793 00 Controller Service I O Carrier Connections Analog inputs The analog to digital daughter cards y ee To From accommodate up to six analog input AD J4 J7 493 75 A D signals Each A D input signal must be Module within 10 volts lt 1 Input 1 e Use pin 3 or 6 to prevent 2 problems with floating grounds s 3 analog between devices 4 4 FI Input 2 e Analog inputs can be connected 5 a Ara we nalog at the BNC connectors of a Model 6 Ground 493 75 Analog In transition 7 module and the outputs from this 8 gee module are connected to the i 9 Model 493 40 I O Carrier module i nput 4 e Analog inputs can be connected e n nput 5 at the BNC connectors of a Model lt q 42 _ 493 77 Filtered Analog Input 13 transition module and the outputs i nput 6 from this module are connected FE to the Model 493 40 I O Carrier 15 module 493 77 filter modules The following filter modules are available for board mounting at the BNC connectors of a Model 493 77 Filtered Analog Input transition module ASSEMBLY NUMBER HZ TYPE 477744 01 50 Besse 477744 02 100 Besse 477744 03 200 Besse 477744 04 500 Besse 477744 05 1000 Besse 477744 06 2000 Besse 477744 07 5000 Besse 477744 08 120 Besse 477744 09 300 Besse Model 493 10 793 00 Controller Service 53 I O Carrier
7. bd K o 154 Model 493 10 793 00 Controller Service Calibrating an LVDT Task1 Get things ready Perform the following before you start sensor calibration 1 Locate relevant documentation e You need information about the sensor such as the serial number model number excitation voltage displacement etc This information can be found on the appropriate Calibration Data sheet included with your system or the Final Inspection card included with all MTS sensors e You need calibration identification numbers for any calibration tools that will be used for this calibration procedure e g the dial indicator used for LVDT calibration The calibration information is usually on a sticker attached to the equipment e You need the appropriate DUC Conditioner serial number 2 Open a station configuration file You need a station configuration file that includes a control channel with a control mode that uses the sensor you intend to calibrate Also to monitor the sensor output signal with an external DVM ensure that you have allocated an analog output resource readout channel in the Station Builder program On the File menu select Open Station and then open the appropriate configuration file on the Open Station window 3 Enter the Calibration password You must access the Calibration user level before you can perform any of the calibration procedures iw gt gt f i Model 4
8. mile z Q Jp 00000000 0000000 Ok 5 O 00000000 0000000 D e N ZS 100 051 058 5 FN 00000000 FS ldeo z 3 lo ell Model 493 10 793 00 Controller Service ADDA II Connections ADDA II Connections Each optional Model 493 50 ADDA II module supports up to four daughter boards Each installed daughter board is assigned a specific ADDA II module front panel connector J11 J18 A hardware interface file hwi defines each type of module and their associated daughter boards and maps each module location for the system software The hwi file and the physical locations for each type of module and associated daughter boards must match Also the ADDA II module address setting on the module must match the hwi file address For more information on the hwi file see The HWI File on page 283 The following A D or D A daughter boards can be installed Model 493 55 A D Model 493 56 D A Model 493 57 DSPAD Model 493 59 Universal Encoder Model 493 10 793 00 Controller Service 61 ADDA II Connections ADDA Il Module 1 0 The Model 493 55 A D Model 493 57 DSPAD and Model 493 56 D A Connections daughter boards are installed in the Model 493 50 ADD II module assembly A connection from the front panel connector to a rear panel BNC transition module allows easy access to the analo
9. to yourself Stand alone The stand alone chassis can be placed on ce installation the floor The chassis location is limited only by the length of the system cables The front panel of the chassis can be removed to access the VMEbus plug in modules Console installation The rack mounted chassis can be installed in any Model 490 8x console Install the console with the 493 10 Rack Mounting kit part number 561395 01 for TestStar IIm or 561395 02 for FlexTest GT The Rack Mounting kit provides the hardware L shaped brackets to support the chassis and mounting screws to secure the chassis to the console rack i T q N 26 Model 493 10 793 00 Controller Service Connecting Electrical Power Connecting Electrical Power Electrical connections must be made by qualified personnel and conform to local codes and regulations An electrical service panel to provide the electrical power feed line voltage to the chassis is not necessary but may be required by local electrical codes Note Local electrical codes supersede any information found here Grounding The chassis will not function correctly if it is not Signal grounded as shown Be sure your power Ground source is also properly grounded The chassis includes two grounds a chassis ground and a Chassis Ground signal ground The two grounding lugs are
10. 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 Auto tuning provides a moderate level of tuning for PIDF control modes automatically For more information see Auto tuning on page 256 What if you adjust If you make an inappropriate adjustment the system will go unstable something wrong or shut down 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 Station Stop or Emergency Stop switch Important In multi station configurations pressing Emergency Stop will shut down the HPU and all stations in the interlock chain Pressing Station Stop on your Remote Station Controller shuts down the HSM for the specific station only 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 the tuning The tuning values are saved as part of the controller parameter set The parameters parameter set can save one set of tuning values for each control mode Model 493 10 793 00 Controller Service 233 About Tuning When to Tune Tuning is needed
11. e The processor module s must be located in the first and second slots e The GRESIII module Gf used should be located in slot 10 It may also be located in slot 2 if a second processor is not used See GRES HI on page 309 e I O carrier modules and or ADDA II modules can be installed in slots 3 to 10 Install a module in slot 3 and any additional modules to the right of it N e 5 z Model 493 10 793 00 Controller Service 31 Installing the Plug in Modules iv 498 711 GRES Ill TE gt 12V CLOCK OUT al EVENT OUT 5 ee EVENT IN I GI J3 IN I 38 33 peA 89 J4 OUT J J510 M T Q J5 DEBUG L 50 33 i o 38 L o 0 J6 STATION Qe ah J o gt seo 88 brat Q 39 SD 88 og ge J go oo o 4 88 89 J7 SERIAL L KOR JT Vo So pe is o l O 38 So 38 39 39 o o2 35 38 3 g Ms MES eg 1 2 3 4 5 6 ri 8 9 10 Setting I O Carrier Use the dipswitch S1 and rotary dipswitch S2 on each I O Carrier addresses module to set its address in accord with its installed chassis slot as follows SLOT 1 2 3 4 5 6 7 8 9 10 NUMBER ADDRESS PPC C20 C22 C24 C26 C28 C2A C2c C2E The dipswitch settings for address C20 is shown below Increm
12. o mn 36 Model 493 10 793 00 Controller Service Installing the Plug in Modules Rear Panel Transition Panels MODEL MODULE NAME FUNCTION 493 71 RS485 Provides four channels of RS 485 interface four channels of station stop interlocks and four channels of emergency stop interlocks The RS 485 interface channels are used for the Remote Station Controller and or temperature controller 493 72 Digital I O Contains sixteen general purpose digital input channels and sixteen general purpose digital output channels 493 73 HPU Transition Board nterfaces the controller with a hydraulic power unit 493 74 HSM Transition Board nterfaces the controller with a hydraulic service manifold and other devices up to two stations 493 75 Analog In BNC Provides six BNC channels for analog input signals The input signals must be within 10 V DC 493 76 Analog Out BNC Provides six BNC channels for analog output signals The output signals are within 10 V DC 493 77 Filtered Analog Input Provides filtering for the Model 493 45 A D analog to digital modules 493 78 Accelerometer Transition nterfaces with up to three low impedance voltage mode Board LIVM accelerometers and three signal conditioned type accelerometers 493 79 Multiple Universal Driver Provides up to six drivers that can be used to drive standard Board 252 servovalves Inputs to this board can originate from either a A
13. Ampl Cntrl OFF Fdback Mean Ampl AMC Gain Model 493 10 793 00 Controller Service 101 Cabling and Programming External Controllers 407 Digital I O Menu Din1 Definition Program in RUN Din1 RUN STOP Din1Pol ACT HI Din2 Definition Hydraulic Interlock Din2 Interlock Din2Pol ACT LOW Dout1 Definition Hydraulics ON Dout1 HYD OFF Dout1Pol ACT LOW Din2 Definition Dout2 Dout2Pol ERE Or Run Stop ACT HI Interlock ACT LOW None ACT HI 102 Model 493 10 793 00 Controller Service Cabling and Programming External Controllers Connecting Interlock Signals to 458 Controllers The Model 493 10 793 00 controller monitors digital I O interlock signals through its Model 493 74 HSM transition module P43A D 9P VVV 24V Jumper RA HYD INTLK P44 45 ANG INPUT D 9S Jumper _ To To v 493 74 j WA O 24V HSM 458 XX RUN Ly Transition Controller iy AA gi EVENT PROGRAM i INTLK INPUT Jumper OFF INTLK l Run Stop Program Interlock Cable v PN 564552 xx J P23B D 9P Jumper 24V avo P28 2 t INTLK CPC 4P i o s INPUT T 20K 2n3904_C o HSM LO 174W 5 e VI To JANO 458 XX 493 74 J Yw Controller SA HSM Vv Transition aa E Hydraulic Enable Interlock Cable PN 564551 XX Model 493 10 793 00 Controller Service 103 J50 connectors Temperature controller hardware resource
14. Do this by adjusting the Manual Cmd slider on the Manual Command window then verify that the Station Signals panel reads what you applied with the slider During the initial calibration and tuning of your system it may take repeated adjustment for the two values to match Note Ifthe actuator response is sluggish and or the signal value does not match the command you will need to adjust the tuning of this contro mode Increase the proportional gain P Gain on the Adjustments tab of the Tuning panel to correct sluggish actuator movement Increase the reset integration value I Gain to help the feedback match the command At this point unless the conditioner is already in calibration the tensile force applied to the force transducer will not equal your commanded value You will adjust gain in the next step so that the actual tensile force and your commanded tensile force match Example Suppose your actuator has a 100 tensile force rating of 10 KN In this step you would apply 8 kN of command and even though the station signals would read 8 kN of feedback the force standard may only read 4 kN This shows the conditioner sensor pair are out of calibration E bd K o 186 Model 493 10 793 00 Controller Service Calibrating a Force Sensor 3 Adjust gain until the actual tensile force equals your tensile force command Adjust the Post amp Gain control on the Calibration tab to increase the tensile force r
15. Program Eurotherm Temperature Controller 104 Cabling and Programming External Controllers Eurotherm Temperature Controller Connection When equipped with a Model 498 71B GRES III plug in module your Model 793 00 controller can program and control one or more Series 2200 2400 Eurotherm Temperature Controllers via the J50 serial connectors on a Model 493 71 Serial Interface transition module In order to use this configuration a special temperature controller resource must be added to your hwi file 493 71 mour JS DEBUG Eurotherm Temperature Controller J7 SERIAL 498765 01 MTS Kom 556343 xx The temperature controller can be connected to any of the four J50 connectors on the serial interface For more information on adding the Eurotherm hwi file resource see Temperature controller on page 307 Use Station Builder to configure a Eurotherm temperature controller Refer to How to Program a Eurotherm Temperature Controller in Chapter 2 Station Builder of the Model 793 00 System Software manual for detailed information Model 493 10 793 00 Controller Service Cabling for External Command Inputs Cabling for External Command Inputs Cabled properly your FlexTest controller can receive programming from an external controller How to Enable and Run External Command Inputs To enable an external c
16. 4 12 J16 J18 q gt 13 4 14 4 15 lt lt 16 Model 493 10 793 00 Controller Service ADDA II Connections Return Gnd Index Ser Clk B Interrogate A Serial Data Input 4 Return Gnd Index Ser Clk B Interrogate A Serial Data Input 3 Return Gnd Index Ser Clk B Interrogate A Serial Data Input 2 Return Gnd Index Ser Clk B Interrogate A Serial Data 65 Emergency Stop Connections Emergency Stop Connections Connectors J23 E STOP Out and J24 E STOP In are located on the Model 493 73 HPU transition board The emergency stop switch and signal are part of a controller wide interlock system Emergency Connector J23 E STOP Out stop output provides an output to external P a mee a al devices when an emergency Devices stop signal is generated The inactive status is shown in the Ea 1 figure Ge Ja Emergency a Stop 3 Emergency Connector J24 E STOP In External J24 stop input accommodates an external E Stop emergency stop switch As shown several connectors a 13 O 24V maintain the continuity of the 8 CN E Stop emergency stop interlock S7 SF Relay OO 7 E Stop Signal 5 iw Cable specifications J23 E STOP Out is a 9 pin type D male connector e 9 contact type D female EMI connector e Cable 24 AWG 10 conductor with overall foil shield Carol C0745 or equivalent with drain wire connected to metallized plastic backs
17. Assign a calibration file on page 181 Task 4 Turn on hydraulic pressure on page 182 Task 5 Verify the conditioner polarity on page 183 Task 6 Set the zero and offset on page 184 Task 7 Gain Delta K Calibration on page 185 Task 8 Gain Linearization Calibration on page 190 Task 9 Millivolt Volt Calibration on page 197 Task 10 Establish the shunt calibration reference on page 200 Task 11 Save the calibration on page 203 Task 12 Calibrate additional ranges on page 203 oO 2 gt r e Model 493 10 793 00 Controller Service 177 Calibrating a Force Sensor Task1 Get things ready Perform the following before you start sensor calibration 1 Locate relevant documentation e g sensor information conditioner serial number and calibration tool ID numbers 2 Set up to monitor load standard output 3 Open a station configuration file You need a station configuration file that includes a control channel with a control mode that uses the sensor you intend to calibrate 4 Enter the Calibration password You must access the Calibration user level before you can perform any of the calibration procedures 5 Set up a signal monitor Note You cannot monitor the output of a new sensor until a sensor calibration file has been created and the sensor assigned to an input signal You will be monitoring the sensor output when making adjustm
18. Remote Station Controller Connection 84 Model 493 10 793 00 Controller Service 39 Service Connections 86 Cabling and Programming External Controllers 88 How to Program an External Controller 89 Connecting Interlock Signals to 407 Controllers 94 Setting Up a 407 to Receive and Send Signals 100 Connecting Interlock Signals to 458 Controllers 103 Eurotherm Temperature Controller Connection 104 Cabling for External Command Inputs 105 Cabling and Using External Readout Devices 108 40 Model 493 10 793 00 Controller Service CE EMC Compliant Cabling CE EMC Compliant Cabling CE EMC compliant cabling is required for all systems shipped to Europe All cabling specifications in this chapter conform to the European CE EMC requirements Cable fabrication All of the cables listed on the Cable Selector drawing are CE EMC compliant when used in an MTS system Where possible use standard cables listed on the System Cable Jumper Plug 493 Package Selection drawing PN 700 000 656 If it is not possible to use standard cables or you are constructing custom cables select cables backshells and connection shields as described in the cable specification for each connector See the appropriate rear panel connector for fabrication information Low frequency It is possible that grounding both ends of the overall shield can ground loops produce a low frequency ground loop current If you experience an unacceptable low frequency noise level tr
19. See How to Assign a Sensor File in Chapter 3 Station Manager of the Model 793 00 System Software manual for a detailed procedure Model 493 10 793 00 Controller Service Calibrating Temposonics Sensors Task 4 Turn on hydraulic pressure This task sets up the Control Panel so you can turn on the hydraulic pressure AS 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 to your system Stay clear of the actuators when applying hydraulic pressure ee See Turn on hydraulic pressure on page 159 for a detailed procedure iw gt f p Model 493 10 793 00 Controller Service 213 Calibrating Temposonics Sensors Task5 Set the zero position The zero position can be set anywhere within the full scale range of the Temposonics sensor 1 Adjust the Manual Cmd slider on the Manual Command window to move the actuator to the position you want to assign as Zero 2 Use Control Mode on the Control Panel to select any control mode that does not use the Temposonics sensor Note _ f the actuator should move after making the change in control modes you will need to reposition the actuator then change to a more stable control mode 3 With the actuator in the desired zero position click the Aut
20. The amount of time to reach low pressure depends on the low pressure setting 72 Model 493 10 793 00 Controller Service Station Connections hwi file settings The following items can be specified in the hwi file For more information see Hydraulic Control on page 286 e HSM ramp rate from zero to high pressure HSM RATE SLOW zero to high pressure in approximately 4 seconds FAST zero to high pressure in approximately 2 seconds e HSM high pressure to zero mode HSM OFF MODE STEP HSM steps from high pressure to zero default RAMP HSM ramps from high pressure to zero Important Unless there is a special need HSM OFF MODE should not be set to RAMP For your safety keep this setting at STEP e HSM low pressure setting as a percentage of full scale LOW PERCENT e HSM high pressure setting as a percentage of full scale HIGH PERCENT e HSM type can be set to PROPORTIONAL SOLENOID or ON_OFF_SOLENOID If you select ON_OFF_SOLENOID only 2 HSM control buttons OFF ON will appear on the Station Manager Station Controls panel For the other selections 3 HSM control buttons will appear OFF LOW HIGH Model 493 10 793 00 Controller Service 73 Station Connections J29 Load Unit Connector J29 Load Unit connects to the load unit lift lock panel Pins 1 2 3 and 4 can be configured for had th x 24 V DC 1 contacts with jumpers X and X ora
21. Ww e o co Q o Copyright information Trademark information Software verification and validation Publication information 2002 MTS Systems Corporation All rights reserved MTS Temposonics and TestWare are registered trademarks of MTS Systems Corporation FlexTest MPT 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 t
22. and system number Know information from 14 prior technical assistance Identify the problem Preface 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 MTS If you do not have or do not know your MTS site number contact your MTS sales engineer 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 MIS 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 Model 493 10 793 00 Controller Service Technical Support Know relevant computer If you are experiencing a computer problem have the following information informat
23. on page 267 Model 493 10 793 00 Controller Service 71 Station Connections J28 HSM Connector J28 HSM controls the pressure of a hydraulic service manifold The controller software can configure the connector for solenoid or proportional control of a 24 volt hydraulic service manifold From Chassis J28 To HSM lo 424V 0 gt 1 Low Pressure C Solenoid E a 2 DC Common i Solenoid or Proportiona a gt 3 Shield C Proportional hi Valve E 4 High Pressure Proportiona Cable specification e P28 is a 4 contact CPC male connector AMP Incorporated e Cable for on off HSMs 18 AWG 2 conductor with overall foil shield Carol C2534 or equivalent with drain wire connected to pin 3 at the chassis e Cable for high low HSMs 18 AWG 4 conductor with overall foil shield Carol C2543 or equivalent with drain wire connected to pin 3 at the chassis Proportional output The proportional output is configured with the controller software e The output signal can be ramped from 20 mA minimum to 700 mA maximum which corresponds with 50 psi 0 4 MPa and 3000 psi 21 MPa By default low pressure is factory set at 750 psi and high pressure is set at 3000 psi e The ramp rate from zero to high pressure can be set to two or four seconds The ramp rate from high pressure to zero can be set to zero two or four seconds e The ramp rate is constant set to the two or four second rate
24. 10 KN In this step you would apply 8 kN of command and even though the station signals would read 8 kN of feedback the force standard may only read 4 kN This shows the conditioner sensor pair are out of calibration Adjust gain until the actual tensile force equals your tensile force command Adjust the Post amp Gain control on the Calibration tab to increase the tensile force reading on the load standard until it equals your tensile force command Apply a compressive force command that is 80 of the full scale range A Adjust the Manual Command slider for a compressive force command that is 80 of the full scale range B Use the Station Signals panel to verify that the compressive force signal is approximately equal to 80 of the full scale range Model 493 10 793 00 Controller Service Calibrating a Force Sensor 12 Record conditioner feedback readings at predetermined tensile force command point Note After shutting down system hydraulics you will enter these recorded readings on the Linearization Data window A Adjust the Manual Cmd slider for a 0 command Record the force standard readout signal and corresponding conditioner feedback reading at the 0 command line of your record sheet C Adjust the Manual Cmd slider for a 2 tensile force command D Record the force standard readout signal and corresponding conditioner feedback reading at the 2 command line of your record sheet E Repeat steps
25. Adjustments tab of the Tuning panel to correct sluggish actuator movement Increase the reset integration value I Gain to help the feedback match the command At this point unless the conditioner is already calibrated the actuator s physical extension will not equal your commanded value You will adjust Delta K in the next step so that the actuator s physical extension and your commanded extension match Example Suppose your actuator has a 100 extension of 10 cm In this step you would apply a 8 cm command and even though the station signals would read 8 cm of feedback the actuator may extend only 4 cm This shows the conditioner sensor pair are out of calibration 6 Adjust Delta K to extend the actuator until it equals your extension command Adjust the Delta K slider on the Calibration tab until the dial indicator or other readout device shows that the actuator s physical extension equals your extension command iw gt f p Model 493 10 793 00 Controller Service 167 Calibrating an LVDT 7 If applicable repeat steps 5 and 6 for all ranges Example Suppose you have an actuator with a full scale capacity of 10 cm and ranges of 10 cm 5 cm 2 cm and 1 cm In this case you would repeat this process and calibrate extension at 80 of each range 8 cm 4 cm 1 6 cm and 0 8 cm Note Some systems use full range conditioners e g Model 493 25 DUC module In this case only one ra
26. Controller y J 6 OUT 1 f ActiveHigh P43 To D 9P 493 74 HSM 24V own 1 Transition gt __ Jumper DRA ae 3 Jumper 4 24v ow 5 H 6 IJ oe OFF INTLK Jumper d 8 Interlock Cable PN 56455 0XX 94 Model 493 10 793 00 Controller Service Cabling and Programming External Controllers How to Jumper the Hydraulic Terminal on a Single Station 407 The following figure shows how to cable the hydraulic terminal on a single station 407 controller 407 Controller No Connection Jumper Plug PN 049 635 901 No Connection Jumper Plug PN 049 635 901 Model 493 10 793 00 Controller Service 95 Cabling and Programming External Controllers Multiple 407 Controller Interlock Connections The following figure shows how to cable interlocks for multiple 407 controllers to the Model 493 10 793 00 controller via its Model 493 74 HSM transition module Use the specified interlock cable PN 56455 Oxx to make these connections for each 407 controller station P28 Digital CPC 4P I O Connector HSM LO la i 24vo t 1 gt 3 Hydraulic j MES 4 DIGITAL gt Interlock T 5 ag fe f ActiveLow 407 7 5 L oemat Run Stop Controller me J El OUT 1 f ActiveHigh Station 1 UY P43 To D 9P 493 74 E HSM 24V OW 1 Transition 2 Jumper HYD INTLK J u 3 Jum
27. FRDUC_53 0UT CHANNEL 1 NAME 493 25 DC Slot 5 1 CONNECTOR J4 MODE DC FILTER 300 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 25 FILENAME FRDUC_53 0OUT CHANNEL 2 NAME 493 25 AC Slot 5 2 CONNECTOR J5 MODE AC FILTER 300 Model 493 10 793 00 Controller Service 271 i gz i D wn oe st F i iar i a ce i i 7 a i i dm D i o gt i h n os i i Qa i 272 DAUGHTER 3 ADDRESS 0x20000 TYPE 493 46 FILENAME D2A_53 0UT CHANNEL 1 NAME Analog Output 1 Slot 5 3 CONNECTOR J6 CHANNEL 2 NAME Analog Output 2 Slot 5 3 CONNECTOR J6 CHANNEL 3 NAME Analog Output 3 Slot 5 3 CONNECTOR J6 CHANNEL 4 NAME Analog Output 4 Slot 5 3 CONNECTOR J6 CHANNEL 5 NAME Analog Output 5 Slot 5 3 CONNECTOR J6 CHANNEL 6 NAME Analog Output 6 Slot 5 3 CONNECTOR J6 DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 7 NAME 493 14 2SVD Slot 5 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED IO CARRIER ADDRESS 0xC2600000 SLOT 6 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME FRDUC_53 0UT CHANNEL 1 NAME 493 25 DC Slot 6 1 CONNECTOR J4 MODE DC FILTER 300 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 2 NAME 493 25 AC Slot 6 2 CONNECTOR J5 MODE AC FILTER 300 Daughter 3 is empty and used for optional boards DAUGHTER 4 ADDRESS 0x300
28. connector that is available for analog outputs The TYPE and FILENAME identify the daughter board as a D A board The address specifies the front panel connector DAUGHTER 2 ADDRESS 0x10000 TY PE 493 46 FILENAME D2A_53 0UT CHANNEL 4 NAME Analog Output 1 Slot 2 CONNECTOR J5 CHANNEL 5 NAME Analog Output 2 Slot 2 CONNECTOR J5 CHANNEL 6 NAME Analog Output 3 Slot 2 CONNECTOR J5 CHANNEL 7 NAME Analog Output 4 Slot 2 CONNECTOR J5 CHANNEL 8 NAME Analog Output 5 Slot 2 CONNECTOR J5 CHANNEL 9 NAME Analog Output 6 Slot 2 CONNECTOR J5 The name in quotes appears in the The board address determines Station Builder application as a system the connector that must be resource You can edit this if you want specified here Model 493 10 793 00 Controller Service 301 Analog Input Analog Input The analog input definition describes the A D Analog Input daughter board 2 t e The CONNECTOR specification identifies the rear panel connector that is available for analog inputs The address specifies the The TYPE and FILENAME identify the daughter front panel connector board as an A D board DAUGHTER 3 ADDRESS 0x20000 TYPE 493 45 FILENAME A2D_53 0UT CHANNEL 1 NAME Analog Input 1 Slot 3 CONNECTOR J6 CHANNEL 2 NAME Analog Input 2 Slot 3 CONNECTOR J6 CHANNEL 3 NAME Analog Input 3 Slot 3 CONNECTOR J6 CHANNEL 4 NAME Analog Input 4 Slot 3 CONNECTOR J6 CHANNE
29. demodulation signal 1 Apply a manual command to fully retract the actuator Slide the Manual Cmd control on the Manual Command window to fully retract the actuator 2 Remove hydraulic pressure Phase adjustments are best performed in a full scale range If the actuator is not fully retracted disable hydraulic pressure 3 Adjust phase for the maximum conditioner output On the Station Signals panel monitor the appropriate AC conditioner feedback signal Adjust the Phase control on the Calibration tab to achieve a maximum value Note When adjusting phase the LVDT feedback may exceed 10 volts You may need to adjust the Gain slider on the Station Setup Drive panel for a lower conditioner gain before continuing phase adjustment iw gt gt f i Model 493 10 793 00 Controller Service 161 Calibrating an LVDT Task 7 Setthe zero and offset Establishing zero requires the actuator to be set at mid displacement when you calibrate the LVDT for equal amounts of actuator extension and retraction Suppose you have an actuator with 10 cm displacement which actually has a 20 cm displacement Setting zero at mid displacement produces a displacement of 10 cm this is the most common approach However you can set zero anywhere within the full scale of the sensor such as with the actuator fully extended or retracted to produce a displacement range of 0 mm 20 mm Before beginning be sure the follow
30. detailed procedure Model 493 10 793 00 Controller Service 139 Shunt Calibration Shunt Calibration Bridge Completion 1 0 Carrier Module 140 Shunt calibration connector On a typical system shunt calibration and bridge completion resistor installation is completed on the I O Carrier module If you have purchased optional sensor cables with transducer ID modules shunt calibration and bridge resistors are installed on these modules The I O Carrier module has a shunt calibration connector on its front panel that allows up to four shunt resistors 1 per slot to be plugged in The SHUNT CAL connector is labeled to indicate which slot the shunt calibration resistor is tied to Each shunt calibration resistor is soldered to a 2 pin holder MTS part number 114338 26 This holder plugs into the front panel connector shown below Refer to the 493 40 41 Carrier I O Shunt Calibration Kit MTS part number 100 028 185 for more detailed information on kit components and installation OO SHUNT CAL 1 VA 10 Option Slot 1 Shunt Cal Resistor Location 2 VAA 41 0 Option Slot 2 Shunt Cal Resistor Location 3 NWA 4 0 Option Slot 3 Shunt Cal Resistor Location 4 VAA IO Option Slot 4 Shunt Cal Resistor Location i rd Model 493 10 793 00 Controller Service Shunt Calibration Bridge completion Each of the four I O option card slots on the I O Carrier module circu
31. p Model 493 10 793 00 Controller Service 183 Calibrating a Force Sensor Task6 Setthe zero and offset This task records the load standard readout as the zero reference Using a load standard Adjust the Manual Cmd slider on the Manual Command window for 0 kN Then zero the load standard readout Using dead weights Remove all dead weights and then click Auto Offset on the Offset Zero tab Inputs panel S bd K o 184 Model 493 10 793 00 Controller Service Calibrating a Force Sensor Task7 Gain Delta K Calibration Calibrate tension Gain controls If you are using Gain Delta K for your calibration type complete the following procedure If not complete Task 8 Gain Linearization Calibration on page 190 or Task 9 Millivolt Volt Calibration on page 197 Force sensors can be calibrated so that a positive output represents actuator compression and a negative output represents actuator tension and vice versa You calibrate the negative side of the output with gain and Indicated output the positive side of the output with Delta K AK 1 AK lt 1 Delta K compensates for differences in symmetry between positive and negative outputs mechanical input Calibrate compression at 80 full scale for each range Note This procedure assumes a positive command extends the actuator and a negative command retracts the actuator If not use the opposite polarity for any val
32. 3 NAME Analog Input 1 Slot Y 3 CONNECTOR J6 CHANNEL 4 NAME Analog Input 2 Slot Y 3 CONNECTOR J6 CHANNEL 5 NAME Analog Input 3 Slot Y 3 CONNECTOR J6 CHANNEL 6 NAME Analog Input 4 Slot Y 3 CONNECTOR J6 CHANNEL 7 NAME Analog Input 5 Slot Y 3 CONNECTOR J6 CHANNEL 8 NAME Analog Input 6 Slot Y 3 CONNECTOR J6 Model 493 10 793 00 Controller Service 291 ay J i t ADDA II module ADDA II module Adding ADDA II modules ADDA II addresses ADDA II daughter boards 292 When the optional Model 493 50 ADDA II module is being used the hwi file describes this module and the A D D A and encoder daughter boards that are installed on it Each Model 493 50 ADDA II module added to the 493 10 Chassis must be described in the ADDA II definition A typical description for an added ADDA II module is shown below ADDAII ADDRESS 0x0 SLOT 7 CLOCK TYPE SLAVE You must set the address on the added ADDA II module to match the address specified in the ADDA II module s definition See Setting ADDA II addresses on page 33 for more detailed information As additional ADDA II modules are installed their addresses increment as follows ADDA II ADDRESS ADDRESS MODULE SET ON ADDA II BOARD Hwi First 0xC4000000 0x0 Second 0xC4100000 0x1 Third 0xC4200000 0x2 Fourth 0xC4300000 0x3 Fifth 0xC4400000 Ox4 The following ADDA II daughter boar
33. 4 15 Excitation Sense Model 493 10 793 00 Controller Service 127 Transducer Connections LVDT connections An LVDT requires an AC conditioning daughter board lt _ E7 Backshell Inner E3 AC Sensor LVDT Guard 3 pp CESE EE PAETE O FB oy ES Transducer ID Module spea Le EL gs a EX 9 __ ____ iz EX asasasas Fi Remote Cal 9 Remote Cal Clk Data to ID a Data from ID ID Circuit Sig Gnd Temposonics l A Temposonics II transducer requires a DC conditioning daughter connections board EX x rer i AS sneen Es EX EXC FDBK A fot 4 joi i FDBK FDBK A D DC FROM F RETURN TEMPOSONICS II I 8 TRANSDUCER D E XJ REMOTE CAL SIG GND CLK DATA TO ID DATA FROM ID ID Circuit E 128 Model 493 10 793 00 Controller Service Temposonics III connections 24 V AUX POWER COM TO 493 40 CARRIER MODULE Force strain sensor connections GND E7 Backshell T S sie ares SPE Inner E3 Guard SEE Er sess SETE FB 5 sn i 4 FBR 13 Future Transducer ID Module FB 4 Ea FBR 2 Future EX 2 E29 EXS 5 Future EX 1 Elo EXS 0 Future Remote Cal 9 Remote Cal Clk 8 Palate i ID Circuit Data from ID 4 Sig Gnd 6 TEMPOSONICS III DAUGHTER BOARD BACKSHELL Transducer Co
34. 50 100 k 20 249 k 10 499 k 350 Q 1 mV V 100 100 k 50 200 k 20 499 k 10 1000 k 700 Q 2 mV V 100 100 k 50 200 k 20 499 k 10 1000 k 700 Q 1 mV V 100 200 k 50 402 k 20 1000 k 10 2000 k 5 Install the shunt calibration resistor as follows A Select the appropriate shunt calibration resistor B Bend the resistor leads 90 for a 0 3 inch separation 228 Model 493 10 793 00 Controller Service Calibrating an Extensometer Cut the resistor leads 0 12 inch from the bend Insert the resistor into the connector solder cups and solder Complete and attach a shunt calibration label as specified on the 493 40 41 Carrier I O Shunt Calibration Kit MTS PN 100 028 185 Install the shunt cal resistor connector assembly into the appropriate slot of the SHUNT CAL connector on the front panel of the appropriate I O Carrier Module CON SHUNT CAL 1 Sh t10 Option Slot 1 Shunt Cal Resistor Location 2 LVN 4 T I O Option Slot 2 Shunt Cal Resistor Location 3 WA 4 I O Option Slot 3 Shunt Cal Resistor Location 4 AA lt 0 Option Slot 4 Shunt Cal Resistor Location ee 6 Perform shunt calibration A Model 493 10 793 00 Controller Service In Station Setup select the appropriate strain channel on the navigation panel click the Channel Input Signals icon and then click the Shunt tab Select the shunt type Use polarity if you are not sure what to select
35. 74 Model 493 10 793 00 Controller Service J43 Interlock Connector J43 Interlock accommodates two general purpose inputs to be connected to the interlock chain Both inputs can accept relay contacts or a logic signal Both configurations are shown Each input can be have either configuration Cable specification Station Connections Input 1 is dedicated as a station interlock Input 2 is dedicated as a program interlock Both inputs are optically isolated If just one contact is used the other must be jumped To J43 From Chassis External Device 24V 0 WW gt 1 Input 1 AW 2 flay Station J ZF Interlock 3 contacts a E NZ 24 Vo MW 5 eS logic Poor il ig dr ver Program gt sy Interlock i 7 a 8 VW 9 contact type D male EMI connector Backshell EMI metallized plastic Cable shielded twisted pairs 24 AWG minimum with drain wire s connected to the metallized backshell at the chassis Power Channel inputs can be 3 volts minimum and 26 volts maximum characteristics from an external voltage source Jumper plug If connector J43 is not used you must install a jumper plug to maintain the integrity of the interlocks Use jumper plug 100 007 948 or jumper pins 1 and 2 3 and 4 5 and 6 7 and 8 Model 493 10 793 00 Controller Service 75 Station Connections J44 Run Stop Run Stop status Connector J44 Run Stop provides the r
36. 793 00 Controller Service Preface 15 Technical Support Identify system type Be prepared to troubleshoot Write down relevant information After you call Problem Submittal Form in MTS manuals 16 Preface 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 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 e If you are not familiar with all aspects of the equipment operation have an experienced user nearby to assist you Prepare yourself in case we need to call you back e 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 Fo
37. 9 2 CONNECTOR J5 DAUGHTER 3 ADDRESS 0x20000 TYPE 493 46 FILENAME D2A_53 0UT CHANNEL 1 NAME Analog Output 1 Slot 9 3 CONNECTOR J6 CHANNEL 2 NAME Analog Output 2 Slot 9 3 CONNECTOR J6 CHANNEL 3 NAME Analog Output 3 Slot 9 3 CONNECTOR J6 CHANNEL 4 NAME Analog Output 4 Slot 9 3 CONNECTOR J6 CHANNEL 5 NAME Analog Output 5 Slot 9 3 CONNECTOR J6 CHANNEL 6 NAME Analog Output 6 Slot 9 3 CONNECTOR J6 DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 7 NAME 493 14 2SVD Slot 9 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED IO CARRIER ADDRESS 0xC2E00000 SLOT 10 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME FRDUC_53 0UT CHANNEL 1 NAME 493 25 DC Slot 10 1 CONNECTOR J4 MODE DC FILTER 300 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 2 NAME 493 25 AC Slot 10 2 CONNECTOR J5 MODE AC FILTER 300 Daughter 3 is empty and used for optional boards DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 10 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED Model 493 10 793 00 Controller Service 281 i gz i D wn oe st F i iar i a ce i a i 7 a i i dm D i o gt i h n os i i Qa i 282 DIO TRANSITION BOARD TRANSITION SLOT 10 CONNECTOR J3 222
38. A and B can not be used with powered MTS transition modules The chassis can be rack mounted or used in a floor standing configuration The chassis has ten VMEbus slots that support a variety of MTS VMEbus plug in modules A typical complement of modules would include e The chassis requires at least one processor module The processor module provides the processing power to manage the other plug in modules that make up the controller e The chassis can have up to eight I O Carrier modules Each I O Carrier module supports up to four daughter boards e An optional GRES module provides several connections to communicate with external devices such as a remote station control module temperature controller and other devices Transition modules are panels plugged into the transition bus located in the rear of the chassis Each transition module allows external devices to interface with the chassis Transition modules provide the following e Hydraulic control connections e Station control connections e Analog input and output connections e Digital input and output connections e Serial connections The chassis has a conduit that allows cables to be routed from the front VMEbus modules to the rear transition modules and out of the chassis Model 493 10 793 00 Controller Service Functional Description Power supply Two power supplies are used One provides 5 VDC and 15 VDC for the plug in modules the other provides 12 VDC for p
39. C and D for other tensile force commands typically at 4 6 8 10 20 40 70 and 100 percent of full scale 13 Record conditioner feedback readings at predetermined compressive force command points A Adjust the Manual Cmd slider for a 2 compressive force command B Record the force standard readout signal and corresponding conditioner feedback reading at the 2 command line of your record sheet C Repeat steps A and B for other compressive force commands typically at 4 6 8 10 20 40 70 and 100 percent of full scale 14 Turn off system hydraulics iw gt f p i Model 493 10 793 00 Controller Service 195 Calibrating a Force Sensor 15 On the Linearization Data window enter the force standard values and corresponding conditioner feedback readings for all command points previously recorded on a separate sheet Click Linearization Data to open the Linearization Data window i Linearization Data x m Fullscale Min Max 1000 0 1000 0 DaN r Data Range From y To 100 Recommended Standard Conditioner 20 000 TTY BETTE 60 000 TTY NET 40 000 OTT REET 20 000 TT EET 0 0000 TINY aT 20 000 ETT ETT 40 000 OTT TT 60 000 TT ET 80 000 TT TET 16 Turn on system hydraulics 17 Verify linearization data A Adjust the Manual Cmd slider for each retraction and extension command point on the Linearization
40. Controller To send programming to an external controller you must Cabling and Programming External Controllers 1 Cable the controllers on page 89 2 Create your configuration file with Station Builder on page 92 3 Adjust the signals with Station Manager on page 93 4 Set up your program on page 93 Task 1 Cable the controllers Cable the analog inputs and outputs between the Model 493 10 chassis and a 407 controller as follows Note Analog I O connectors are located on the rear panel of the chassis 1 Connect a 493 76 Analog Out BNC connector to the program analog input on the 407 Controller Connections for single or multiple 407 controllers are shown If you will monitor sensor feedback for data acquisition or control feedback connect the external controller s conditioner output to a 493 77 Filtered Analog Input BNC connector For conditioner output locations on various MTS devices see Sample conditioner output connections on page 92 ee AA WARNING Do not interrupt Model 493 10 793 controller power when you are programming another controller A power interrupt may cause the external controller to react to a zero command and move the actuator unexpectedly Ensure power cannot be removed accidently while a test is in progress For more detailed information about analog I O connections see Analog I O Connections on page 52 Model 493 10 793 00 Controller Ser
41. Data window B At each command point verify both the force standard value Standard and its corresponding conditioner feedback value Conditioner C Check validity before entering each pair of values on a new Calibration Data Sheet S bd K o 196 Model 493 10 793 00 Controller Service Calibrating a Force Sensor Task9 Millivolt Volt Calibration If you are using mV V Calibration for your calibration type complete the following procedure If not complete Task 7 Gain Delta K Calibration on page 185 or Task 8 Gain Linearization Calibration on page 190 Millivolt volt calibration is used for transducers that have two different slopes positive and negative Positive Tension Slope mv V Negative Compression Slope mV V In this calibration process system software calculates conditioner Delta K Gain and Gain values from previously measured mV V values under both tension and compression The slope and gain values are derived from and are relative to the output of the load cell transducer as follows Compression mV V Delta K Gain Tension MNN Where Compression is specified using the Neg Compression or Pos Compressive entry box on the Calibration tab Tension is specified using the Neg Tension or Pos Tension entry box on the Calibration tab iw gt f p Model 493 10 793 00 Controller Service 197 S bd K ca Calibrating a
42. Digital Input 5 INPUT 6 NAME Digital Input 6 Model 493 10 793 00 Controller Service 273 i gz i D wn oe st F i iar i a ce i a i 7 a i i dm D i o gt i h n os i i Qa i 274 2 23232222222 PUT 7 NAME Digital Input 7 PUT 8 NAME Digital Input 8 PUT 9 NAME Digital Input 9 PUT 10 NAME Digital Input 10 PUT 11 NAME Digital Input 11 PUT 12 NAME Digital Input 12 PUT 13 NAME Digital Input 13 PUT 14 NAME Digital Input 14 PUT 15 NAME Digital Input 15 PUT 16 NAME Digital Input 16 CONNECTOR J4 OU OU OU OU OU OU OU OU OU OU OU OU OU OU OU OU TPUT 1 NAME Digital Output 1 TPUT 2 NAME Digital Output 2 TPUT 3 NAME Digital Output 3 TPUT 4 NAME Digital Output 4 TPUT 5 NAME Digital Output 5 TPUT 6 NAME Digital Output 6 TPUT 7 NAME Digital Output 7 TPUT 8 NAME Digital Output 8 TPUT 9 NAME Digital Output 9 TPUT 10 NAME Digital Output 10 TPUT 11 NAME Digital Output 11 TPUT 12 NAME Digital Output 12 TPUT 13 NAME Digital Output 13 TPUT 14 NAME Digital Output 14 TPUT 15 NAME Digital Output 15 TPUT 16 NAME Digital Output 16 Model 493 10 793 00 Controller Service 8 Station Configuration HSM power limits Interlocks RSC A D analog inputs HWI settings Model 493 10 793 00 Controller Service 275 The 8 Stati
43. Digital vo Connectors J10 and J20 on the side of the module and on top of the module are the same I The top connectors are used Eira sta 1 0 Channels when the module is configured for use in a console mnj o 5 g 5 g Inputs N i h a 1 EJ a jega 1 alma JE 00000000000 90040000000 o o o oo o o ie sg External Device VDC cE a Bare aa Input Devices gi ma oo 0 z ogo AL oo oo 3 J z jk A E a E 9 E 82 Model 493 10 793 00 Controller Service Workstation Connection Workstation Connection The workstation computer is connected to the Model 498 96 Processor module installed in the VMEbus of the chassis It is an Ethernet 10 100 Base T connection The workstation computer must have an Ethernet compatible connector 498 98 2 Power PC J BFL T O cpu rst O O Pme O Note If your processor has more than one Ethernet 10 100 Base T connection use the connection labeled LAN 1 Lm MT
44. 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 to your system Stay clear of the actuators when applying hydraulic pressure ee 1 On the Station Manager window ensure that the channel associated with the extensometer signal you are calibrating has strain selected for its active control mode 2 If the Interlock indicator is lit click Reset If the indicator lights again you must determine the cause and correct it before proceeding 3 In the power selection box click the Power Low button and then Power 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 4 If an HSM is present click the Power Low button and then Power High for the appropriate HSM 5 Apply a positive strain command and observe the strain feedback value on your meter If you have control of the actuator proceed to Task 5 on page 220 If you do not have control of the actuator for example the actuator is hunting or moving in the wrong direction disable hydraulics change the conditioner polarity and then perform Task 4 again For more detailed information on applying hydraulic pressure and clearing interlocks refer to Chapter 3 Station M
45. EET 20 000 TT TTT 00000 ETN RTE 20 000 TT TT 40 000 OTT TT 0 000 TT TET te 00 000 00 000 _Dan_ Model 493 10 793 00 Controller Service Calibrating a Force Sensor Force sensor If the force sensor has been previously calibrated use the following recalibration procedure 1 Locate the calibration data sheet for the appropriate conditioner 2 Turn off system hydraulics 3 Click Linearization Data on the Calibration tab to open the Linearization Data window 4 Transfer Standard and Conditioner data from the conditioner s calibration data sheet to corresponding data entries on the Linearization Data window 5 Turn on system hydraulics 6 Verify linearization data A Adjust the Manual Cmd slider for each tensile and compressive force command point on the Linearization Data window B At each command point verify both the dial indicator value Standard and its corresponding conditioner feedback value Conditioner by comparing them with the corresponding values on the Calibration Data sheet If the data is valid Stop this procedure If the data is not valid Proceed to the next step 7 Click Reset on the Linearization Data window to return to default values 8 Exercise the force standard Use the Manual Cmd slider on the Manual Command window to cycle the load standard readout between zero and full tension three times This removes sensor hysteresis Example When calibrati
46. Force Sensor Gain Conditioner Output Voltage Excitation Voltage x Compression mV V Where Conditioner Output Voltage is typically 10 Vdc Excitation Voltage is specified using the Excitation entry box on the Calibration tab Compression is specified using the Negative Compression or Positive Compressive entry box on the Calibration tab mV V positive tension Use the following procedure if your force transducer is set up so that a calibration positive output represents actuator retraction tension 1 Select mV V Pos Tension for Cal Type on the Calibration tab of the Inputs panel Note For convenience during mV V positive tension calibration Gain and Delta K are presented as read only displays on the Inputs panel 2 From the Calibration Data sheet for your force transducer enter the following values on the Calibration tab A Enter the full scale force values in the Fullscale Min Max entry boxes B Adjust Pos Tension for the required tension sensitivity value mV V C Adjust Neg Compression for the required compression sensitivity value mV V D Adjust Excitation for the required calibration excitation value Vdc 198 Model 493 10 793 00 Controller Service Calibrating a Force Sensor mV V positive Use the following procedure if your force transducer is set up so that a compression calibration positive output represents actuator extension compression 1 Select mV V Pos Compression for Cal Type on th
47. How to Warm Up the System Hydraulics in Chapter 5 Tuning of the Model 793 00 System Software manual for a detailed procedure You make servovalve adjustments to optimize the valve response to your program commands Normally servovalves are balanced and tuned at the factory and then optimized by the MTS service engineer who installs your system However if you change or replace a hydraulic component or notice erratic servovalve response during a test you may need to readjust your servovalve settings Model 493 10 793 00 Controller Service 113 Use the following paragraphs to determine when to perform each servovalve adjustment Note During system installation perform all of the adjustments in this section Initial adjustments Perform initial adjustments when initially installing the system or replacing a hydraulic component These adjustments such as setting servovalve polarity are only needed once and should not require readjustment See Setting the Servovalve Polarity on page 115 Valve balance While running a test on a properly tuned system you observe that the controlling sensor s peak and valley amplitudes are unequal When you have completed a mechanical valve adjustment always adjust the valve balance See Adjusting Valve Balance on page 117 2 i ih Ez gt i gt k nn Dither Adjust the dither while running a test on a properly tuned system you observe
48. I O carrier daughter boards connecting 45 description 34 35 320 I O carrier module 252 servovalve connection 47 256 servovalve connection 48 257 servovalve connection 49 accelerometer connection 56 analog I O cable specifications 55 analog I O connection 52 analog inputs 53 bridge completion circuits 141 connecting force strain sensor 129 connecting LVDT 128 D A connection 54 64 daughter boards 45 encoder connections 58 J3 Service connector 87 servovalve cable specifications 46 servovalve connections 46 shunt calibration connector 140 initial limit detectors 124 innerloop signals 120 tuning 119 installing 493 10 chassis 26 plug in modules 30 transition panels 36 VMEbus modules 31 integral gain 241 interlock HSM transition connections 75 76 interlocks 21 J jumpers shunt cal 131 4 8 wire sensor cable 130 active guard 130 bridge balance 132 digital I O transition module 80 digital universal conditioner DUC 130 excitation sense 131 HPU converter 264 hydraulic terminal 407 94 95 96 J24 E stop input 67 J25 HPS 68 J29 load unit 74 J43 interlock 75 single ended excitation 132 Model 493 10 793 00 Controller Service L load unit HSM transition connections 74 load washer definitions 304 low frequency ground loops correcting noise problem 41 LVDT I O carrier connection 128 LVDT calibration about 149 actuator extension 167 actuator retraction 165 additional ranges 175 check conditoner pola
49. In the Current Shunt Value box click the On button Note the Current Shunt Value it should be 60 90 80 is ideal of the calibrated range of the sensor Click Update to copy the Current Shunt Value into the Shunt Reference Value box and then click Off 229 iw gt f p Calibrating an Extensometer Task9 Save the calibration settings Click Update File on the Calibration tab to save the current calibration values to your current sensor calibration file Task 10 Calibrate any additional ranges This task describes how to calibrate additional ranges Each sensor calibration file can have calibration data for four ranges If you have a need for additional ranges create another sensor calibration range e Use the calibration values from the previous range as a starting point e If you adjust the zero reference it may affect the other ranges Note Some systems do not provide or require multiple ranges such as those using full range conditioners e g Model 493 25 DUC module In this case only one range is used typically 100 Adding a range If sensor calibration file must have additional ranges defined perform the following 1 Open the sensor file for the sensor you have just calibrated 2 Click Add under Range Definition 3 Select the units for the range and then enter the absolute value of the range 4 Save the new range to the calibration file 5 Calibrate the added rang
50. JAY _ AK lt 1 mechanical input To calibrate the negative extensometer output 1 Use the Manual Cmd slider to adjust the calibrator between zero and 100 of the extensometer s full scale range three times This exercises the extensometer to remove any hysteresis 2 Apply a negative command equal to 80 of the negative full scale value in this example 8 cm cm 3 Note the strain signal value on your meter 4 If the signal value does not match the commanded level increase the Post Amp Gain control on the Calibration tab to achieve an 80 value 8 cm cm Record your final strain signal value from the meter for the 80 output Model 493 10 793 00 Controller Service 221 iw gt gt f i Calibrating an Extensometer Note _ f you cannot apply enough Post amp gain to achieve an 80 value you will need to disable hydraulics change the Excitation voltage enable hydraulics and then repeat this task 5 Repeat steps 1 4 for a 20 40 60 and 100 negative output Calibrate the positive To calibrate the positive extensometer output output compression 1 Use the Manual Cmd slider to adjust the calibrator between zero and 100 of the extensometer s full scale range three times This exercises the extensometer to remove any hysteresis 2 Apply a positive command equal to 80 of the positive full scale value Gin this example 8 cm cm 3 Monitor the strain signal value on your
51. Model 493 74 HSM transition board contains two separate circuits the system wide interlock HPU and the station interlock HSM an o 2 T System wide interlock The emergency stop circuit consists of a loop that only runs through the rear panel transition boards of the chassis Any board that generates an interlock by breaking this system wide loop causes the hydraulic power unit to be shut down This will also cause all of the stations to shut down Note The emergency stop circuit meets the requirements of the Machinery Safety Directive EN 60204 1 1992 section 9 2 5 4 This means the emergency stop circuit is hard wired with electromechanical components Model 493 10 793 00 Controller Service 21 Functional Description Station interlocks Each station represents all of the components associated with an interlock chain All of the modules plugged into the chassis can be assigned to stations If one of the stations generates an interlock all of the components assigned to the station are shut down Standard configurations support up to four independent stations i T gz i i pz 22 Model 493 10 793 00 Controller Service Specifications Specifications PARAMETER SPECIFICATION Environmental For indoor use only Temperature 5 40 C 41 104 F Relative humidity 10 85 noncondensing Altitude For use at altitudes up to 2000 m 6500 ft Power input power factor cor
52. OUT CHANNEL 2 NAME 493 25 AC Slot 5 2 CONNECTOR J5 MODE AC FILTER 300 Daughter 3 is empty and used for optional boards Model 493 10 793 00 Controller Service DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 5 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED IO CARRIER ADDRESS 0xC2600000 SLOT 6 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME FRDUC_53 0UT CHANNEL 1 NAME 493 25 DC Slot 6 1 CONNECTOR J4 MODE DC FILTER 300 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 2 NAME 493 25 AC Slot 6 2 CONNECTOR J5 MODE AC FILTER 300 Daughter 3 is empty and used for optional boards DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 6 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED IO CARRIER ADDRESS 0xC2800000 SLOT 7 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME FRDUC_53 0UT CHANNEL 1 NAME 493 25 DC Slot 7 1 CONNECTOR J4 MODE DC FILTER 300 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 2 NAME 493 25 AC Slot 7 2 CONNECTOR J5 MODE AC FILTER 300 Daughter 3 is empty and used for optional boards Model 493 10 793 00 Controller Service 279 i gz i D wn oe st F i iar i a ce f i 7 DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 F
53. P1000 Minimum E CE E Maximum 100 0000 4 ag gt 0 0010 10 0000 1 I 1 1 1 1 I 1 Formatting Reset 1 0000 EJ Reset Display Unit l none h l 4 0 0000 Proportional gain P Proportional 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 The tuning command is shown as a gray square waveform and the black waveform is the sensor feedback Gain Too Low Optimum Gain Gain Too High Keep in mind e s proportional gain increases the error decreases and the feedback signal tracks the command signal more closely e Higher gain settings increase the speed of the system response e Too much proportional gain can cause the system to become unstable e Too little proportional gain can cause the system to become sluggish e Gain settings for different control modes may vary greatly For example the gain for force may be as low as 1 while the gain for strain may be as high as 10 000 Note The rule of thumb is adjust gain as high as it will go without going unstable 240 Model 493 10 793 00 Controller Service About Tuning Integral gain I Integral gain introduces an integral of the error signal that gradually over time boosts the low frequency response of the servovalve command Integral gain increases system re
54. Pe ae board for Temposonics III sensors DAUGHTER 2 ADDRESS 0x2 TY PE 493 59 5 CHANNEL 9 NAME TemposonicsIII Input 1 CONNECTOR J13 CHANNEL 10 NAME TemposonicslIII Input 2 CONNECTOR J14 296 Model 493 10 793 00 Controller Service Digital 1 0 The DIO Transition Board definition describes the Model 493 72 Digital I O Transition Panel digital input and outputs The information shown defines 16 digital inputs and 16 digital outputs ay J DIO TRANSITION BOARD TRANSITION SLOT 4 CONNECTOR J3 PUT 1 NAME Digital Input 1 PUT 2 NAME Digital Input QM ZA The name in quotes G PUT 3 NAME Digital Input 3 appears in Station Builder PUT 4 NAME Digital Input 4 as a system resource You PUT 5 NAME Digital Input 5 can edit this name PUT 6 NAME Digital Input 6 PUT 7 NAME Digital Input 7 PUT 8 NAME Digital Input 8 PUT 9 NAME Digital Input 9 PUT 10 NAME Digital Input 10 PUT 11 NAME Digital Input 11 PUT 12 NAME Digital Input 12 PUT 13 NAME Digital Input 13 PUT 14 NAME Digital Input 14 PUT 15 NAME Digital Input 15 PUT 16 NAME Digital Input 16 CONNECTOR J4 OUTPUT 1 NAME Digital Output 1 OUTPUT 2 NAME Digital Output 2 OUTPUT 3 NAME Digital Output 3 OUTPUT 4 NAME Digital Output 4 OUTPUT 5 NAME Digital Output 5 OUTPUT 6 NAME Digital Output 6 OUTPUT 7 NAME Digital Output 7 OUTPUT 8 NAME Digital Output 8 OUTPUT 9 NAME Digital Output 9 OUTPUT 10 NA
55. RSC 1 HOST PORT GRES COM 1 FILENAME POD HEX Note If you do not have an RSC this line must be commented out and a Jumper plug installed in J50 For additional information on editing your hwi file to accommodate RSCs contact MTS 308 Model 493 10 793 00 Controller Service GRES Ill GRES III The Model 498 71 GRES III module supports both the Remote Station Controller RSC and the Temperature Controller and must be added to your system when using either of these components To add a GRES III module to your system 1 2 Install the GRES III module in slot 10 of the chassis front panel In your system hwi file remove the comment markers definition from either side of the GRES III module definition shown below GRESIII ADDRESS 0xC0800000 SLOT 10 SERIAL TRANSITION BOARD TRANSITION SLOT 10 STARTING INTERLOCK 1 SERIAL PORT 1 NAME GRES COM 1 SERIAL PORT 2 NAME GRES COM 2 SERIAL PORT 3 NAME GRES COM 3 SERIAL PORT 4 NAME GRES COM 4 SERCLK RATE 4915200 HI RATE 4096 0 LO RATE 25 6 SYSTEM RATE 4096 CLOCK TYPE MASTER we Move to an appropriate section of the hwi file In the hwi file definition for the Model 493 40 I O Carrier module providing the master clock signal typically found in slot 3 change CLOCK TYPE MASTER to CLOCK TYPE SLAVE Model 493 10 793 00 Controller Service 309 ay J A Sample File A Sample File This is an tsiis
56. TYPE 493 48 FILENAME NONE e A two stage valve driver daughter board may be identified as TYPE 493 14 FILENAME D2VD_53 OUT e A three stage valve driver daughter board may be identified as TYPE 493 15 FILENAME D3VD_53 OUT Model 493 10 793 00 Controller Service 289 ay J 2 x t I O Carrier Connector assignment Channel numbering 290 e The D A output daughter board is identified as TYPE 493 46 FILENAME D2A_53 OUT e The A D input daughter board is identified as TYPE 493 45 FILENAME A2D_53 OUT Each daughter board definition requires a board address The address specifies a Carrier I O module front panel connector J4 J7 In the following example a 493 21 Universal Conditioner is assigned a board address ADDRESS 0x00000 which specifies the front panel connector J4 CONNECTOR J4 DAUGHTER 1 ADDRESS 0x00000 TYPE 493 21B FILENAME DUCB_53 OUT CHANNEL 1 NAME 493 21B DC Slot 3 1 CONNECTOR J4 MODE DC FILTER 1000 Channel numbers must be defined in terms of all analog outputs and all analog inputs in each I O Carrier Channel numbers can t be shared with other resources of the same type The hwi file has analog output channels 1 X and analog input channels 1 X Note Channel numbering is unique to each I O Carrier module Resources of the same type on different I O Carrier modules can have the same channel numbers For example the analog
57. and your commanded retraction match iw gt f p Model 493 10 793 00 Controller Service 169 Calibrating an LVDT Example Suppose your actuator has a 100 retraction of 10 cm In this step you would apply a 8 cm command and even though the station signals would read 8 cm of feedback the actuator may retract only 4 cm This shows the conditioner sensor pair are out of calibration 3 Adjust gain to retract the actuator until it equals your retraction command Adjust the Post Amp Gain control on the Calibration tab until your dial indicator or other readout device shows that the actuator s physical retraction equals your retraction command 4 Apply an extension command that is 80 of the full scale range A Adjust the Manual Cmd slider for an extension command that is 80 of the full scale range B Verify that your LVDT displacement signal feedback is approximately equal to 80 of the full scale range 5 Record dial indicator and conditioner feedback readings at predetermined retraction command points on the Linearization Data window Note After shutting down system hydraulics you will enter these recorded readings on the Linearization Data window A Adjust the Manual Cmd slider for a 0 command Record the dial indicator value for the 0 command C Enter the corresponding conditioner feedback reading in the Conditioner column at the appropriate row in the window D Adjust the Ma
58. be performed on a sensor when it is in control of the servo loop 6 Determine the shunt calibration resistor from the following table BRIDGE SENSITIVITY RANGE RESISTOR RESISTANCE FULL SCALE VALUE 350 Q 2 mV V 100 49 9 k 50 100 k 20 249 k 10 499 k 350 Q 1 mV V 100 100 k 50 200 k 20 499 k 10 1000 k 200 Model 493 10 793 00 Controller Service Calibrating a Force Sensor BRIDGE SENSITIVITY RANGE RESISTOR RESISTANCE FULL SCALE VALUE 700 Q 2 mV V 100 100 k 50 200 k 20 499 k 10 1000 k 700 Q 1 mV V 100 200 k 50 402 k 20 1000 k 10 2000 k 7 If you have sensor cables with optional transducer ID modules complete the following procedure If not proceed to Step 8 Install the shunt calibration resistor into the R9 location of the sensor ID module The sensor identification cartridge is molded into the sensor cable Solder the shunt cal resistor here 8 If you do not have transducer ID modules on your sensor cables install the shunt calibration resistor as follows A m o Oo w Model 493 10 793 00 Controller Service Select the appropriate shunt calibration resistor Bend the resistor leads 90 for a 0 3 inch separation Cut the resistor leads 0 12 inch from the bend Insert the resistor into the connector solder cups and solder Complete and attach a shunt calibration label as specified on the 493 40 41 Carrier I O Shunt Calibration Kit
59. connected together with an external shorting bar when the chassis is manufactured e For the console configuration remove the shorting bar from the ground lugs and connect the chassis ground to the console rail e For a stand alone configuration always connect the shorting wire to both ground lugs Stand alone Console Configuration Configuration Chassis ground cable P N 37766 1 02 connected to the vertical conductive rail System ground cable P N 397092 xx connected to other components SE Signal common cable P N 377661 01 connected to the power panel Chassis System ground cable ground is connected P N 054023 xx through the power cord connected to the load frame or other components a e 2 gt i 5 Model 493 10 793 00 Controller Service 27 T q N Connecting Electrical Power AC grounding Power AC power disconnect 28 The AC power ground is through the power cord The power cord must be plugged into both the chassis and the power source for proper grounding a U Proper grounding is required for safe operation It is also required to meet EMC emission and susceptibility requirements D All equipment related to the chassis should be connected on the same fused power circuit e The power supply can accept single phase voltages within 90 264 V AC at frequencies between 47 6
60. 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 13 and increase the gain setting iw gt gt f i Model 493 10 793 00 Controller Service 151 Calibrating an LVDT Actuator not fully e Ifthe actuator does not move at all return to Step 13 and retracted or extended increase the gain setting e Ifthe actuator extends the servovalve polarity is correct e Ifthe actuator retracts the servovalve polarity must be reversed Change the Polarity setting on the Valve tab of the Drive panel from Normal to Inverted or vice versa 16 In the Station Manager navigation pane click the Function Generator icon to display the Function Generator panel 17 Set up the Function Generator with the following settings CONTROL SETTING Control Channel The control channel you are tuning Control Mode Displacement Adaptive None Compensator Target Setpoint 0 Amplitude 5 of full scale Frequency 1 Hz Wave Shape square 18 Set up the Station Manager window s Scope to display the channel s command and feedback signals A In the Station Manager toolbar click the Scope button to display the Scope window B Set up the Scope window to display the channel s command and feedback signals 19 In the Station Controls panel click Program Run to start the function generator 2
61. does not require ranges its resolution is always the same See How to Create a Sensor File in Chapter 3 Station Manager of the Model 793 00 System Software manual for a detailed procedure In the Resolution box enter the encoder resolution supplied in the encoder documentation Note If want to use units different than those supplied in the sensor documentation enter the full scale and resolution in the supplied units first and then switch to the desired full scale units The units conversion will be calculated automatically Note When you change the encoder resolution on the Calibration tab it immediately changes the resolution of signal values displayed on the Station Signals Meters and Scope windows Task3 Assign a calibration file Model 493 10 793 00 Controller Service This task links a sensor calibration file created in Task 2 to a hardware resource The purpose for this is to select one of the sensor ranges for the input signal definition See How to Assign a Sensor File in Chapter 3 Station Manager of the Model 793 00 System Software manual for a detailed procedure 207 iw gt f p Calibrating Encoders Task 4 Turn on hydraulic pressure This task sets up the Control Panel so you can turn on the hydraulic pressure D 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 th
62. file When you load a station that does not have a sensor file assigned to one or more of its signals by default the system software looks for calibration information in the transducer ID See How to Save Data to an ID Module on page 144 The molded ID module has a removable cover and includes provisions for e lt A shunt calibration resistor e Upto three bridge completion resistors e A transducer ID circuit card The circuit card has the bridge completion and shunt calibration resistors on one side and the transducer ID circuit on the other e RO R7 and R8 are the bridge completion resistors e R9 is the shunt calibration resistor The following is the schematic diagram of the bridge balance and bridge completion circuit Model 493 10 793 00 Controller Service 143 Shunt Calibration Sensor ID Module I I FB 1 I EX Reomp gt i Pre amp I Rcomp R7 l i I FBR Ea FB I i I H I i Rg y Rcomp R8 gt I EX T I How to Assign a Refer to How to Assign a Sensor with a Transducer ID Module in Sensor with an ID Chapter 3 Station Manager of the Model 793 00 System Software Module manual for a detailed procedure How to Save Data to Refer to How to Save Data to a Transducer ID Module in Chapter 3 an ID Module Station Manager of the Model 793 00 System Software manual for a detailed proc
63. for a detailed procedure You can attempt to further improve tuning using the following techniques e Ifyou are running Advanced auto tuning increase the Tracking to make the feedback track the command more closely e Use the auto tuning settings as a starting point when manually tuning each control mode e If your feedback signal is noisy use a tuning filter Model 493 10 793 00 Controller Service 257 Tuning a CLC Control Mode Tuning a CLC Control Mode CLC control modes are used for specimen installation and removal Channel limited channels require two feedback signals The first one is used as the master feedback it is normally displacement and the second one is used as the limiting feedback it is normally force When you command the actuator over a channel limited channel the controller will not allow the actuator to exceed limits specified on either the master or limiting channels If force feedback gt upper limit And displacement error is positive Then use upper limit error Limit Force Limit P Gain f o Feedback Lower SO Lower Limit Limit Error Manual Displacement gas Command Error If force feedback dower limit And displacement error is negative Then use lower limit error Otherwise use displacement error Displacement Active P Gain Active P Gain 10 0 Servovalve Feedback H mM z g Command
64. for those who are experienced at calibrating sensors The abbreviated procedure lists the tasks and steps of the calibration procedure Each task and step includes the page number of the detailed procedure where the task step is described Model 493 10 793 00 Controller Service 145 iw gt f p i Detailed procedures The detailed procedures follow the abbreviated procedures They provide an enhanced sequence of the calibration procedure for those who are inexperienced at calibrating sensors Each detailed procedure is a step by step procedure arranged by tasks Each task is a group of detailed steps that accomplish a portion of the procedure Some steps include examples or helpful information Some tasks refer to more detailed procedures S bd K o 146 Model 493 10 793 00 Controller Service Before You Begin Before You Begin System warm up Signal polarity Before you start sensor calibration be sure the following are true e The sensors are properly connected to the controller see Typical Cabling on page 38 e A station configuration file has been created that includes the hardware resources associated with the sensors you want to calibrate e The Station Manager program is running and the appropriate station configuration file is open e You have completed an initial nominal tuning of the sensor channel you are calibrating This is especially important if you have
65. initial setting of the associated limit each range detectors are 130 of the range value For example suppose you select Range 1 of your system s force sensor and that Range 1 is 10 kN In this case the initial placement of the limit detectors will be 13 KN Initial 13kN Limit ___p The application places 10 kN the initial limit detectors at 130 of the selected range as Range 1 0 Fe shown d 10 kN Initial 13kN Limit By default limit detectors are initially disabled So even if you enable a limit detector at its initial setting 130 of its range value it still will not work because the sensor conditioner s hardware will saturate before attaining 130 of the current range 124 Model 493 10 793 00 Controller Service Enabling limit detectors To make a limit detector work you must change its initial setting so that it is within 100 of the selected range as shown Be aware of detector settings when changing ranges Sensor Signals To allow a limit detector to work in a given range you must e Change its limit value so that it falls within 100 of its range and e Enable it change its selected action from Disable to the desired action 9 kN Limit 10kN ARR Range 1 0 S FEE v 10 kN 7 KN Limit To set error and limit detectors see How to Set Limit Detectors and How to Set Error Detectors in Chapter 3 Stati
66. linearization data Important Changing conditioner polarity after calibration may invalidate linearization data If you need to change conditioner polarity for example when moving a sensor to a different test system the sensor may need to be recalibrated Initial LVDT For initial calibration of an LVDT complete the following procedure calibration 1 Select Gain Linearization for Cal Type on the Calibration tab of the Inputs panel 2 Apply a retraction command that is 80 of the range s full scale A Adjust the Manual Cmd slider on the Manual Command window for 80 of the full scale range B Use the Station Signals panel to verify that your LVDT displacement signal equals 80 of the full scale range During the initial calibration and tuning of your system it may require repeated adjustment for the retraction command and displacement values to match Note _ f the actuator response is sluggish and or the signal value does not match the command you will need to adjust the tuning of this contro mode Increase the proportional gain P Gain on the Adjustments tab of the Tuning panel to correct sluggish actuator movement Increase the reset integration value I Gain to help the feedback match the command At this point unless the conditioner is already in calibration the actuator s physical retraction will not equal your commanded value You will adjust gain in the next step so that the actuator s physical retraction
67. match the command At this point unless the conditioner is already in calibration the tensile force applied to the force transducer will not equal your commanded value You will adjust gain in the next step so that the actual tensile force and your commanded tensile force match Example Suppose your actuator has a 100 tensile force rating of 10 KN In this step you would apply 8 kN of command and even though the station signals would read 8 kN of feedback the force standard may only read 4 kN This shows the conditioner sensor pair are out of calibration 4 Adjust gain until the actual tensile force equals your tensile force command Adjust the Post amp Gain control on the Calibration tab to increase the tensile force reading on the load standard until it equals your tensile force command 5 Apply a compressive force command that is 80 of the full scale range A Adjust the Manual Command slider for a compressive force command that is 80 of the full scale range B Use the Station Signals panel to verify that the compressive force signal is approximately equal to 80 of the full scale range 6 Record force standard and conditioner feedback values at predetermined tensile force command points Note After shutting down system hydraulics you will enter these recorded readings on the Linearization Data window A Adjust the Manual Cmd slider for a 0 command Record the force standard s readout value and corresp
68. 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 DO EET Ef See Turn on hydraulic pressure on page 159 for a detailed procedure S bd K 182 Model 493 10 793 00 Controller Service Calibrating a Force Sensor Task 5 Verify the conditioner polarity This task checks the polarity of the conditioner Different types of test systems are configured with different conditioner polarities The polarity of the conditioner the polarity of the valve driver and the connection positions of system cabling all play a role in controlling the actuator and determining how signals are displayed This procedure assumes the servovalve polarity is set to Normal on the Station Setup Drive panel Valve tab 1 Check the sensor connection Be sure the force sensor is properly connected to the rear panel of the controller 2 Apply a load to the force sensor Push on the force sensor with your hand and note the signal value on the DVM or Station Signals panel If the signal value is positive for actuator compression the conditioner polarity is correct If desired you can change the conditioner polarity to make the signal value negative for actuator compression Note The polarity setting should be the same when calibrating additional ranges for the same sensor iw gt f
69. multiple ranges such as those using full range conditioners e g Model 493 25 DUC module In this case only one range is used typically 100 See How to Create a Sensor File in Chapter 3 Station Manager of the Model 793 00 System Software manual for a detailed procedure For LVDT calibration set the following initial conditioner calibration values CONTROL SETTING Polarity Normal Pre Amp Gain 1 0 Post Amp Gain 1 5 Excitation 10 volts Phase 45 Delta K 1 Zero 0 Model 493 10 793 00 Controller Service 157 iw 2 gt r e Calibrating an LVDT Task3 Assign a calibration file This task links a sensor calibration file created in Task 2 to a hardware resource The purpose for this is to select one of the sensor ranges for the input signal definition See How to Assign a Sensor File in Chapter 3 Station Manager of the Model 793 00 System Software manual for a detailed procedure S bd K o 158 Model 493 10 793 00 Controller Service Calibrating an LVDT Task 4 Turn on hydraulic pressure This task activates the hydraulic pressure i AL 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 to your system Stay clear
70. of the sensor conditioner combination Each DC conditioner supports a shunt resistor Perform a shunt calibration to establish a new shunt reference value for a DC sensor conditioner pair as follows 1 Turn off hydraulic power 2 Remove the load standard 3 Turn on hydraulic power 4 Zero the DC sensor output Adjust the Manual Cmd slider on the Manual Command window for a 0 kN output The sensor output must be 0 000 kN for a proper shunt calibration 5 Change the control mode Change Control mode on the Manual Command window to a Displacement control mode Shunt calibration cannot be performed on a sensor when it is in control of the servo loop 6 Determine the shunt calibration resistor from the following table BRIDGE SENSITIVITY RANGE RESISTOR RESISTANCE FULL SCALE VALUE 350 Q 2 mV V 100 49 9 k 50 100 k 20 249 k 10 499 k 350 Q 1 mV V 100 100 k 50 200 k 20 499 k 10 1000 k 700 Q 2 mV V 100 100 k 50 200 k 20 499 k 10 1000 k 700 Q 1 mV V 100 200 k 50 402 k 20 1000 k 10 2000 k Model 493 10 793 00 Controller Service 137 Shunt Calibration 7 If you have sensor cables with optional transducer ID modules complete the following procedure If not proceed to Step 8 Install the shunt calibration resistor into the R9 location of the sensor ID module The sensor identification cartridge is molded into the sensor cable Solder the shunt calibration resistor here
71. points for the tension A Adjust the Manual Cmd slider to achieve a load standard readout of zero B Adjust the Manual Cmd slider between zero and full tension three times This exercises the force sensor to remove hysteresis C Establish the zero reference Using a load standard e Adjust the Manual Cmd slider for 0 kN Then zero the load standard readout Using dead weights Remove all dead weights Then adjust the Offset control for a Signal Value of 0 kN on the Input Signals window D Adjust the Manual Cmd slider to achieve a force standard reading of 20 tension and record the meter reading Repeat this step for 40 60 80 and 100 compression iw gt f p Model 493 10 793 00 Controller Service 189 S bd K o Calibrating a Force Sensor Task8 Gain Linearization Calibration Initial force sensor calibration 190 If you are using Gain Linearization for your calibration type complete the following procedure If not complete Task 7 Gain Delta K Calibration on page 185 or Task 9 Millivolt Volt Calibration on page 197 Important Using linearization data requires specific conditioner zeroing practices Ensure that Electrical Zero Lock on the Offset Zero menu is set to Locked Adjusting electrical zero after calibration may invalidate linearization data Important Changing conditioner polarity after calibration may invalidate 1 linearization data If you need
72. scope feature for controller scope tuning control modes Review the following e Select Scope on the Station Manager Display menu e Select a continuous sweep e Enter the minimum and maximum ranges on the Y axis to zoom into the area of interest For more information on the controller scope refer to the Model 793 00 System Software manual Using an oscilloscope An oscilloscope has a higher resolution and is faster than the software controller scope Review the following e You must have a Readout channel defined in the Station Builder e Set up the Readout channel in the Station Manager program to monitor the sensor signal of the control mode you intend to tune e Or you could monitor the error signal You can tune using either signal e Connect the oscilloscope to the appropriate BNC connector on the Analog Out transition module Ch 1 Ch 6 located at the rear panel of the Model 493 10 Chassis Model 493 10 793 00 Controller Service 253 Tuning Displacement Tuning Displacement A displacement control mode uses the feedback signal from an LVDT linear variable differential transformer You do not need a specimen to tune a displacement control mode When to tune A displacement control mode usually only needs to be tuned once However you may want to retune a 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 attach
73. small amplitude commands or run at low frequencies Dither exaggerated Z AN Test Waveform Dither amplitude was set during installation The signal values in your station parameter set reflect that initial dither amplitude procedure and are probably adequate for your test 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 The following must be true If not go to Getting Things Ready on page 116 e The hydraulic fluid and the servovalve are at operating temperature e Command compensators are turned off Refer to How to Check and Adjust Dither Amplitude in Chapter 5 Tuning of the Model 793 00 System Software manual for a detailed dither amplitude adjustment procedure Model 493 10 793 00 Controller Service Tuning the Inner loop Tuning the Inner loop The innerloop proportional gain and rate derivative adjustments are the same types of adjustments as the proportional and derivative gain adjustments of the outerloop tuning controls Important Procedure Perform inner loop
74. the force sensor The actuator acts as a specimen reacting against the force sensor Review the following recommendations if you must tune without a specimen e Ifyou are using a load frame adjust the load unit crosshead so the actuator can reach the force sensor e Carefully adjust the actuator using a tuned length control mode so it contacts the force sensor e Switch to force control before you proceed with initial tuning Monitoring Waveforms What to monitor You do not need to monitor the entire waveform Instead zoom in on the area of interest 250 When you tune the servoloop you need to monitor the results of your adjustments There are two ways to monitor a waveform during tuning e An oscilloscope is preferred e The controller scope is adequate if you do not have an oscilloscope Note Set up your scope to monitor the area of the waveform that shows characteristics useful for tuning You can monitor the sensor feedback or the error signal of the contro mode 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 Se Model 493 10 793 00 Controller Service About Tuning If the amplitude of the feedback cannot be achie
75. volts maximum from an external voltage source e Jumpers select the debounce time for each group of four inputs Jumper X2 configures inputs 1 4 Jumper X3 configures inputs 5 8 Jumper X4 configures inputs 9 12 Jumper X5 configures inputs 13 16 No jumper sets the debounce to 20 msec Jumper pins 1 and 4 to set the debounce to 10 msec Jumper pins 2 and 3 to set the debounce to 1 msec Jumper pins 1 and 4 2 and 3 to set the debounce to 0 1 msec Digital I O 493 72 Digital I O Access Panel J3 Transition Module External Device 18 S _9 o 12 Opto ra CH1 Coupler e 1 i L i External Switch i TA AS or 29 PH a Relay Contact 36 epee VvV sw Digital I O 493 72 Digital I O Access Panel J3 Transition Module External Device Poet 18 S _9 0 12 5 Opto i CH1 Coupler 1 i dl i si a Wy 20 CH1 y Cm n re V sw 80 Model 493 10 793 00 Controller Service Digital I O Connections Digital outputs Connector J4 Out provides sixteen general purpose digital outputs that can send digital logic signals to external switches or logic devices e Minimum output current drive is 6 mA Maximum output current drive is 20 mA Note The maximum output current can vary from unit to unit The minimum guaranteed output current is 6 MA and the maximum output current is 20 MA You can connect the digital outputs in parallel to incr
76. 0 On the Tuning panel Adjustments tab increase P Gain while observing the displacement feedback signal E bd K o 152 Model 493 10 793 00 Controller Service Calibrating an LVDT 21 Initial tuning is achieved when the displacement feedback signal approximates the square wave as shown below The tuning command is shown as a gray square waveform and the black waveform is the sensor feedback Gain Too Low Optimum Gain Gain Too High oO 2 gt r e Model 493 10 793 00 Controller Service 153 Calibrating an LVDT Abbreviated Procedure Online readers All procedure entries are hypertext links Click on any entry to jump to the corresponding page The following abbreviated procedure outlines a displacement sensor LVDT calibration process More detailed calibration information is available on the pages listed Task 1 Get things ready on page 155 Task 2 Create a calibration file on page 157 Task 3 Assign a calibration file on page 158 Task 4 Turn on hydraulic pressure on page 159 Task 5 Verify the conditioner polarity on page 160 Task 6 Set the phase on page 161 Task 7 Set the zero and offset on page 162 Task 8 Gain Delta K Calibration on page 165 Task 9 Gain Linearization Calibration on page 169 Task 10 Save the calibration on page 175 Task 11 Calibrate additional ranges on page 175 S
77. 00 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 6 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED IO CARRIER ADDRESS 0xC2800000 SLOT 7 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME FRDUC_53 0UT CHANNEL 1 NAME 493 25 DC Slot 7 1 CONNECTOR J4 MODE DC FILTER 300 Model 493 10 793 00 Controller Service DAUGHTER 2 ADDRESS 0x10000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 2 NAME 493 25 AC Slot 7 2 CONNECTOR J5 MODE AC FILTER 300 Daughter 3 is empty and used for optional boards DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 7 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED IO CARRIER ADDRESS 0xC2A00000 SLOT 8 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 1 NAME 493 25 DC Slot 8 1 CONNECTOR J4 MODE DC FILTER 300 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 2 NAME 493 25 AC Slot 8 2 CONNECTOR J5 MODE AC FILTER 300 Daughter 3 is empty and used for optional boards DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 8 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED DIO TRANSITION BOARD TRANSITION SLOT 10 CONNECTOR J3 INPUT 1 NAME Digital Input 1 INPUT 2 NAME Digital Input 2 INPUT 3 NAME Digital Input 3 INPUT 4 NAME Digital Input 4 INPUT 5 NAME
78. 10 793 00 Controller Service 55 I O Carrier Connections Accelerometer Connections An accelerometer requires the Model 493 48 Acceleration daughter board installed in a Model 493 40 I O Carrier module and the Model 493 78 Accelerometer Transition Board Each Model 493 48 Acceleration daughter board supports up to three accelerometers The transition board accommodates two types of accelerometers Low impedance Voltage Mode LIVM type accelerometers and High Level Signal Conditioned type accelerometers 493 21B Universal Conditioner oq Accelerometer o _ Accelerometer LIVM 493 21B Universal Conditioner Accelerometer 493 21B Universal Conditioner 493 48 Acceleration Conditioner High Level Accelerometer Signal Conditioned Accelerometer 128 Out 493 21B Universal Conditioner 493 21B Universal Conditioner 493 21B Universal Conditioner 493 48 Acceleration Conditioner 56 Model 493 10 793 00 Controller Service 1 0 Carrier jumper settings I O Carrier Connections Before installing a Model 493 48 Acceleration Conditioner daughter board in a Model 493 40 I O Carrier module specific jumpers must be set Jumper settings depend on the number and conf
79. 137 shunt resistor table 137 321 sensor calibration file creating 157 180 sensors ranges 122 service connections J3 Service O carrier 87 J39 power monitor 86 servovalve adjust valve balance 117 adjusting dither amplitude 118 dither 114 1 O carrier cable specifications 46 I O carrier connection 46 polarity check 151 signal polarity 115 valve balance 114 warmup 116 shunt calibration 136 200 I O carrier connector 140 procedure 137 shunt resistor connector 140 shunt resistor table 137 when to use 136 signal polarity 147 specifications 493 10 chassis 23 sensor cables 133 specimens 249 changing 232 tuning with 249 tuning without 250 square wave shape 247 stabilizing with acceleration feedback 244 with delta P feedback 243 station connections 71 station signals available for monitoring 108 descriptions 109 external readout of 110 strain control modes 238 system cables analog I O 55 part number list 43 sensor cables 44 servovalve cables 46 system warm up 147 T Temposonics calibration setting resolution 212 temposonics calibration signal monitoring 211 322 Temposonics sensor calibration calibration file 212 connections 210 defining an input 210 setting resolution 217 setting zero 214 Temposonics sensor definitions hwi file 306 Temposonics sensors 210 definitions hwi file 296 transducer cables part numbers 134 specifications 133 transducer connections 127 transducer ID module assigni
80. 2222222222222 PUT 1 NAME Digital Input 1 PUT 2 NAME Digital Input 2 PUT 3 NAME Digital Input 3 PUT 4 NAME Digital Input 4 PUT 5 NAME Digital Input 5 PUT 6 NAME Digital Input 6 PUT 7 NAME Digital Input 7 PUT 8 NAME Digital Input 8 PUT 9 NAME Digital Input 9 PUT 10 NAME Digital Input 10 PUT 11 NAME Digital Input 11 PUT 12 NAME Digital Input 12 PUT 13 NAME Digital Input 13 PUT 14 NAME Digital Input 14 PUT 15 NAME Digital Input 15 PUT 16 NAME Digital Input 16 CONNECTOR J4 OU OU OU OU OU OU OU OU OU OU OU OU OU OU OU OU TPUT 1 NAME Digital Output 1 TPUT 2 NAME Digital Output 2 TPUT 3 NAME Digital Output 3 TPUT 4 NAME Digital Output 4 TPUT 5 NAME Digital Output 5 TPUT 6 NAME Digital Output 6 TPUT 7 NAME Digital Output 7 TPUT 8 NAME Digital Output 8 TPUT 9 NAME Digital Output 9 TPUT 10 NAME Digital Output 10 TPUT 11 NAME Digital Output 11 TPUT 12 NAME Digital Output 12 TPUT 13 NAME Digital Output 13 TPUT 14 NAME Digital Output 14 TPUT 15 NAME Digital Output 15 TPUT 16 NAME Digital Output 16 Model 493 10 793 00 Controller Service Appendix E The HWI File ay J TestStar IIm and FlexTest GT controllers use hardware interface Chwi files to determine what electronic components are available to your system where they are located and which connectors are associated with them The electronic c
81. 24 AWG minimum with drain wire s connected to the metallized backshell at the chassis Model 493 10 793 00 Controller Service 77 Station Connections J49 Auxiliary Power Connector J49 Aux Pwr provides 5 V DC 15 V DC and 24 V DC from the chassis internal power supply to drive external high level conditioners proximity switches solenoids and so forth e The outputs are fused at 0 75 A to protect the power supply from an external short e The fuses can be reset by shutting off power and waiting a few minutes the fuses automatically reset when cooled then reapplying power From J49 To Chassis External Devices F7 15Vde O0 OT 0 1 6 Analog o 2 Ground S 7 F4 15V DC O enue 3 F9 24 V DC O O VO 9 24V 8 Common S m 5V DC O SLO 5 5V 4 Ground 7 Cable specification e 9 contact type D male EMI connector e Backshell EMI metallized plastic e Cable shielded twisted pairs 22 AWG minimum with drain wire s connected to the metallized backshell at the chassis 78 Model 493 10 793 00 Controller Service Digital I O Connections Digital 1 0 Connections The Model 493 72 Digital I O transition module has two connectors one provides connections for sixteen digital inputs and the other provides connections for sixteen digital outputs From J3 To From
82. 3 00 Controller Service 63 ADDA II Connections D A Connections Digital to analog daughter cards support up to eight program or readout signals to external devices Each D A signal is an analog output within 10 volts e Each readout signal is from a 16 bit digital to analog converter e Each output is a 10 V analog output e The Model 493 56 D A daughter card provides analog signals to the Model 493 82 Analog Out transition module Analog outputs are available at the BNC connectors of a Model 493 82 Analog Out transition module for external devices DVM oscilloscope From 1p External D A Device gt 1 Output 8 2 gt 3 Output 7 Jii J13 7 2 J15 J17 __p 5 Output 6 6 eile Output 5 g 9 Output 4 gt 10 11 Output 3 J12 J14 12 14 Output 2 gt 15 gt 16 l Output 1 64 Model 493 10 793 00 Controller Service ADDA II Universal Encoder Connections Up to four encoders can be connected to the Model 493 80 ADDA II Encoder Transition module when the Model 493 50 ADDA II module is fully populated with Universal Encoder cards Each encoder requires a Model 493 59 Universal Encoder daughter installed on the Model 493 50 ADDA II module To From Encoder Transition Module i 1 lt 2 lt gt 3 Jit J13 lt 4 J15 J17 qq 5 asH_s gt 6 lt M 7 dt 8 lt lt 9 lt lt 10 it 11 J12 J14
83. 3 10 793 00 Controller Service Appendix B Model 493 07 Pump Interface J25 L The 493 07 Pump Interface PN 499694 xx is designed to connect the 493 10 chassis to a hydraulic power unit HPU such as MTS Model 506 HPU or equivalent relay operated pump The pump interface converts logic level signals to and from the 493 10 chassis to relay signals used by the HPU pump For pumps that are 24V PLC compliant the pump interface is not needed This includes all Series 505 HPUs and 506 52 92 HPUs D You must have the Model 493 07 Pump Interface designed for the correct voltage before installation Connecting a 24 V interface box to a 115 V AC HPU causes improper operation Be sure the voltage marked on the cover of the 493 07 Pump Interface matches the required voltage for the hydraulic power unit The following figure shows the main components of the 493 07 Pump Interface including connectors and jumpers Shown with cover removed i a w y i 3 3 7 es o O oO To HPU To 493 73 HPU Transition be Module J25 Model 493 10 793 00 Controller Service 263 Q tajn dem a A mn ar 7 q D gz 264 Jumper configurations n Disconnect all cables from the Model 493 07 Pump Interface before removing the cover Failure to
84. 3 Hz e The maximum continuous power usage is approximately 1000 W The current draw depends on the local voltage supply A 15 amp line should be adequate for the chassis and the computer e The power supply automatically selects the proper voltage range and line frequency e The power supply is protected with an external circuit breaker in the On Off switch that trips at a 10 ampere overload An internal fuse in the power supply is not user accessible or repairable e An outlet strip is supplied with the floor standing chassis The computer components may be plugged directly into the outlet strip of a vertical console or a floor standing console Turn off the AC power switch Remove the AC power cord from the unit This will remove all AC power from the 493 10 chassis Note Be sure to locate the chassis so you have adequate access to disconnect the power cord from the chassis Model 493 10 793 00 Controller Service Outlet Strip vertical outlet strip Power Panel Model 493 10 793 00 Controller Service Outlet Strip Connecting Electrical Power Voltage Outlet Strip Outlet Strip printer etc w circuit breaker Line Voltage 29 N e 5 z T 4 N Installing
85. 30000 TYPE 493 14 FILENAME DVD_53 0UT CHANNEL 3 NAME 493 14 2SVD Slot 1 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED See Valve Signals on page 298 for descriptions of Clamp definitions Valve Signals The MODE identifies single or multiple valve driver support The settings are SINGLE or DUAL Dual valve driver support requires a special manifold The TYPE and FILENAME identify the daughter board as a valve driver D m J The board address determines the connector that must be The RANGE identifies the output specified here in mA of the valve driver itself The settings are 25 or 50 The name in quotes appears in the Station Builder application as a system resource You can edit this if you want Three stage valve driver DAUGHTER 1 ADDRESS 0x300000 TY PE 493 15 FILENAME D3VD_53 0UT CHANNEL 3 NAME 493 15 3SVD Slot 1 CONNECTOR J1 CLAMP DISABLED Model 493 10 793 00 Controller Service 299 Valve Signals Multiple Universal For special applications the Model 493 79 Multiple Universal Driver Driver MUD board can provide up to six driver signals to drive standard 252 servovalves Inputs to the MUD board originate from a Model 493 46 D A daughter board on the a Model 493 40 Carrier modules See ADDA II Connections on page 61 2 x t A typical hwi file definition for a D A board MUD board combination is shown here The add
86. 4 ADDRESS 0x30000 TYPE 493 15 FILENAME D3VD_53 OUT CHANNEL 7 NAME 493 15 3SVD Slot 7 4 CONNECTOR J7 CLAMP DISABLED DIO TRANSITION BOARD TRANSITION SLOT 4 CONNECTOR J3 PUT 1 NAME Digital Input 1 PUT 2 NAME Digital Input 2 PUT 3 NAME Digital Input 3 PUT 4 NAME Digital Input 4 PUT 5 NAME Digital Input 5 PUT 6 NAME Digital Input 6 PUT 7 NAME Digital Input 7 PUT 8 NAME Digital Input 8 PUT 9 NAME Digital Input 9 PUT 10 NAME Digital Input 10 PUT 11 NAME Digital Input 11 PUT 12 NAME Digital Input 12 PUT 13 NAME Digital Input 13 PUT 14 NAME Digital Input 14 PUT 15 NAME Digital Input 15 PUT 16 NAME Digital Input 16 CONNECTOR J4 OUTPUT 1 NAME Digital Output 1 OUTPUT 2 NAME Digital Output 2 OUTPUT 3 NAME Digital Output 3 OUTPUT 4 NAME Digital Output 4 OUTPUT 5 NAME Digital Output 5 2222222222222222 Model 493 10 793 00 Controller Service 315 A Sample File OUTPUT 6 NAME Digital Output 6 OUTPUT 7 NAME Digital Output 7 OUTPUT 8 NAME Digital Output 8 OUTPUT 9 NAME Digital Output 9 OUTPUT 10 NAME Digital Output 10 OUTPUT 11 NAME Digital Output 11 OUTPUT 12 NAME Digital Output 12 OUTPUT 13 NAME Digital Output 13 OUTPUT 14 NAME Digital Output 14 OUTPUT 15 NAME Digital Output 15 OUTPUT 16 NAME Digital Output 16 2 t TEMP CONTROL TYPE Eurotherm 2208 HOST PORT GRES COM 1 BAUD 9600 CHANNEL 1 NAME Tem
87. 6 A tuning program produces a cyclic program command to exercise the system while you make the initial tuning adjustments A square wave is best because it demands the maximum response of the servo hydraulic system The square wave tuning program may not be suitable for all systems The following describe the different waveform characteristics Model 493 10 793 00 Controller Service About Tuning Square Tapered Square A square waveform requires the servovalve to open rapidly to a large opening 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 e Monitor the feedback or error signal to evaluate the system stability Ramp Tapered Ramp A ramp waveform also called a triangle waveform requires the actuator to move at a constant rate This requires the servovalve to move quickly between two discrete openings Cycling a ramp waveform produces a triangle waveform
88. 793 00 Controller Service Calibrating a Force Sensor Task 11 Save the calibration It is important that you save your sensor calibration values On the Station Setup window Inputs panel click the Calibration tab and then Save This saves current calibration values on the Calibration Sensor and Shunt tabs to the sensor calibration file Task 12 Calibrate additional ranges Adding a range This task describes how to calibrate additional ranges Each sensor calibration file can have calibration data for four ranges If you have a need for additional ranges simply create another sensor calibration range e Use the calibration values from the previous range as a starting point e If you adjust the zero reference it may affect the other ranges Note Some systems do not provide or require multiple ranges such as those using full range conditioners e g Model 493 25 DUC module In this case only one range is used typically 100 If the sensor calibration file must have additional ranges defined perform the following 1 On the Tools menu select Sensor File Editor 2 Open the sensor file for the sensor you have just calibrated 3 Click Add under Range Definition 4 Select the units for the range and then enter the absolute value of the range 5 Save the new range to the calibration file 6 Calibrate the added range Note Ranges can also be added on the Sensor tab and calibrated on the Calibration tab Mo
89. 93 00 Controller Service Adjusting Valve Balance Adjusting Valve Balance Prerequisites Procedure The valve balance adjustment electrically compensates for minor electrical and mechanical imbalance in the servovalve Your servovalve is typically balanced during installation at its midstroke position The signal values in your station parameter set reflect that initial servovalve balance procedure For optimal performance you should balance your servovalve again after you position your actuator to the test start position The following must be true If not go to Getting Things Ready on page 116 e The hydraulic fluid and the servovalve are at operating temperature e Command compensators are turned off Refer to How to Check and Adjust Valve Balance in Chapter 5 Tuning of the Model 793 00 System Software manual for a detailed valve balancing procedure Model 493 10 793 00 Controller Service 117 N oO lt i lt lt 1 O i gt c n 2 i ih Ez gt i gt k n Dither Dither 118 Dither adjustment prerequisites Adjusting dither amplitude Dither is a low amplitude high frequency sine wave that your controller applies to your servovalve s spool Dither keeps your servovalve s spool in motion so it operates smoothly and does not silt up or stick to its cylinder walls It is especially useful for tests that use
90. 93 10 793 00 Controller Service A Sample File IO CARRIER ADDRESS 0xC2200000 SLOT 4 CLOCK TYPE SLAVE ay J DAUGHTER 1 ADDRESS 0x00000 TYPE 493 21B FILENAME DUCB_53 OUT CHANNEL 1 NAME 493 21B DC Slot 4 1 CONNECTOR J4 MODE DC FILTER 1000 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 21 FILENAME DUC_53 0UT CHANNEL 2 NAME 493 21 AC Slot 4 2 CONNECTOR J5 MODE AC FILTER 1000 Daughter 3 is empty and used for optional boards DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 4 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED IO CARRIER ADDRESS 0xC2400000 SLOT 5 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 21B FILENAME DUCB_53 OUT CHANNEL 1 NAME 493 21B DC Slot 5 1 CONNECTOR J4 MODE DC FILTER 1000 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 21B FILENAME DUCB_53 OUT CHANNEL 2 NAME 493 21B AC Slot 5 2 CONNECTOR J5 MODE AC FILTER 1000 Daughter 3 is empty and used for optional boards DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 5 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED Model 493 10 793 00 Controller Service 313 2 i t A Sample File 314 IO CARRIER ADDRESS 0xC2600000 SLOT 6 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 21B FILENAME DUCB_53 OUT CHANNEL 1 NAME 493 21B DC Slot 6 1 CONNECTOR J4 MODE DC F
91. 93 10 793 00 Controller Service 155 Calibrating an LVDT 4 Set up a signal monitor Note You cannot monitor the output of a new sensor until a sensor calibration file has been created and the sensor assigned to an input signal You will be monitoring the sensor output when making adjustments throughout this procedure You can monitor the sensor output in the same units that you are using for the calibration You can use an external DVM to monitor sensor output from a BNC connector on the Analog Out panel located on your controller chassis If you do not have an Analog Out panel use the Meters window or Station Signals panel to monitor sensor output On the Station Manager Display menu select Station Setup In the navigation pane select Station Signals to display the Station Signals panel to monitor current values for user defined signals For more information on using the Station Signals panel refer to About the Station Signals Panel in Chapter 3 Station Manager of the Model 793 00 System Software manual S bd T 2 156 Model 493 10 793 00 Controller Service Calibrating an LVDT Task2 Create a calibration file Conditioner calibration values This task creates a sensor calibration file and sets up your ranges A typical complement of ranges could be 100 50 20 and 10 of full scale You may create ranges for any percentage of full scale Note Some systems do not provide or require
92. A II module Encoders Encoders require a special daughter board be plugged into the ADDA II module The encoder daughter board can occupy any of the four ADDA II address locations e The encoder daughter board supports four encoder signals e The encoder daughter board processes the pulse stream from an encoder Encoder daughter boards use the following designators for each type of encoder 1 for absolute encoders 3 for incremental encoders and 5 for Temposonics II encoders The designation 3 specifies a daughter i board for incremental encoders DAUGHTER 3 ADDRESS 0x3 TYPE 493 59 3 CHANNEL 13 NAME Encoder Input 1 CONNECTOR J15 CHANNEL 14 NAME Encoder Input 2 CONNECTOR J15 CHANNEL 15 NAME Encoder Input 3 CONNECTOR J16 CHANNEL 16 NAME Encoder Input 4 CONNECTOR J16 Model 493 10 793 00 Controller Service 295 ay J ADDA II module Temposonics Ill Temposonics III sensors require a special daughter board on the ADDA module The Temposonics III daughter board can occupy any of the four ADDA address locations e The Temposonics III daughter board supports two double wide Temposonics sensor signals i t e The Temposonics III daughter board processes pulses from the digital output of a Temposonics III sensor e The Analog I O signal definitions on page 301 and page 302 also apply to the Temposonics III definition The designation 5 specifies a daughter
93. ANSITION BOARD TRANSITION SLOT 6 CHANNEL 1 NAME HSM 3 CONNECTOR J28A CONNECT TO MAIN TRUE TYPE PROPORTIONAL HSM RATE SLOW LOW PERCENT 50 HIGH PERCENT 100 CHANNEL 2 NAME HSM 4 CONNECTOR J28B CONNECT TO MAIN TRUE TYPE PROPORTIONAL HSM RATE SLOW LOW PERCENT 50 HIGH PERCENT 100 GRESIII ADDRESS 0xC0800000 SLOT 10 SERIAL TRANSITION BOARD TRANSITION SLOT 10 STARTING INTERLOCK 1 SERIAL PORT 1 NAME GRES COM 1 SERIAL PORT 2 NAME GRES COM 2 SERIAL PORT 3 NAME GRES COM 3 Model 493 10 793 00 Controller Service 311 2 i t A Sample File 312 SERIAL PORT 4 NAME GRES COM 4 SERCLK RATE 4915200 HI RATE 4096 0 LO RATE 25 6 SYSTEM RATE 4096 CLOCK TYPE MASTER IO CARRIER ADDRESS 0xC2000000 SLOT 3 CLOCK MODE BINARY HI RATE 4096 SYSTEM RATE 4096 MEDIUM SYSTEM RATE 256 0 LOW SYSTEM RATE 25 6 CLOCK TYPE SLAVE When adding a GRESIII CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 21 FILENAME DUC_53 0UT CHANNEL 1 NAME 493 21 DC Slot 3 1 CONNECTOR J4 MODE DC FILTER 1000 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 21B FILENAME DUCB_53 OUT CHANNEL 2 NAME 493 21B AC Slot 3 2 CONNECTOR J5 MODE AC FILTER 1000 Daughter 3 is empty and used for optional boards DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 3 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED Model 4
94. Calibrate an Extensometer 215 Chapter 7 Tuning 231 About Tuning 232 If You ve Never Tuned Before 233 When to Tune 234 Control Mode Characteristics 236 How the Tuning Controls Work 239 Creating a Tuning Program 246 Other Considerations 249 Monitoring Waveforms 250 Tuning Displacement 254 Tuning Force 255 Auto tuning 256 How to Auto Tune Control Modes 257 Tuning a CLC Control Mode 258 6 Model 493 10 793 00 Controller Service Appendix A Hydraulic Configurations 259 Appendix B Model 493 07 Pump Interface 263 Appendix C Maintenance 265 Appendix D Optional Station Configurations 267 6 Station Configuration 268 8 Station Configuration 275 Appendix E The HWI File 283 Processor 285 Hydraulic Control 286 I O Carrier 287 ADDA II module 292 Digital I O 297 Valve Signals 298 Analog Output 301 Analog Input 302 Conditioner Signals 303 Acceleration conditioner signals 304 Encoder temposonics sensor support 306 Temperature controller 307 Remote station controller 308 GRES III 309 A Sample File 310 Index 317 Model 493 10 793 00 Controller Service 7 8 Model 493 10 793 00 Controller Service Preface Safety first Before you attempt to use your MTS product or 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 always maintain a healthy respect for it Improper installation oper
95. Connections D A Connections Digital to analog daughter cards support up to six program or readout From To signals to external devices Each D A D A J4 J7 n signal is an analog output within 10 _ D volts 1 2 i Output 1 e Each readout signal is from a 16 3 E bit digital to analog converter v 4 e Each output is a 10 V analog 5 amie output 5 6 e The Model 493 46 D A daughter A Output 3 card provides analog signals to lt 8 i the Model 493 76 Analog Out 9 Outta transition module Analog outputs s 0 are available at the BNC 7 n Output 5 connectors of a Model 493 76 ja x Analog Out transition module for v Z external devices DVM 13 Output 6 oscilloscope ee 14 15 54 Model 493 10 793 00 Controller Service I O Carrier Connections Cable specification The cable specifications apply to both the analog inputs and analog outputs The cable from the front panel of the I O Carrier module has the following specification e 15 contact type D male EMI connector e Backshell EMI metallized plastic e Cable type up to 6 shielded twisted pairs each with the drain wire connected to the signal source The cable to the Ch 1 Ch 6 connectors on the rear panel have the following specifications e BNC connector UG88 U e Cable RG 58 coaxial e Use of a smaller coaxial cable and a RG 174 BNC connector with an appropriate cable end is permissible Model 493
96. DDA II board 6 outputs or a Model 493 46 D A board 6 outputs 493 80 Encoder Transition nterfaces with up to four encoders 493 81 Analog In BNC Provides up to eight channels of analog input to each Model 493 55 A D module The input signals must be within 10 V DC 493 82 Analog Out BNC Provides eight channels of analog output from the Model 493 56 D A modules The output signals are within 10 V DC 493 83 Filtered Analog Input Provides up to eight channels of filtered analog input to each Model 493 10 793 00 Controller Service Model 493 55 A D module 37 N e 5 z Installing the Plug in Modules T q N 38 Model 493 10 793 00 Controller Service Chapter 3 Cabling This section describes the cable connections to the Model 493 10 Chassis Note For information on connecting power cables see Connecting Electrical Power on page 27 Contents CE EMC Compliant Cabling 41 Typical Cabling 42 Cable Part Numbers 43 I O Carrier Connections 45 Valve Connections 46 Multiple Universal Driver Connections 50 Analog I O Connections 52 Accelerometer Connections 56 Encoder Connections 58 Remote Setpoint Adjust Connections 60 ADDA II Connections 61 Emergency Stop Connections 66 Hydraulic Power Unit Connection 68 Station Connections 71 J28 HSM 72 J29 Load Unit 74 J43 Interlock 75 J44 Run Stop 76 J49 Auxiliary Power 78 Digital I O Connections 79 Workstation Connection 83
97. DRESS 148 150 203 191 PROCESSOR ADDRESS 0x00000 SLOT 1 FUNCTION CONTROL PROCESSOR NUMBER 1 INTERRUPT LEVEL 5 FILENAME tsiismcdsp o SHARED MEMORY 0x700000 SYSTEM OPTIONS VELOCITY LIMITER INTERLOCKS 6 HPU TRANSITION BOARD TRANSITION SLOT 9 NAME HPU MAIN POWER TRUE FIRST ON TRUE LAST OFF TRUE VISIBLE TRUE CONNECTOR J25 HSM TRANSITION BOARD TRANSITION SLOT 8 CHANNEL 1 NAME HSM 1 CONNECTOR J28A CONNECT TO MAIN TRUE TYPE SOLENOID CHANNEL 2 NAME HSM 2 CONNECTOR J28B CONNECT TO MAIN TRUE TYPE SOLENOID Model 493 10 793 00 Controller Service 269 i gz i D Sel st i iar i y K i a i 7 HSM TRANSITION BOARD TRANSITION SLOT 6 CHANNEL 1 NAME HSM 3 CONNECTOR J28A CONNECT TO MAIN TRUE TYPE SOLENOID CHANNEL 2 NAME HSM 4 CONNECTOR J28B CONNECT TO MAIN TRUE TYPE SOLENOID HSM TRANSITION BOARD TRANSITION SLOT 4 CHANNEL 1 NAME HSM 5 CONNECTOR J28A CONNECT TO MAIN TRUE TYPE SOLENOID CHANNEL 2 NAME HSM 6 CONNECTOR J28B CONNECT TO MAIN TRUE TYPE SOLENOID IO CARRIER ADDRESS 0xC2000000 SLOT 3 CLOCK MODE BINARY SYSTEM RATE 2048 MEDIUM SYSTEM RATE 256 0 LOW SYSTEM RATE 25 6 CLOCK TYPE MASTER DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 1 NAME 493 25 DC Slot 3 1 CONNECTOR J4 MODE DC FILTER 300 DAUGHTER 2 AD
98. DRESS 0x10000 TYPE 493 25 FILENAME FRDUC_53 0UT CHANNEL 2 NAME 493 25 AC Slot 3 2 CONNECTOR J5 MODE AC FILTER 300 DAUGHTER 3 ADDRESS 0x20000 TYPE 493 45 FILENAME A2D_53 OUT CHANNEL 3 NAME Analog Input 1 Slot 3 3 CONNECTOR J6 CHANNEL 4 NAME Analog Input 2 Slot 3 3 CONNECTOR J6 CHANNEL 5 NAME Analog Input 3 Slot 3 3 CONNECTOR J6 CHANNEL 6 NAME Analog Input 4 Slot 3 3 CONNECTOR J6 CHANNEL 7 NAME Analog Input 5 Slot 3 3 CONNECTOR J6 CHANNEL 8 NAME Analog Input 6 Slot 3 3 CONNECTOR J6 270 Model 493 10 793 00 Controller Service a i i dm D i o gt i h n os i i Qa i DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 3 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED IO CARRIER ADDRESS 0xC2200000 SLOT 4 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME FRDUC_53 0UT CHANNEL 1 NAME 493 25 DC Slot 4 1 CONNECTOR J4 MODE DC FILTER 300 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 25 FILENAME FRDUC_53 0OUT CHANNEL 2 NAME 493 25 AC Slot 4 2 CONNECTOR J5 MODE AC FILTER 300 Daughter 3 is empty and used for optional boards DAUGHTER 4 ADDRESS 0x30000 TYPE 493 15 FILENAME D3VD_53 0UT CHANNEL 1 NAME 493 15 3SVD Slot 4 3 CONNECTOR J7 CLAMP DISABLED IO CARRIER ADDRESS 0xC2400000 SLOT 5 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME
99. Definition define a range 8 Define the full scale of the range 9 Set the sensor full scale and resolution Set the units and enter the full scale minimum and maximum for the range The system software supports non symmetrical full scales In the Resolution box enter the resolution value supplied in the extensometer documentation Note f you want to use units different than those supplied in the sensor documentation enter the full scale and resolution in the supplied units first and then switch to the desired full scale units The units conversion will be calculated automatically 10 Enter initial calibration values iw gt f p 11 Save your sensor file and close the Sensor File Editor Model 493 10 793 00 Controller Service 217 Calibrating an Extensometer Task3 Assign a sensor calibration file This task links a sensor calibration file created in Task 2 to a hardware resource The purpose for this is to select one of the sensor ranges for the input signal definition For a detailed description of this procedure refer to How to Assign a Sensor File in Chapter 3 Station Manager of the Model 793 00 System Software manual S bd K ca 218 Model 493 10 793 00 Controller Service Calibrating an Extensometer Task 4 Turn on hydraulic pressure This task activates the hydraulic pressure and ensures you have control of your actuator lO AL WARNING
100. ENC_53 0UT CHANNEL 3 NAME 493 47 Encoder Slot 2 CONNECTOR J6 MODE Incremental MODE specifies what type of device is to be connected Options are INCREMENTAL TEMPO24BIT TEMPO25BIT and TELEDYNE The channel name appears in the Station Builder application as a system resource with input and output appended to it These special analog inputs outputs are handled differently than other analog channels 306 Model 493 10 793 00 Controller Service Temperature controller Temperature controller This indicates a Eurotherm 2200 or 2400 series temperature controller is connected to the controller A GRESIII module is needed to support either a temperature controller or RSC For information on adding a GRES III module see GRES II on page 309 Due to hardware limitations if an RSC is used on COM1 and a temperature controller is on COM2 or vice versa the temp controller baud rate must be 9600 The same goes for COM3 amp COM4 TEMP CONTROL TYPE Eurotherm 2208 These entries must match HOST PORT GRES COM 2 the configuration of the BAUD 9600 4 Oe ne controller CHANNEL 1 NAME Temp Control 1 ADDRESS 0x1 The channel name appears in the Station Builder application as a system resource with input and output appended to it These special analog inputs outputs are handled differently than other analog channels Model 493 10 793 00 Controller Service 307 ay J Remote station controll
101. ETE x logic signal without jumpers X and X MW 4 Cross FA AR ZZ Head Ie Sa a 3 Lock X Jumper X2 for Channel A pe 3 Jumper X1 for Channel B VW GA station Jumper X4 for Channel A 24V DC 13 010 Stop Jumper X3 for Channel B Sa CH 8 eal Emergency 7v Sto l p E Stop 7 4 0 0 Pins 5 7 8 and 13 maintain the continuity of the emergency stop v 3 interlock 9 Shield 24V HSM hi H gt 12 Crosshead Cross Head Unlock Solenoid 14 DC Common VV Cable specification e P29 is a 15 contact type D male EMI connector e Cable for load frames with crosshead locks built after 1985 18 AWG 8 conductor with overall foil shield Alpha 5388C or equivalent with drain wire connected to pin 9 at both ends of the cable e Cable for all load frames without crosshead locks 22 AWG 6 conductor with overall foil shield Alpha 5386C or equivalent with drain wire connected to pin 9 at both ends of the cable pin 9 may be pin E at the load frame Jumper plug If connector J29 is not used you must install a jumper plug to maintain the integrity of the interlocks Use jumper plug 100 007 947 or jumper pins 3 and 4 5 and 7 8 and 13 Station stop The Emergency Stop connection can also be configured as a station stop When this is done be sure that you have other Emergency Stop boxes near by Pressing Station Stop will shut down the hydraulics to an individual station without shutting down power to the hydraulic power unit
102. Fifth 0xC2800000 Sixth OxC2A00000 Seventh OxC2C00000 Eighth OxC2E00000 Model 493 10 793 00 Controller Service 287 2 x t I O Carrier Each added I O Carrier Module requires the entry of a four line description Clock Type 288 IO CARRIER ADDRESS 0xC2000000 SLOT 3 CLOCK MODE BINARY HI RATE 4096 SYSTEM RATE 4096 MEDIUM SYSTEM RATE 256 0 LOW SYSTEM RATE 25 6 CLOCK TYPE MASTER When adding a GRESIII CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 21B FILENAME DUCB_53 OUT CHANNEL 1 NAME 493 21B DC Slot 3 1 CONNECTOR J4 MODE DC FILTER 1000 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 21B FILENAME DUCB_53 OUT CHANNEL 2 NAME 493 21B AC Slot 3 2 CONNECTOR J5 MODE AC FILTER 1000 Daughter 3 is empty and used for optional boards DAUGHTER 4 ADDRESS 0x30000 TY PE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 3 4 CONNECTOR J7 RANGE 25 MODES SINGLE CLAMP DISABLED IO CARRIER ADDRESS 0xC2200000 SLOT 4 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 21B FILENAME DUCB_53 OUT CHANNEL 1 NAME 493 21B DC Slot 4 1 CONNECTOR J4 MODE DC FILTER 1000 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 21B FILENAME DUCB_53 0UT CHANNEL 2 NAME 493 21B AC Slot 4 2 CONNECTOR J5 MODE AC FILTER 1000 Each added I O Carrier module receives master clock signals from the first I O Carrier module in slot 3 or a GRES II module if installed and ha
103. HANNEL 1 NAME 493 25 DC Slot 3 1 CONNECTOR J4 MODE DC FILTER 300 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 2 NAME 493 25 AC Slot 3 2 CONNECTOR J5 MODE AC FILTER 300 Daughter 3 is empty and used for optional boards Model 493 10 793 00 Controller Service 277 i gz i D wn oe st F i iar i a ce ft i 7 a i i dm D i o gt i h n os i i Qa i 278 DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 3 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED IO CARRIER ADDRESS 0xC2200000 SLOT 4 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME FRDUC_53 0OUT CHANNEL 1 NAME 493 25 DC Slot 4 1 CONNECTOR J4 MODE DC FILTER 300 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 2 NAME 493 25 AC Slot 4 2 CONNECTOR J5 MODE AC FILTER 300 Daughter 3 is empty and used for optional boards DAUGHTER 4 ADDRESS 0x30000 TYPE 493 15 FILENAME D3VD_53 OUT CHANNEL 1 NAME 493 15 3SVD Slot 4 3 CONNECTOR J7 CLAMP DISABLED IO CARRIER ADDRESS 0xC2400000 SLOT 5 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 1 NAME 493 25 DC Slot 5 1 CONNECTOR J4 MODE DC FILTER 300 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 25 FILENAME FRDUC_53
104. ILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 7 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED IO CARRIER ADDRESS 0xC2A00000 SLOT 8 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 1 NAME 493 25 DC Slot 8 1 CONNECTOR J4 MODE DC FILTER 300 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 2 NAME 493 25 AC Slot 8 2 CONNECTOR J5 MODE AC FILTER 300 DAUGHTER 3 ADDRESS 0x20000 TYPE 493 25 FILENAME FRDUC_53 0UT CHANNEL 3 NAME 493 25 AC Slot 8 3 CONNECTOR J6 MODE AC FILTER 300 DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 8 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED IO CARRIER ADDRESS 0xC2C00000 SLOT 9 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME FRDUC_53 OUT CHANNEL 1 NAME 493 25 DC Slot 9 1 CONNECTOR J4 MODE DC FILTER 300 280 Model 493 10 793 00 Controller Service a i i dm D i o gt i h n os i i Qa i DAUGHTER 2 ADDRESS 0x10000 TYPE 493 45 FILENAME A2D_53 OUT CHANNEL 2 NAME Analog Input 1 Slot 9 2 CONNECTOR J5 CHANNEL 3 NAME Analog Input 2 Slot 9 2 CONNECTOR J5 CHANNEL 4 NAME Analog Input 3 Slot 9 2 CONNECTOR J5 CHANNEL 5 NAME Analog Input 4 Slot 9 2 CONNECTOR J5 CHANNEL 6 NAME Analog Input 5 Slot 9 2 CONNECTOR J5 CHANNEL 7 NAME Analog Input 6 Slot
105. ILTER 1000 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 21B FILENAME DUCB_53 OUT CHANNEL 2 NAME 493 21B AC Slot 6 2 CONNECTOR J5 MODE AC FILTER 1000 Daughter 3 is empty and used for optional boards DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT CHANNEL 1 NAME 493 14 2SVD Slot 6 4 CONNECTOR J7 RANGE 25 MODE SINGLE CLAMP DISABLED IO CARRIER ADDRESS 0xC2800000 SLOT 7 CLOCK TYPE SLAVE DAUGHTER 1 ADDRESS 0x00000 TYPE 493 45 FILENAME A2D_53 OUT CHANNEL 1 NAME Analog Input 1 Slot 7 1 CONNECTOR J4 CHANNEL 2 NAME Analog Input 2 Slot 7 1 CONNECTOR J4 CHANNEL 3 NAME Analog Input 3 Slot 7 1 CONNECTOR J4 CHANNEL 4 NAME Analog Input 4 Slot 7 1 CONNECTOR J4 CHANNEL 5 NAME Analog Input 5 Slot 7 1 CONNECTOR J4 CHANNEL 6 NAME Analog Input 6 Slot 7 1 CONNECTOR J4 Model 493 10 793 00 Controller Service A Sample File DAUGHTER 2 ADDRESS 0x10000 TYPE 493 46 FILENAME D2A_53 0UT CHANNEL 1 NAME Analog Output 1 Slot 7 2 CONNECTOR J5 CHANNEL 2 NAME Analog Output 2 Slot 7 2 CONNECTOR J5 CHANNEL 3 NAME Analog Output 3 Slot 7 2 CONNECTOR J5 CHANNEL 4 NAME Analog Output 4 Slot 7 2 CONNECTOR J5 CHANNEL 5 NAME Analog Output 5 Slot 7 2 CONNECTOR J5 CHANNEL 6 NAME Analog Output 6 Slot 7 2 CONNECTOR J5 ay J DAUGHTER 3 ADDRESS 0x20000 TYPE 493 47 FILENAME ENC_53 OUT CHANNEL 7 NAME 493 47 Encoder Slot 7 3 CONNECTOR J6 MODE INCREMENTAL DAUGHTER
106. J3 Service connector are provided for service and troubleshooting only These signals are defined by the I O option daughter boards that are installed on a respective Model 493 40 I O Carrier module Some of these signals may be uncalibrated Before use take appropriate steps to determine the characteristics of these signals Model 493 10 793 00 Controller Service 87 Cabling and Programming External Controllers Cabling and Programming External Controllers This section describes e Cabling and programming the Model 493 10 793 00 controller to analog program and feedback signals from a 407 controller e Connecting the Model 493 10 793 00 controller to interlock signals from a 407 controller e Setting up a 407 controller to send and receive Model 493 10 793 00 controller signals e Connecting the Model 493 10 793 00 controller to interlock signals from 458 controllers The Model 493 10 793 00 controller supports a special serial connection and software setup for use with Series 2200 and 2400 Eurotherm temperature controllers For more information see Eurotherm Temperature Controller Connection on page 104 Important When used as programmer the 793 00 controller does not have automated mode switching capabilities Control mode selection on the 793 00 controller does not effect the control mode of the controller to which it is sending test commands 88 Model 493 10 793 00 Controller Service How to Program an External
107. J4 To External Device 493 72 Digital Input 493 72 Digital Output External Device 1 tja Ch Channel 1 Inpu 20 i i 20 annel 1 Outpu 2 E ie C Channel 2 Inpu 21 i i 21 hannel 2 Outpu 3 E C Channel 3 Inpu 22 i i 22 hannel 3 Outpu 4 4 Ch Channel 4 Inpu 23 i 23 annel 4 Outpu 5 z Ch annel 5 Inpu 24 i f 24 Channel 5 Outpu 6 6 Ch 6 Ch 60 annel 6 Inpu 25 k i 25 anne utpu 7 7 Ch 7 Ch 70 annel 7 Inpu 26 i 7 26 anne utpu 8 8 Ch 8 Ch 80 annel 8 Inpu 27 i i 27 anne utpu 9 T 9 Ch 9 Ch 90 annel 9 Inpu 25 i 28 anne utpu Channel 10 Input 10 i 10 Channel 10 Output 29 3 29 11 11 Ch 1 Ch 1 Output anne nput 30 i i 30 anne utpu Channel 12 Input 12 7 t iz Channel 12 Output 31 ig 31 Channel 13 Input 13 7 Channel 13 Output 32 32 Channel 14 Input 14 Channel 14 Output 33 z 33 Channel 15 Input 13 j 15 Channe 5 Output 34 34 Channel 16 Input 16 a 16 Channel 16 Output 35 35 18 O 12 V DC 12 V DC o 18 19 19 36 36 37 37 v v Model 493 10 793 00 Controller Service 79 Digital I O Connections Digital inputs The J3 In connector accommodates up to sixteen digital signals from external devices You can use digital input signals to trigger test events with your controller applications e All of the inputs are optically isolated and support relay contacts or logic inputs see the following figure e Channel inputs can be 3 volts minimum and 26
108. L 5 NAME Analog Input 5 Slot 3 CONNECTOR J6 CHANNEL 6 NAME Analog Input 6 Slot 3 CONNECTOR J6 A The name in quotes appears in the The board address determines Station Builder application as a system the connector that must be resource You can edit this if you want specified here 302 Model 493 10 793 00 Controller Service Conditioner Signals Conditioner Signals The conditioner definitions describe the characteristics of the Digital Universal Conditioner DUC daughter board ay J e Each DUC daughter board specifies the type of conditioning the DUC will perform AC or DC are the only choices for the MODE specification e The FILTER specification can be set to 0 no filter 50 Hz 100 Hz 300 Hz 500 Hz or 1000 Hz The TYPE and FILENAME The address specifies the identify the daughter board as front panel connector a conditioner DAUGHTER 1 ADDRESS 0x00000 TYPE 493 21B FILENAME DUCB 53 0UT CHANNEL 1 NAME 493 21B DC Slot 4 CONNECTOR J4 MODE DC FILTER 1000 DAUGHTER 2 ADDRESS 0x10000 TY PE 493 21 FILENAME DUC_53 0UT CHANNEL 2 NAME 493 21 DC Slot 5 CONNECTOR J5 MODE DC FILTER 1000 DAUGHTER 3 ADDRESS 0x20000 TY PE 493 21 FILENAME DUC_53 0UT CHANNEL 3 NAME 493 21 AC Slot 6 CONNECTOR J6 MODE AC FILTER 1000 This specifies if the conditioner The name in quotes appears in the operates as an AC or DC conditioner Station Builder applica
109. ME Digital Output 10 OUTPUT 11 NAME Digital Output 11 OUTPUT 12 NAME Digital Output 12 OUTPUT 13 NAME Digital Output 13 OUTPUT 14 NAME Digital Output 14 OUTPUT 15 NAME Digital Output 15 OUTPUT 16 NAME Digital Output 16 Z Z2 ZZZ ZZZ ZEZ ZEZ Z SS SS eS SS SSS SS SS St ZZ Model 493 10 793 00 Controller Service 297 Valve Signals Valve Signals The valve driver definition describes the valve driver daughter board Your hwi file supports two and three stage valve drivers 2 x t e The preferred and recommended module location is ADDRESS 0x30000 and CONNECTOR J7 e To prevent unwanted actuator movement when a hydraulic interlock occurs the valve will be clamped as specified with the Clamp definition in the hwi file as follows DISABLED Valve does not clamp This is the default action if the clamp entry is omitted ZERO Clamps the servovalve to zero if valve balance is used it will clamp to this value POSITIVE Clamps the servovalve to positive 50 spool opening on a 2 stage valve driver 50 outer loop command on the 3 stage valve driver NEGATIVE Clamps the servovalve to negative 50 spool opening on a 2 stage valve driver 50 outer loop command on a 3 stage valve driver 298 Model 493 10 793 00 Controller Service Two stage valve driver The address specifies the front panel connector DAUGHTER 1 ADDRESS 0x
110. MTS PN 100 028 185 201 iw gt gt f i S bd K o Calibrating a Force Sensor F Install the shunt cal resistor connector assembly into the appropriate slot of the SHUNT CAL connector on the front panel of the appropriate I O Carrier Module CON SHUNT CAL 1 mnn 2 VVV 3 VV 4 ANES PR S 1 0 Option Slot 1 Shunt Cal Resistor Location 4 0 Option Slot 2 Shunt Cal Resistor Location 4 I O Option Slot 3 Shunt Cal Resistor Location I O Option Slot 4 Shunt Cal Resistor Location 9 Verify that force is still zero While it is unlikely it is possible for the force signal to change when the control mode changes If it does click Auto Offset on the Offset Zero tab Inputs panel to zero the force output 10 Perform shunt calibration The shunt calibration controls are located on the Shunt tab in the Inputs panel A In Station Setup select the appropriate force channel on the navigation panel click the Channel Input Signals icon and then click the Shunt tab B Select the shunt type Use polarity if you are not sure what to select C Inthe Current Shunt Value box click the On button Note the Current Shunt Value it should be 60 90 80 is ideal of the calibrated range of the sensor D Click Update to copy the Current Shunt Value into the Shunt Reference Value box and then click Off 202 Model 493 10
111. NAME tsiismcdsp o SHARED MEMORY 0x700000 SYSTEM OPTIONS VELOCITY LIMITER INTERLOCKS 8 HPU TRANSITION BOARD TRANSITION SLOT 9 NAME HPU MAIN POWER TRUE FIRST ON TRUE LAST OFF TRUE VISIBLE TRUE CONNECTOR J25 HSM TRANSITION BOARD TRANSITION SLOT 8 CHANNEL 1 NAME HSM 1 CONNECTOR J28A CONNECT TO MAIN TRUE TYPE SOLENOID CHANNEL 2 NAME HSM 2 CONNECTOR J28B CONNECT TO MAIN TRUE TYPE SOLENOID 276 Model 493 10 793 00 Controller Service a i i bd D i Se i zS i HSM TRANSITION BOARD TRANSITION SLOT 6 CHANNEL 1 NAME HSM 3 CONNECTOR J28A CONNECT TO MAIN TRUE TYPE SOLENOID CHANNEL 2 NAME HSM 4 CONNECTOR J28B CONNECT TO MAIN TRUE TYPE SOLENOID HSM TRANSITION BOARD TRANSITION SLOT 4 CHANNEL 1 NAME HSM 5 CONNECTOR J28A CONNECT TO MAIN TRUE TYPE SOLENOID CHANNEL 2 NAME HSM 6 CONNECTOR J28B CONNECT TO MAIN TRUE TYPE SOLENOID HSM TRANSITION BOARD TRANSITION SLOT 2 CHANNEL 1 NAME HSM 7 CONNECTOR J28A CONNECT TO MAIN TRUE TYPE SOLENOID CHANNEL 2 NAME HSM 8 CONNECTOR J28B CONNECT TO MAIN TRUE TYPE SOLENOID IO CARRIER ADDRESS 0xC2000000 SLOT 3 CLOCK MODE BINARY SYSTEM RATE 1024 MEDIUM SYSTEM RATE 256 0 LOW SYSTEM RATE 25 6 CLOCK TYPE MASTER DAUGHTER 1 ADDRESS 0x00000 TYPE 493 25 FILENAME FRDUC_53 0OUT C
112. OR J3 acceleration CHANNEL 2 NAME 493 48 Accel 2 CONNECTOR J3 conditioner CHANNEL 3 NAME 493 48 Accel 3 CONNECTOR J3 daughter board DAUGHTER 1 ADDRESS 0x00000 TY PE 493 21B FILENAME DUCB_53 0UT CHANNEL NAME 493 21B DC Slot 3 CONNECTOR J4 MODE DC FILTER 1000 AUXILIARY INPUT 493 48 Accel 1 AUGHTER 2 ADDRESS 0x10000 TY PE 493 21B FILENAME DUCB_53 0UT CHANNEL 2 NAME 493 21B DC Slot 4 CONNECTOR J5 MODE DC FILTER 1000 AUXILIARY INPUT 493 48 Accel 2 Defines the auxiliary Input gach ber ser UGHTER 3 ADDRESS 0x20000 TY PE 493 21B FILENAME DUCB 53 0UT udk kk rer CHANNEL 3 NAME 493 21B DC Slot 5 CONNECTOR J6 MODE DC lt FILTER 1000 AUXILIARY INPUT 493 48 Accel 3 AUGHTER 4 ADDRESS 0x30000 TY PE 493 21B FILENAME DUCB 53 0UT HANNEL 4 NAME 493 21B AC Slot 6 CONNECTOR J7 MODE AC FILTER 1000 RANGES RANGE Range 1 RANGE Range 2 RANGE Range 3 RANGE Range 4 Defines the resources needed MK En A BT E Digital Output 1 ZEROBIT Digital Output 2 ONEBIT Digital Output for load washing 3 Model 493 10 793 00 Controller Service 305 D ay Encoder temposonics sensor support Encoder temposonics sensor support The encoder definition describes the optional 493 47 Digital Encoder daughter board This board must be installed if you want to monitor encoder or Temposonics sensor feedback x t DAUGHTER 3 ADDRESS 0x20000 TY PE 493 47 FILENAME
113. Proportional Gain The CLC control mode uses one of three error signals The Limiting P Gain adjustment acts as a conversion factor to scale the limit feedback to similar units as the active P feedback Tuning Procedure Refer to How to Tune a CLC Control Mode in Chapter 5 Tuning of the Model 793 00 System Software Manual for a detailed CLC tuning procedure 258 Model 493 10 793 00 Controller Service Appendix A Hydraulic Configurations This section describes how to connect the Model 493 10 Chassis to a variety of MTS hydraulic configurations You will use the following connectors and cables to connect the Model 493 10 Chassis to your HPU 493 Chassis to 493 07 Pump Interface 493 07 Pump Interface to HPU 15 contact type D female EMI connector at J25 of the 493 73 HPU Transition module in the rear panel of the Model 493 10 Chassis Backshell EMI metallized plastic 14 contact type CPC male connector at J1 of the 493 07 Pump Interface chassis Cable 24 AWG 10 conductor with overall foil shield Carol C0745 or equivalent with drain wire connected to metallized plastic backshell at the 493 10 chassis and pin 14 at the 493 07 Pump Interface chassis 24 contact type CPC female connector at J25 of the 493 07 Pump Interface chassis 14 contact type MS connector at J1 of the HPU Cable 18 AWG 14 conductor with overall foil shield Alpha 2248C or equivalent with drain wire connected to pin 4 of connector J25 an
114. S A CAUTION The symbol shown here indicates that you must not connect telecommunications equipment to the Gd equipment showing this symbol Several modules have connectors that look similar to a phone connector Special cables are required Installing telecommunications equipment cables can cause equipment damage to the electrical components of the chassis or to your telecommunications system Model 493 10 793 00 Controller Service 83 Remote Station Controller Connection Remote Station Controller Connection 84 498 718 GRES Ill 12 CLOCK OUT WY EVENT OUT NZ EVENT IN N Q J3 IN i J6 STATION yoy 498765 01 The optional Remote Station Controller RSC module requires a Model 498 71B GRES III VMEbus module and a Model 493 71 Serial Interface transition module to be installed in the chassis The RSC can be connected to any of the four J50 connectors of the serial interface An interlock is permanently assigned to each J50 connector e g J50A Interlock 1 Connecting an RSC automatically assigns the RSC pod to the interlock The hwi file defines which connector is used for each station For more information see HWI file additions on page 85 The RSC control panel is available in two configurations one provides an E Stop and HPS control for single station configurations and the other provides a Station Stop with no HPS cont
115. S HPS Chassis J25 pee b low level Y cable 397135 01 OR bas 7 501822 XX 407 Controller gt J 519958 XX CE J25 HPS 260 Model 493 10 793 00 Controller Service Compatible Controllers 397107 XX 24V DC High level Y cable 397108 XX 115 V AC 054078 01 24V DC 397138 XX 24 V DC 054018 01 115 V AC 397 146 XX 115 V AC 493 10 493 07 Pump HPU Chassis J25 J1 Interface J25 HPS HPS HPS 458 or 397087 XX 24V DC 490 01 397088 XX 115 V AC 49705 For standard 493 07 jumper setting only Alternate settings are required for 436 11 and 413 05 controllers You can mix 493 07 458 490 and 497 05 controllers directly on the same HPU without the use of an HPU isolation box lt Qa z ft a z O y e g n You cannot mix 493 07 458 490 and or 497 05 controllers with 436 413 05 or 413 8X controllers unless you use an isolation box You can jumper the 493 07 converter box so you can use it directly with 436 and 413 05 controllers However if you do this you must use an isolation box if you attempt to mix the 493 07 with 458 490 and 497 05 controllers See Appendix B Model 493 07 Pump Interface on page 263 Model 493 10 793 00 Controller Service 261 a bd 5 2 2 E E 5 gt 262 Model 49
116. 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 Aramp 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 e Monitor the feedback or error signal to evaluate the system stability Sine Tapered Sine 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 e Monitor the feedback or error signal to evaluate the system stability Model 493 10 793 00 Controller Service 247 About Tuning 248 Random function generator Frequency Amplitude When tuning AIC compensator configurations it is necessary to generate random functions to properly simulate typical test conditions Random functions employ a pre emphasis filter to make the convergence rate constant over all frequencies The random function options include e Random 1 F e Random 1 F e Random Flat none e Random F e Random F A low frequency waveform is adequate for most testing Tests at higher frequencies cause a frequency shift that cannot be completely corrected with the PIDF adjustments e Do your initial tuning at a low frequency and then fine tune at the highest frequ
117. The SOLENOID and ON_OFF_SOLENOID types do not need an entry to define their characteristics The proportional characteristics should be commented out or deleted 286 Model 493 10 793 00 Controller Service I O Carrier I O Carrier The I O Carrier definition describes each Model 493 40 I O Carrier module installed in the 493 10 Chassis and their installed daughter boards Up to 8 I O Carrier modules can be installed in your system Each I O Carrier module can support up to 4 daughter boards ay J The I O Carrier module in slot three provides the master clock CLOCK TYPE MASTER for all other Carrier I O modules If a GRES II module is added always to Slot 10 the clock type for this I O Carrier module must be changed to CLOCK TYPE SLAVE Adding I O Carrier Each Model 493 40 I O Carrier module added to the 493 10 Chassis Modules must be described in the I O Carrier definition A typical description for an added I O Carrier module is shown below IO CARRIER ADDRESS 0xC2200000 SLOT 4 CLOCK TYPE SLAVE You must set the address on the added I O Carrier module to match the address specified in the I O Carrier module s definition See Setting I O Carrier addresses on page 32 1 0 Carrier Addresses As additional I O Carrier modules are installed their addresses increment as follows 1 O CARRIER ADDRESS MODULE First 0xC2000000 Second 0xC2200000 Third 0xC2400000 Fourth 0xC2600000
118. The filter is located in the top of the chassis stand alone version It can be accessed from the rear of the chassis Slide the filter out from the top of the transition modules Note The filter has a top and a bottom be sure you re install the filter in the proper orientation Clean the air filter with soapy water and then dry it completely z 3 oO ej 9 ej oO o Model 493 10 793 00 Controller Service 265 lt p 266 Model 493 10 793 00 Controller Service Appendix D Optional Station Configurations This section describes how to configure your Model 493 10 Chassis to support an optional six or eight stations When configuring your system for a six or eight stations you must consider the following Ensure that the hwi file is correctly set for the desired multi station configuration especially the interlock and HSM board settings Power to each HSM is limited Cross head interlocks with solenoid power are not supported Remote Station Control RSC is not supported AC input power must be at least 115 V AC Auxiliary power out of J49 on the Model 493 74 HSM Transition board is not supported See The HWI File on page 283 for more information on setting up your hwi file Model 493 10 793 00 Controller Service 267 i gz T i N m i i O i a K 9 i n 6 Station Configuration The 6 station confi
119. The purpose of a tuning program is to produce a command that reflects the most demanding system response expected from a test Note The Function Generator is very useful for quickly setting up a tuning program If you use the same tuning program on a regular basis you may wish to create and save your tuning procedure using Basic TestWare or by using the optional MultiPurpose TestWare application 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 Note Always monitor the sensor feedback or error signal to evaluate the control accuracy See Monitoring Waveforms on page 250 A typical tuning program is a low amplitude 5 to 10 of full scale low frequency 1 Hz to 2 Hz square waveform This section 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 Auto tuning provides a moderate level of tuning for PIDF control modes Auto tuning exercises the actuator with a sweep function while monitoring the feedback of the control mode being tuned The response of the control mode is determined and the appropriate tuning parameters are calculated For more information refer to Auto tuning on page 25
120. al monitoring 206 encoder definitions hwi file 306 encoders hwi file definitions 295 error signal 251 Eurotherm temperature controller cabling 104 how to configure 104 programming 104 extensometer calibration adjust offset 220 calibrate compression 222 calibrate tension 221 calibration file assigning 218 creating 217 gain delta K 221 record data 222 shunt calibration 229 shunt calibration reference 228 external controllers 105 adjust command signal 107 allocating resources 106 cabling 106 conditioner outputs MTS products 92 external readout devices 108 adjust readout signals 111 cabling 110 create readout channel 111 sending station signals to 110 station signals available 108 F feed forward gain 243 Model 493 10 793 00 Controller Service force sensor gain delta K calibration 185 gain linearization calibration 190 millivolt volt calibration 197 mV V positive compression calibration 199 mV V positive tension calibration 198 force sensor calibration about 176 additional ranges 203 check conditioner polarity 183 initial values 180 mounting force standard 179 prerequisites 176 setting offset 184 setting zero 184 shunt cal reference 200 shunt calibration 202 shunt resistor table 200 signal monitoring 178 216 what you need 176 force tuning auto tune 257 prerequisites 255 procedure 255 force strain sensor I O carrier connection 129 forward loop filter 245 full range conditioner calib
121. alve Driver supports the inner loop signals The following figure shows the connections between the valve driver and the valve See Cable Part Numbers on page 43 to connect the valve to the I O Carrier module See also the servovalve manual for single and dual valve configuration wiring information Model 493 15 Valve Driver To From J4 J7 To From I O Carrier Servovalve p Excitation Excitation lt q Feedback Feedback Signal Ground oO O NOORA ON fk Valve Command 10 11 Valve Command 12 13 14 15 Controller Valve VDT Inner Loop Test Command Command es gt gt Actuator LVDT Outer Loop Feedback 48 Model 493 10 793 00 Controller Service I O Carrier Connections 257 valve connections The Series 257 Servovalve is a 3 stage servovalve that requires a power driver The Model 493 15 Valve Driver supports the inner loop signals The following figure shows the connections between the valve driver and the valve See Cable Part Numbers on page 43 to connect the valve to the I O Carrier module See also the servovalve manual for single and dual valve configuration wiring information Model 493 15 Valve Driver To From J4 J7 To From I O Carrier Servovalve Excitation m Excitation q Feedback Feedback Signal Ground O O N OO FF WwW DY m
122. anager in the Model 793 00 System Software manual Model 493 10 793 00 Controller Service 219 iw gt f p Calibrating an Extensometer Task5 Adjust offset This task verifies the sensor s zero position and offsets any imbalance due to specimen size forces from test components cable length and so forth The zero position can be set anywhere within the full scale range of the strain sensor Note The arms of the extensometer must be in the zero reference position Depending on the extensometer this can be accomplished using the zero pin stop block or a special fixture 1 Adjust the Manual Cmd slider for 0 cm cm 2 Click Auto Offset icon on the Station Controls panel to display the Signal Auto Offset window 3 If the current strain output is not zero click the Auto Offset icon next to the signal value to offset it automatically S bd K o 220 Model 493 10 793 00 Controller Service Calibrating an Extensometer Task6 Gain Delta K Calibration If you are using Gain Delta K for your calibration type complete the following procedure If not complete Task 7 Gain Linearization Calibration on page 223 Calibrate the negative This task calibrates the extensometer negative output using the output tension calibration Gain controls Since the Gain setting will affect your Delta K setting you should always calibrate the negative side first AK 1 Indicated output
123. are application Refer to the Model 793 10 MultiPurpose TestWare manual for more detailed information Model 493 10 793 00 Controller Service 93 Cabling and Programming External Controllers Connecting Interlock Signals to 407 Controllers The Model 493 10 793 00 controller monitors digital I O interlock signals through its Model 493 74 HSM transition module s J43A and J43B connectors Use these connectors when connecting to 407 controllers Model 493 74 HSM transition module connectors are as shown in the figure Interlock cabling to 407 controllers depends on your system s configuration There are three possible configurations Single station one 407 controller runs a single test program Multiple stations two or more independent 407 controllers each run different test programs Master dependent station one master 407 controller daisy chained with other dependent 407 controllers together run a single test program Single 407 Controller Interlock Connections The following figure shows how to cable interlocks for a single station 407 controller to the Model 493 10 793 00 controller via its Model 493 74 HSM transition module Use the specified interlock cable PN 56455 0xx to make these connections P28 Digital CPC 4P I O Connector HSM LO N Hoda w ie a gur mena yale 2 7 4 N1 J ActiveLow ja Vv 3 AY 5 L ocita Run Stop
124. astic e Cable type 4 conductor w foil shield and drain 100935 80 or equivalent with the drain wire connected to metallized plastic backshell at the chassis e For 256 and 257 servovalves the valve LVDT uses the same type of connectors as the actuator LVDT e Servovalve valve LVDT Y cable required for 256 xx or 257 xx servovalves 397105 XX 46 Model 493 10 793 00 Controller Service I O Carrier Connections 252 servovalve The Series 252 Servovalve is a 2 stage servovalve The Model 493 14 connections Valve Driver supports single or dual valve configurations The following figure shows the connections at the valve driver and the connections between the valve and the valve driver See Cable Part Numbers on page 43 to connect the valve to the I O Carrier module See also the servovalve manual for single and dual valve configuration wiring information Model 493 14 Valve Driver From J4 J7 To I O Carrier Servovalve 1 2 3 4 5 6 7 8 p 9 Valve Command 10 gt 11 Valve Command 12 Valve 2 Command 13 Valve 2 Command 14 15 g Controller Test Command Control Valve L Command Mode Driver gt Actuator LVDT Feedback Model 493 10 793 00 Controller Service 47 I O Carrier Connections 256 servovalve The Series 256 Servovalve is a 3 stage servovalve The Model 493 15 connections V
125. at is 80 of the positive full scale range A Adjust the Manual Cmd slider for a positive strain command that is 80 of the full scale range B Verify that your extensometer feedback signal is 80 of the full scale range 12 Record conditioner feedback readings at predetermined negative strain command points Note After shutting down system hydraulics you will enter these recorded readings on the Linearization Data window A Adjust the Manual Cmd slider for a 0 command B Record the calibrator s readout value and the corresponding conditioner feedback in the 0 row of your record sheet S bd K o 226 Model 493 10 793 00 Controller Service Calibrating an Extensometer Adjust the Manual Cmd slider for a 2 strain command D Record the calibrator s readout value and the conditioner feedback reading in the 2 row of your record sheet E Repeat steps C and D for other negative strain commands typically at 4 6 8 10 20 40 70 and 100 percent of full scale 13 Record conditioner feedback readings at predetermined positive strain command points A Adjust the Manual Cmd slider for a 2 positive strain command B Record the standard s readout value and the conditioner feedback reading at the 2 row of your record sheet C Repeat steps A and B for other positive strain commands typically at 4 6 8 10 20 40 70 and 100 percent of full scale 14 Turn
126. ation 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 system Other MTS manuals 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 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 Contents Conventions 10 Technical Support 13 Model 493 10 793 00 Controller Service Preface 9 Conventions Conventions The following paragraphs describe some of the conventions that are used in your MTS manuals Hazard conventions As necessary hazard notices may be embedded in this manual These notices 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 all three levels Note For ge
127. ator piston area expressed as in cm2 W any directly coupled mass including the actuator piston mass expressed in Ibs kg V hydraulic fluid volume contained inside the actuator and manifold expressed as in cm e If the system response deteriorates when adding delta P then change the polarity of the signal If changing polarity does not improve system response try adjusting the stabilization filter See Stabilization Filter on page 245 e Check all amplitudes for overshoot Do not allow more than 10 overshoot preferably none at any amplitude of a square wave response e Delta P will not compensate for additional compliance from swivels linkages test tables and so forth In this case a mass accelerometer signal from an accelerometer may be used in place of a delta P signal for stabilization See Acceleration stabilization below 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 and test tables 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 comma
128. auxiliary data signals station signals listed in your software windows include the name of their associated control channel For example if your channel is labeled Ch 1 the available station signals would be Ch 1 Output Ch 1 Command and so forth The following table provides a description of the various station signals DESCRIPTION Displays the time reference signal derived from the internal clock that increments continually This signal exists to support data acquisition by test program applications such as Basic TestWare and MultiPurpose TestWare It is not practical to monitor the time signal with an external readout device Rollover Time Displays the time reference signal derived from the internal clock that resets every hour Like the time signal this signal exists to support data acquisition by test program applications It is not practical to monitor the hourly rollover time with external readout devices Output Displays the test control signal sent to the valve driver in volts Command Displays the program command signal in engineering units Comp Cmd Displays the value of the compensated command signal in engineering units This signal is only valid when using Peak Valley AIC APC or ALC compensators Count Displays the number of segments played out so far in the selected control channel When using a Station Manager meter this signal is only available for the Timed meter Error Displays the e
129. board requires the optional ADDA II module 493 57 DSPAD Converts up to eight external analog signals to digital signals for use by the controller A DSP chip provides digital filtering This board requires the optional ADDA II module 493 59 Universal Encoder Processes the signals from incremental absolute and Temposonics III encoders This board requires the optional ADDA II module N e 5 z Model 493 10 793 00 Controller Service 35 Installing the Plug in Modules Transition Panels The transition panels need to be installed in specific slots of the rear panel chassis This is done to allow proper air flow in the chassis For consistency install the modules according to the following guidelines Starting from the left chassis slot slot 10 and working to the right install the modules as shown If you do not have one of the modules install the next one you do have Install multiple modules of the same model number next to each other 10 9 6 5 4 3 2 1 B A 493 71 493 73 493 74 493 72 493 78 493 77 493 7 Serial HPU HSM Digital vo Accel Filtered In Interface Transition J50A av Ch1Ain cht cht KI service J43A intik J43B z O BJ ey 680 KO On 292 323 09 09 59 59 z 080 ee S
130. bration for DC sensors is described for systems with and without ID modules on their sensor cables Transducer ID modules are also discussed including assigning sensors and saving data to ID modules Contents Sensor Signals 122 About Sensor Ranges and Detectors 122 Transducer Connections 127 Full Range Digital Universal Conditioner FRDUC Jumpers 130 Sensor Cables 133 Shunt Calibration 136 Shunt Calibration Bridge Completion 140 Model 493 10 793 00 Controller Service 121 Sensor Signals Sensor Signals With the Station Builder program you can allocate station resources conditioners to sensors connected to your test system Once a conditioner is linked to a sensor the sensor signal feedback can be used as a control mode and or for data acquisition Available sensor signals vary with the type of controller in your system TestStar IIm and FlexTest GT controllers support the following types of sensor signals e AC conditioner signals are conditioned by a Digital Universal Conditioner DUC daughter board plugged into the I O Carrier module on the 493 10 chassis The DUC must be configured for the AC mode An LVDT requires AC conditioning e DC conditioner signals are conditioned by a Digital Universal Conditioner DUC daughter board plugged into the I O Carrier module on the 493 10 chassis The DUC must be configured for the DC mode A force transducer load cell requires DC conditioning About Sensor Ranges an
131. chanical input You calibrate the negative side of the output with gain and the positive side of the output with Delta K OF eee Delta K compensates for differences in symmetry between the positive and negative outputs You should calibrate actuator extension at 80 of full scale for each range Gain controls Pre Amp gain is a selectable gain amplifier with predefined values Since changes in Pre Amp gain can cause spikes in the feedback signal Pre Amp gain can only be adjusted when hydraulics are off Post Amp gain is a finer operator defined gain control that can be adjusted when hydraulics are on The Total gain value is calculated by multiplying the Pre Amp and Post Amp gain values If the total desired gain amount is known from a calibration sheet you can enter the amount in the Total gain box and the software will calculate the Pre Amp and Post Amp gain values automatically iw gt gt f i Model 493 10 793 00 Controller Service 165 Calibrating an LVDT When you are calibrating an AC conditioner use the Post Amp gain control to increase gain If more gain is needed you must disable hydraulics and increase the Pre Amp gain You can then turn on hydraulics and continue to adjust the Post Amp gain slider Note This procedure assumes a positive command extends the actuator and a negative command retracts the actuator If not use the opposite polarity for any values given 1 Select Gai
132. conditioners 122 full range 122 connections encoders 204 318 control modes characteristics 236 displacement 237 force 237 strain 238 controller chassis DUC jumpers 130 controller connection CTM programmer 88 controller scope tuning use 253 CTM programmer controller connections 88 D d gain see derivative gain DC conditioners calibration 176 checking polarity 183 DC sensor calibration shunt calibration 137 shunt resistor table 137 delta P sensors stabilizing with 243 derivative gain 242 digital I O definitions hwi file 297 digital I O access panel 82 digital I O connections 79 digital I O transition module J3 In connector 80 J4 out connector 81 digital inputs J3 In connector 80 digital outputs cable specification 81 J4 out connector 81 displacement calibrate actuator extension 167 calibrate actuator retraction 165 control modes 237 mounting dial indicator 162 sensor calibration 149 displacement tuning 254 auto tune 257 prerequisites 254 procedure 254 when to tune 254 dither about 118 adjusting dither amplitude 118 Model 493 10 793 00 Controller Service E electrical power connecting 27 grounding 27 emergency stop cable specifications 66 E STOP Out connector 66 HPU transition connectors 66 enabling limit detectors 125 encoder I O carrier connections 58 encoder calibration calibration file 207 connections 204 defining an input 204 setting resolution 207 setting zero 204 209 sign
133. d Detectors Sensor description Sensor ranges Full range conditioners 122 Your system s sensors convert measured mechanical values such as force displacement and pressure into electrical signals that after conditioning are suitable for feedback for closed loop control Sensors and sensor conditioners are calibrated together in pairs against a standard to ensure their outputs accurately represent the physical properties they are measuring Every sensor has a full scale capacity that defines its maximum operating range For example an actuator that can extend its piston 6 cm from its fully retracted position is referred to as an actuator with a 6 cm stroke The displacement sensor used with the actuator has a full scale capacity of 6 cm Some sensor conditioners such as Model 493 25 Digital Universal Conditioners are full range conditioners They have only one range that spans the sensor s full scale capacity Model 493 10 793 00 Controller Service Ranged conditioners Range example Ranges represent a portion of the sensor s capacity Selecting ranges Select a full scale range to optimize the maximum sensor output for a test cm Sensor Signals Certain conditioners such as the Model 493 21B AC DC Universal Conditioner use two or more ranges Each range defines the electronic amplitude of the sensor s feedback signal for the purpose of providing better signal resolution In other words it redef
134. d pin A of the pump connector Hydraulic pump The following diagrams show how to connect the chassis to a configurations hydraulic power unit Single 493 chassis with a 24 V PLC programmable logic controller pump or 505 pump Single 493 chassis with a non PLC pump Multiple 493 chassis with a non PLC pump Compatible controllers controlling a pump Model 493 10 793 00 Controller Service 259 lt Qa z ft a z O y e g n Single 493 Chassis with a 24 V PLC pump 506 52 92 or 505 pump 397137 XX 493 10 HPU Chassis J25 HPS a S Note The following three configurations have cables to support both 24 V DC and 115 V AC control voltages A 493 07 Pump Interface is D available for each voltage not both Be sure the cables and pump interface are rated for the same voltage 2 Single 493 Chassis with a non PLC pump E 5 397138 XX 24 V DC 397107 XX 24 V DC gt 397146 XX 115 V AC 397108 XX 115 V AC 493 10 493 07 Pump HPU Chassis J25 J1 Interface J25 HPS HPS HPS Multiple 493 Chassis and 407 Controllers 397138 XX 24V DC 397146 XX 115 V AC 397107 xx 24V DC 493 10 397 108 xx 115 V AC Chassis J25 HPS 493 07 Pump HPU J1 Interface J25 493 10 HP
135. dback signal You must know which conditioner module is connected to the LVDT Note _ f you are recalibrating a sensor use the existing calibration values as a Starting point You will need a dial indicator gage or for longer displacements a measuring device such as a long ruler laser or optical detector to calibrate an LVDT All calibration tools should also be calibrated to an industry standard e During calibration Manual Offset should always be set to zero e When calibrating sensors that use a full range conditioner e g 493 25 DUC ensure that Electrical Zero Lock is checked on the Offset Zero tab of the Inputs panel e After completing LVDT calibration do not change the electrical zero adjustment Readjustment of electrical zero after calibration will change the point at which linearization takes place disturbing other calibration settings especially delta k iw gt f p Calibrating an LVDT Pre calibration tuning Use the following procedure for initial tuning of the LVDT sensor channel prior to calibration Pre tuning is especially important if the LVDT has never been calibrated 1 On the Station Manager toolbar select Calibration in the User Level access box 2 From the Display menu on the Station Manager window select Station Setup to display the Station Setup window 3 In the Station Setup window navigation pane select the displacement channel you want to tune 4 From t
136. ded excitation Bridge balance Jumper W8 connects EX to ground for situations requiring single ended excitation EX EX EX GND Default CE ID vse HB vs R32 changes the offset of the bridge balance circuit If the zero offset is too large when the sensor bridge is balanced you should add an appropriately sized resistor R32 E BD Default No Resistor HE BD Positive Offset ENHED Negative Offset Model 493 10 793 00 Controller Service Transducer Connections Sensor Cables A typical system is provided with a standard set of sensor cables as specified on the System Cable Jumper Plug 493 Package Selection drawing PN 700 000 656 Refer to this drawing for the most current part numbers Standard sensor cables do not have ID modules Sensor cables with an ID module built into them are available as an option Sensor cables with ID modules use a system cable to bridge the sensor cable to the appropriate connector on the rear panel of the chassis Specifications e 15 contact type D male EMI connector e Backshell EMI metallized plastic e Cable type For all applications including CE EMC Compliance use MTS cable material 505301 01 two 22 AWG twisted pairs with inner and outer braided shield for the excitation and feedback signals plus a twisted quad for the ID signals and a single wire for the shunt calibration signal Shield connections can vary from sensor to sensor e If purchased as an option each
137. definition for a MUD board Model 493 10 793 00 Controller Service I O Carrier Connections Output connections Fach valve driver output is an RJ45 connection that contains two valve drive output lines and a cable loss detection loop From J1 J8 To I O Carrier Servovalve ___ Valve Command p Valve Command Cable Loss O N OO FP W DY Cable Loss Cable loss detection The cable loss detection wire loops out to the servovalve and back to the driver output allowing MUD board logic to detect a cable break or a cable disconnect at the MUD board output A cable loss will not be detected if the cable is disconnected at the servovalve Model 493 10 793 00 Controller Service 51 I O Carrier Connections Analog I O Connections The Model 493 45 A D and Model 493 46 D A daughter boards are installed in the Model 493 40 I O Carrier front panel module A connection from the front panel daughter board connector to a rear panel BNC transition module allows easy access to the analog channels Note The external analog source can be a stand alone function generator another controller or a computer controlled analog output 293 40 External Analog Source 1 0 Carrier Analog Out Analog Monitor 493 10 Chassis o EETEEELELLLELELEEEELLELEELLELLELELLTETETELLIS
138. del 493 10 793 00 Controller Service 203 iw gt f p E bd K o Calibrating Encoders Calibrating Encoders Determine installed 204 location Defining an input Zeroing Encoders are connected to the controller through a 493 40 Carrier I O board The encoder requires the Model 493 47 Encoder Interface daughter board to be installed in a Model 493 40 Carrier I O board The Carrier I O connector you use is based on the installed location of the Model 493 47 Encoder Interface daughter board on the board of the Carrier I O module To determine the installed location of the Model 493 47 Encoder Interface daughter board use the Hardware tab on the Station Signals window Access Station Signals on the Station Setup window navigation pane Defining an encoder sensor input signal is no different from any other input signal However specific resources must be available to define either input signal Use the Station Builder program to allocate an encoder to the station configuration file and assign units to the signal Feedback resources labeled Encoder Input or Heidenhain 417 425 Input indicate that an optional encoder daughter board is installed in the Model 493 40 Carrier I O board The encoder signal is defined in the Station Setup Inputs panel Signal definition is handled the same way as any other input signal Note Keep in mind that you cannot zero an encoder if it
139. do so could expose the operator to dangerous voltages If the Pump Interface remains connected to a 120 volt HPU this voltage will be present Always remove all cable before removing the cover As shipped the HPU interface on the 493 07 Pump Interface is compatible with 458 10 20 490 01 TestStar ID 493 xx and 497 05 controllers The 493 07 Pump Interface may be connected to other controllers as shown in the following table using a Y cable Note Ifthe 493 10 chassis is the only device connected to the HPU the Jumper settings do not matter COMPATIBLE WITH JUMPERS Model 458 05 10 20 40 Standard jumper setting Model 490 01 Model 497 05 E10 E11install E12 E13 install E14 E15install E16 E17install E10 E13 remove E14 E17 remove Model 413 05 Jumper change required Model 436 11 Model 407 05 E10 E11 remove E12 E13 remove E14 E15 remove E16 E17 remove E10 E13 install E14 E17 install Note The Model 493 07 Pump Interface can not be compatible with both groups of controllers at the same time If this functionality is needed use an HPU isolation box Model 493 10 793 00 Controller Service Appendix C Maintenance This section describes how to maintain the Model 493 10 Chassis Cleaning the chassis Remove any dust from the chassis with Endust for Electronics or equivalent Cleaning the air filter Be sure the cooling fan is operational and not clogged Clean or replace the filter as required
140. ds can be installed e Model 493 55 A D 8 Channel e Model 493 56 D A 8 Channel e Model 493 57 DSPAD 8 Channel e Model 493 59 Universal Encoder 1 Channel Model 493 10 793 00 Controller Service ADDA II module Each daughter board can be assigned to one of the four ADDII module rear panel connectors Daughter board ID e Each A D or D A daughter board definition is followed by eight signal definitions e A second daughter board of the same type A D or D A continues the channel count sequence For example a second A D daughter board begins at channel 9 ADDAII ADDRESS 0x0 This block defines an This specifies an A D daughter ae a ADDA II module hard CLOCK TYPE SLAVE This block defines an ADDA II daughter board DAUGHTER 1 ADDRESS 0x1 TYPE 493 55 FILTER OFF ATT DAUGHTER 4 ADDRESS 0x4 TYPE 493 56 FILTER OFF These define an ADDA II This specifies a D A daughter daughter board location board The analog I O definitions provide A D channels and D A channels for analog inputs and outputs from the 498 Analog In transition boards Model 493 10 793 00 Controller Service 293 ay J ADDA II module Input and output e The channel numbers for the analog inputs represent the available channels analog to digital converters following the list of AC and DC conditioner signals i t e The channel numbers for the analog outputs represent the available digital to analog conver
141. e Note Ranges can also be added on the Sensor tab and calibrated on the Calibration tab S bd K o 230 Model 493 10 793 00 Controller Service Chapter 7 Tuning Tuning affects the response and stability of the servo control loop Proper tuning improves the performance of the system Note Precise tuning is not necessary A good tuning adjustment is one that produces near optimal behavior over a wide variety of conditions e Each control mode uses a different sensor feedback signal for servo loop control Each control mode must be tuned e Tuning optimizes test performance by minimizing the system error in the selected control mode Contents About Tuning 232 If You ve Never Tuned Before 233 When to Tune 234 Control Mode Characteristics 236 How the Tuning Controls Work 239 Creating a Tuning Program 246 Other Considerations 249 Monitoring Waveforms 250 Tuning Displacement 254 Tuning Force 255 Auto tuning 256 Tuning a CLC Control Mode 258 Model 493 10 793 00 Controller Service 231 About Tuning About Tuning When you tune you are setting the stability and response of the servo control loop Proper tuning improves the performance of the test system Time Lag phase shift Proper tuning reduces error and phase lag Program Command gt Feedback higher Proportional gain Feedback lower Proportional gain Inaccurate tuning increases the error and phase la
142. e 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 aaa aaa ry See Turn on hydraulic pressure on page 159 for a detailed procedure S bd K o 208 Model 493 10 793 00 Controller Service Calibrating Encoders Task5 Set the zero position The zero position can be set anywhere within the full scale range of the encoder A Adjust the Manual Cmd slider on the Manual Command window to move the actuator to the position you want to assign as zero B Use Control Mode on the Change control modes on the Control Panel Select any control mode that does not use the encoder Note _ f the actuator should move after making the change in control modes you will need to reposition the actuator then change to a more stable control mode C With the actuator in the desired zero position click the Auto Zero button on the Offset Zero tab Inputs panel Task6 Save the calibration It is important that you save your sensor calibration values On the Station Setup window Inputs panel click the Calibration tab and then Save This saves current calibration values on the Calibration Sensor and Shunt tabs to the sensor calibration file iw gt f p Model 493 10 793 00 Controller Service 209 Calibrating Temposonics Sensors Calibrating Tempo
143. e polarity of the conditioner the polarity of the valve driver and the orientation of system cabling all play a role in controlling the actuator and determining how signals are displayed This procedure assumes the servovalve polarity is set to Normal on the Station Setup Drive panel Valve tab 1 Check the sensor connection Be sure the displacement sensor is properly connected 2 In the Station Controls toolbar click the Manual Command button to display the Manual Command window In the Manual Command window A Select the appropriate Channel B For the Control Mode select the displacement associated with the LVDT signal you are calibrating C Click Enable Manual Command 3 Move the Manual Cmd slider to apply a positive command extend the actuator A Monitor the displacement feedback On the Station Signals panel monitor the appropriate displacement feedback signal If the signal value is positive for actuator extension the conditioner polarity is correct If desired you can change the conditioner polarity to make the signal value negative for actuator extension Note The polarity setting should be the same when calibrating additional ranges for the same sensor E bd K o 160 Model 493 10 793 00 Controller Service Calibrating an LVDT Task6 Setthe phase This task determines the proper phase adjustment The phase adjustment matches the phase of the AC feedback signal to the 10 kHz
144. e Calibration tab of the Inputs panel Note For convenience during mv v positive compression calibration Gain and Delta K are presented as read only displays on the Inputs panel 2 From the Calibration Data sheet for your force transducer enter the following values on the Calibration tab A Enter the full scale force values in the Fullscale Min Max entry boxes B Adjust Neg Tension for the required tension sensitivity value mV V C Adjust Pos Compression for the required compression sensitivity value mV V D Adjust Excitation for the required calibration excitation value Vdc iw gt f p Model 493 10 793 00 Controller Service 199 S bd K o Calibrating a Force Sensor Task 10 Establish the shunt calibration reference Each resistive bridge type transducer DC sensor uses a shunt resistor to check the calibration accuracy of the sensor conditioner combination Each DC conditioner supports a shunt resistor 1 Turn off hydraulic power 2 Remove the load standard 3 Turn on hydraulic power 4 Zero the force sensor output Adjust the Manual Cmd slider on the Manual Command window for a 0 kN output The sensor output must be 0 000 kN for a proper shunt calibration If not return to Set the zero and offset on page 184 5 Change the control mode Change Control mode on the Manual Command window to a Displacement control mode Shunt calibration cannot
145. e Model 493 10 793 00 Controller Service Technical Support Technical Support Start with your manuals Technical support numbers MTS web site www mts com E mail Telephone Fax The manuals supplied by MTS provide most of the information you need to use and maintain your equipment If your equipment includes MTS software look for README files that contain 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 Model 493 10 793 00 Controller Service Preface 13 Technical Support Before you contact MTS Know your site number
146. e that Electrical Zero Lock on the Offset Zero menu is set to Locked Adjusting electrical zero after calibration may invalidate linearization data Adjust the Manual Cmd slider on the Manual Command to adjust the calibrator between zero and 100 of the extensometer s full scale range three times This exercises the extensometer to remove any hysteresis Apply a negative strain command that is 80 of the negative full scale range A Adjust the Manual Cmd slider for a negative strain command that is 80 of the full scale range B Verify that your extensometer feedback signal is 80 of the full scale range During the initial calibration and tuning of your system it may require repeated adjustment for the negative strain command and feedback values to match At this point unless the conditioner is already in calibration the negative strain applied to the extensometer will not equal your commanded value You will adjust gain in the next step so that the actual strain and your commanded strain match Adjust gain until the actual strain equals your strain command Adjust the Post amp Gain control to increase the negative strain reading on the calibrator until it equals your negative strain command Apply a positive strain command that is 80 of the positive full scale range A Adjust the Manual Cmd slider for a positive strain command that is 80 of the full scale range Model 493 10 793 00 Controller Service 223
147. e zero position on page 214 Task 6 Save the calibration on page 214 E bd K o 210 Model 493 10 793 00 Controller Service Calibrating Temposonics Sensors Task1 Get things ready 1 Review Before You Begin on page 147 2 Locate relevant documentation When calibrating a Temposonics sensor you will need information about the sensor such as the serial number model number a specification called measuring step resolution etc 3 Open a station configuration file You need a station configuration file that includes a control channel and a control mode that uses the Temposonics sensor you intend to calibrate On the File menu click Open Station to open the appropriate configuration file 4 Enter the Calibration password You must access the Calibration user access level before you can perform any of the calibration procedures On the Station Manager toolbar select the Calibration user level on the Access Level list 5 Set up a signal monitor Note You cannot monitor the output of a new sensor until a sensor calibration file has been created and the sensor assigned to an input signal You will be monitoring temposonics sensor output when making adjustments throughout this procedure You can monitor the temposonics sensor output in the same units that you are using for the calibration You can use an external DVM to monitor temposonics sensor output from a BNC connector on the A
148. eading on the load standard until it equals your tensile force command 4 Repeat steps 2 and 3 for all ranges Example Suppose you have an actuator with a full scale capacity of 10 kN and ranges of 10 kN 5 KN 2 kN and 1 KN In this case you would repeat this process and calibrate tension at 80 of each range 8 kN 4 kN 1 6 kN and 0 8 kN Note Some systems do not provide or require multiple ranges such as those using full range conditioners e g Model 493 25 DUC module In this case only one range is used typically 100 Note This procedure assumes a positive command extends the actuator and a negative command retracts the actuator If not use the opposite polarity for any values given Calibrate 1 Exercise the force sensor compression Use the Manual Cmd slider on the Manual Command window to cycle the force standard readout between zero and full compression three times This removes any hysteresis in the sensor Example When calibrating a 10 kN range exercise the load standard between 0 and 10 kN 2 Apply a compressive force command that is 80 of the range s full scale Do this by adjusting the Manual Cmd slider on the Manual Command window then verify that the Station Signals panel reads what you applied with the slider During the initial calibration and tuning of your system it may take a while for the two values to match Note _ f the actuator response is sluggish and or the signal
149. ease the current drive When connected in parallel the station must be configured so all paralleled outputs are driven from the same event e The output is rated for a maximum of 30 V DC e Fused 12 V DC is available at pins 18 and 19 e If an output is not used a jumper is not needed to complete a circuit e The outputs are optically isolated e The outputs are triggered by the system controller 493 72 Digital I O Digital I O Transition Board J4 Access Panel External Device FORDRER SER 12 Gail Ext Voltage Opto oa 9 18 Coupler CH2 AG i 2 TNn CH2 21 O Ty r 36 V ee KT Cable specification The cabling information shown assumes a single cable destination with an overall shield In other applications the cable may have more than one destination For these applications an overall shield is not practical and non EMI connectors and back shells are permissible e 37 contact type D male EMI connector e Back shell EMI metallized plastic e Cable shielded twisted pairs as required 24 AWG minimum with drain wire s connected to the metallized backshell at the chassis Model 493 10 793 00 Controller Service 81 Digital I O Connections Digital 1 0 The digital inputs and outputs can be cabled to an optional digital 1 0 access panel access box The box is a convenient way to wire digital sources and destination to the Model 493 72 Digital I O transition module 493 72
150. ed 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 LVDT ranges are changed e You deem it necessary as a result of scheduled system calibration or you feel system response should be improved or reduced Prerequisites Be sure the following items are completed before you begin tuning the displacement control mode e Hydraulic pressure is off e The specimen is not installed e You have created a station configuration file e You have created a station parameter set Tuning procedure Refer to Tuning Displacement in Chapter 5 Tuning of the Model 793 00 System Software manual for a detailed tuning procedure 254 Model 493 10 793 00 Controller Service Tuning Force Tuning Force To complete this task you will make sure the force tuning values established 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 The displacement tuning values established in the station parameter set are unlikely to require adjustment Optimal force tuning values however are a function of your specimen s compliance which may change over time or from test to test You should also tune force whenever you make any change to the force train suc
151. edure 144 Model 493 10 793 00 Controller Service Chapter 6 Calibration Contents Prerequisite Initial calibration Abbreviated procedures This chapter describes how to calibrate the sensors connected to your system All sensors require calibration to ensure that their outputs accurately represent the physical condition they sense e g force or displacement When you calibrate a sensor you are calibrating the test system to properly interpret the sensor signal Sensors included with your test system are usually factory calibrated and the corresponding sensor calibration files are included with your system software If you change a sensor or add a new sensor to your system you must calibrate the new sensor conditioner pair against a standard to ensure the sensor s accuracy You must calibrate all sensors before they can be used to support control modes or auxiliary data channels Before You Begin 147 Calibrating an LVDT 149 Calibrating a Force Sensor 176 Calibrating Encoders 204 Calibrating Temposonics Sensors 210 Calibrating an Extensometer 215 You must have a Station Builder configuration file that includes the sensor s you wish to calibrate If you are calibrating a sensor for the first time you may find it necessary to e Perform an initial tuning of the sensor channel before calibration e Perform the procedure twice The abbreviated procedure provides an overview of the calibration procedure
152. either of the following e A sinusoidal test waveform is distorted at its maximum and minimum points peak and valley values change This will normally be more observable during a test that has either a low frequency or a low amplitude test waveform This indicates that dither amplitude is insufficient e An unusual sound hammering squealing or pounding coming from the test system This indicates that dither amplitude is excessive See Adjusting dither amplitude on page 118 Inner loop tuning Perform inner loop tuning when initially installing a system or fine tuning a system that employs a 3 stage valve driver See Tuning the Inner loop on page 119 114 Model 493 10 793 00 Controller Service Setting the Servovalve Polarity Setting the Servovalve Polarity Servovalve polarity determines the direction the servovalve moves the actuator in response to a positive command It can be set to normal or invert Typically a servovalve set to normal polarity extends the actuator in response to a positive command Conversely 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 Please note the following e The polarity of the servovalve must be checked before sensor calibration begins and before hydraulic pressure is applied for the first t
153. em 1 0 Connector J54 Sys I O provides three digital inputs and one digital output The inputs are connected to the high and low inputs of an opto isolator The out is from the collector and emitter of an opto isolator See the Digital I O Connections on page 79 for circuit drawings To From To From HPU J54 External Devices 24V O 1 lt 2 Input 1 lt 3 volt 24V o 5 6 Input 2 7 a 24V G 9 lt 10 Input 3 lt fl a gt 12 13 gt 14 ag Output 1 15 Cable specification J54 Sys I O is a 15 contact type D female connector e 15 contact type D male EMI connector e Backshell EMI metallized plastic e Cable 24 AWG 4 connector with overall foil shield Belden 9534 or equivalent with drain wire connected to metallized plastic backshell at the chassis and to ground at the emergency stop station 70 Model 493 10 793 00 Controller Service Station Connections Station Connections Each Model 493 74 HSM transition board controls up to two stations A standard chassis configuration supports up to four stations Each station has the following connections e J28 Hydraulic service manifold HSM e J29 Load unit e J43 Interlock e J44 Remote run stop e J49 Auxiliary power As a system option the 493 10 chassis can be configured to support for six or eight stations See Optional Station Configurations
154. em Software manual for more detailed information Model 493 10 793 00 Controller Service 107 Cabling and Using External Readout Devices Cabling and Using External Readout Devices Cabled appropriately your controller can send station signals to external readout devices such as oscilloscopes and digital volt meters You define which signal is sent to the readout device with the Adjust Readouts window Refer to About Monitoring Signals Using External Readout Devices in Chapter 3 Station Manager of the Model 793 00 System Software manual for more information Station signal The block diagram identifies the station signals you can monitor diagram Compensated Command Command Output Valve Driver Signals from Other Modes of PIDF Controller this Channel Output Valve Driver Signal Test Command HO a Command Compensator Scalar convert control Mode signal to counts Se Switch ai S Z Na Closed Absolute Error Loop N 7 Generator Sete Dela P Load Cell Feedback Stabilization i Reba Feedback Input Signal Conditioning Signal Inner Outer Error Detector A LVDT Feedback S R Input Signal Conditioning Signal Absolute Error Error Sensor Signal Stabilization 108 Model 493 10 793 00 Controller Service Station signal descriptions SIGNAL Time Cabling and Using External Readout Devices Except for time and
155. ency in your test program Common values are 1 2 Hz e Servo adjustments that do not improve performance at high frequencies generally indicate that the servovalve is running at 100 capacity or the HPU is running at 100 capacity This characteristic can easily be seen when tuning with a sine waveform The feedback waveform appears to be more like a ramp waveform when running at 100 capacity A system tuned at a low amplitude may become unstable at high amplitudes Tuning should be accomplished under conditions similar to the anticipated usage e Use a moderate amplitude 5 to 10 full scale for initial tuning e Be sure the maximum velocity of the tuning command is 10 to 50 of the maximum velocity of the system e Increase the amplitude for fine tuning e You may find it helpful to check tuning over a variety of amplitudes by creating a test that cycles once at each of the target amplitudes If you have the optional MultiPurpose TestWare application run the test to acquire timed data so you can evaluate the results for each amplitude Model 493 10 793 00 Controller Service About Tuning Other Considerations Servovalves Most of the servovalve adjustments are performed during the system installation and do not require periodic adjustment There are two types of servovalves e Three stage servovalves such as the MTS Series 256 and 257 Servovalves have an inner loop control system which must be tuned before the outer
156. ent the rotary dipswitch as required to complete I O Carrier module addressing i mn 32 Model 493 10 793 00 Controller Service Installing the Plug in Modules Setting ADDA Il Use the onboard rotary dipswitches 3 2 and front panel rotary addresses dipswitch on each ADDA II module to set its address in accord with its installed chassis slot as follows SLOT 1 2 3 4 5 6 7 8 9 10 NUMBER ADDRESS PPC PPC c40 C41 C42 C43 C44 C4A c4c The dipswitch settings for address C40 are shown below Increment the front panel dipswitch as required to complete ADDA II module addressing S2 On ADDA Il Front Panel N e 5 z Model 493 10 793 00 Controller Service 33 i T 4 N Installing the Plug in Modules Front Panel VMEbus Modules MODEL MODULE NAME FUNCTION 493 40 1 0 Carrier Supports up to four daughter boards 493 50 ADDA II This optional module supports up to four 8 channel A D Model 493 55 or D A Model 493 56 daughter boards This module also supports the 8 channel DSPAD 8 channel Delta Sigma A D and 4 channel Universal Encoder daughter cards 498 96 2 Processor Provides an interface between the controller and an external 4989 96 3 computer The processor module also manages the plug in modules and transition panels 498 71B GRES Ill Interfaces with a Remote Station Control RSC module and temperature control
157. ents throughout this procedure You can monitor the sensor output in the same units that you are using for the calibration S bd K o 178 Model 493 10 793 00 Controller Service Calibrating a Force Sensor 6 Mount the force standard The illustration shows a load standard in line with the force train coupled with the force f i sensor The load standard reacts like a Q o stiff specimen Be sure the gain settings PID for the T control mode are appropriate Force Transducer If th 2 e control mode has not lt Load Standard been tuned yet use some default values Then recalibrate the sensor after the initial tuning iw gt f p Model 493 10 793 00 Controller Service 179 S bd K o Calibrating a Force Sensor Task 2 180 Conditioner calibration values Create a calibration file This task creates a sensor calibration file and sets up any ranges you may want A typical complement of ranges could be 100 50 20 and 10 of full scale You can create ranges for any percentage of full scale Example Suppose you have an actuator with a full scale capacity of 10 kN You might create ranges for 10 kN 5 kN 2 0 KN and 1 0 KN Note Some systems do not provide or require multiple ranges
158. er Remote station controller The Remote Station Controller RSC module is a table top stand mounted or hand held module that is primarily used for specimen installation and the starting and stopping of tests The RSC definition is always the same A GRES III module is needed to support an RSC in your system For information on adding a GRES III module see GRES III on page 309 x t HWI file additions In order to use one or more RSCs with your Model 493 10 Chassis two sections must be added to your hwi file an RSC section and a GRES III section Note Remote Station Controllers are not available with the optional 6 or 8 station system configurations Note Ifyou specified RSC support when you ordered your test system RSC and GRES III sections will be added to your hwi file at the factory RSC section The RSC section of the hwi file defines a number of RSC parameters including e NAME The name entry names the RSC resource it is arbitrary e HOST PORT The host port entry specifies which Com port on the GRES III plug in module the Model 493 71 Serial Interface transition module port is mapped to This determines which port the RSC must be plugged into e FILENAME The filename entry specifies the name of the file in the NTBIN folder that contains the firmware for the RSCs pod hex is the default file A configuration file that defines an RSC contains the following entries RSC NAME
159. er daughter board be installed in the I O Carrier module The following conditioners can be installed e Model 493 21B Digital Universal Conditioner e Model 493 25 Digital Universal Conditioner e Model 493 47 Encoder e Model 493 48 Acceleration Conditioner Each Model 493 40 I O Carrier module can include up to four daughter boards Each installed daughter board is assigned a specific I O Carrier module front panel connector J4 J7 I O These connections can be used for any type of sensor provided the appropriate daughter board is installed A hardware interface file hwi defines each type of module and their associated daughter boards and maps each module location for the system software The hwi file and the physical locations for each type of module and associated daughter boards must match For more information on the hwi file see The HWI File on page 283 If purchased as To From an option a Conditioner J4 J7 transducer ID E module is 2 1 Excitation 5 gt 2 Excitation located in the To From transducer vy 3 Guard Transducer itati 4 Feedback cable Excitation Feedbac d_ and feedback 5 Feedback o signals are 6 Signal Common passed through 8 Clock to the gt 11 Data to Sensor ID transducer lt _ 14 Data from Sensor ID 10 Excitation Sense To From i Transducer 9 Remote Calibration ID Module 4 12 Feedback Return 4 13 Feedback Return 14
160. g and Programming External Controllers Sample conditioner This table shows connector assignments for various MTS products you output connections can use with your Model 493 10 793 00 controller Conditioning Sensors with Other MTS Products MTS PRODUCT SENSOR OUTPUT Model 408 81 Testing Panel Sensor output is available at the rear panel connector Model 408 82 DC Conditioner J201 or J202 Model 409 81C Temperature Controller Temperature output via an analog signal is available at rear panel connector J1 Model 448 82 85 Test Controller with Sensor output is available at rear panel connector Model 448 21 22 AC and DC Conditioners J335 Ensure sensor conditioners are set as follows X1 2 amp 3 X2 2 amp 3 Model 458 10 20 MicroConsole with Sensor output is available at the MicroConsole rear Model 458 11 12 13 14 AC and DC panel connector Jx03 Connector Jx03 represents the Controllers module location J100 J600 MicroConsole jumper Jx00 should be set to 1 amp 2 standard setting Task 2 Create your configuration file with Station Builder Using Station Builder define controller resources to provide programming to an external controller Refer to How to Create Your Station Configuration File and Creating Program Channels in Chapter 2 Station Builder of the Model 793 00 System Software manual for more detailed information 92 Model 493 10 793 00 Controller Service Task 3 Adjust the signal
161. g 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 To make tuning easier the Station Manager application includes an auto tuning feature that automatically determines tuning values for PIDF control modes This feature works well for most control modes If you prefer to tune manually or want to optimize your current tuning values you can use the manual tuning controls Compensating for Optimal system operation may require a level of detuning to specimen changes compensate for 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 Asa 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 bg For the greatest control accuracy use a compensator 232 Model 493 10 793 00 Controller Service About Tuning If You ve Never Tuned Before If you are unfamiliar with the tuning controls review the following guidelines Before you start tuning you should e Define upper and lower limits for the displacement and force sensor before you start tuning e Tune the displacement control mode first since no specimen is needed
162. g channels Note The external analog source can be a stand alone function generator another controller or a computer controlled analog output External Analog Source Analog Monito 7 I l JJ 493 87 ANALOG OUTPUT janata aTa aA Board 1 Daughter Board 2 CELI 493 10 Chassis Board 3 Board 4 Front Rear Cable Conduit m 62 Model 493 10 793 00 Controller Service ADDA II Connections Analog inputs The analog to digital daughter cards accommodate up to eight analog input signals Each A D input signal must be within 10 volts e Analog inputs can be connected at the BNC connectors of a Model 493 81 Analog In transition module and the outputs from this module are connected to the Model 493 50 ADDA II module e Analog inputs can be connected at the BNC connectors of a Model 493 83 Filtered Analog Input transition module and the outputs from this module are connected to the Model 493 50 ADDA II module To From A D 493 81 Analog In Module lt _ 1 Input 8 lt lt 2 aa lt 3 nput 7 iti J13 ES 4 J15 J17 ag 5 nput 6 tm 6 lt 7 i nput 5 4 8 9 Input 4 lt lt 10 11 Input 3 J12 J14 4 12 J16 J18 4 143 lt 14 Input 2 4 15 F 16 Input 1 Model 493 10 79
163. gain settings e Tends to amplify noise from sensors e Tends to decrease system response when set too high Keep in mind e Too much derivative gain can create instability at high frequencies and too much proportional gain may cause a ringing or screeching sound e Too little derivative gain can make a rumbling sound The correct amount of derivative gain results in the system running quietly Note Series 256 and 257 Servovalves may require derivative gain applied to both the inner control loop and outer control loop Note Excessive negative D Gain can cause your system to become unstable 242 Model 493 10 793 00 Controller Service About Tuning Feed forward gain F Feed forward gain is like derivative gain except that it introduces a derivative of the command signal It anticipates how much valve opening is needed to reach the required response and adds that to the valve command like compensating for phase lag Original Command Adjusting feed forward causes the command to begin sooner so the feedback may track the original command more closely Feed Forward Command Original Feedback Feed forward gain e Does not compensate for normal changes during testing such as temperature changes servovalve droop and so forth e May be used to minimize phase lag e Should be used in a way similar to derivative gain However it is applied to the test command signal instead of the feedback signal Feed forward gai
164. guration can provide either six or eight channels of control A typical 6 channel 6 station configuration requires 12 Digital Universal Conditioners and 6 two stage valve drivers A typical 8 channel 6 station configuration requires 16 Digital Universal Conditioners and 8 two stage valve drivers HSM power limits HSM power current is limited to 1 5 A per HSM Interlocks For 6 station configurations the hwi file must contain the line INTERLOCKS 6 This line must be a discrete entry not part of any other hwi section Cross head interlocks with solenoid power are not supported for 6 station configurations RSC Remote Station Control RSC is not supported for 6 station configurations HWI file This is an example of a ftgt hwi file that defines resources for a 6 station 6 channel FlexTest GT system This system includes standard hardware including e five 2 stage valve drivers e One 3 stage valve driver e One A D daughter board e One D A daughter board e Twelve Universal Conditioners 6 AC and 6 DC 268 Model 493 10 793 00 Controller Service a i i bd D i Se i zS i The file listing The following is an actual ftgt hwii file Both processor entries are needed for single processor systems PROCESSOR ADDRESS 0xC8000000 SLOT 1 FUNCTION SUPERVISOR PROCESSOR NUMBER 0 INTERRUPT LEVEL 2 FILENAME tsiismcsup o PORT ETHERNET IP AD
165. h as changing fixtures Prerequisites Be sure the following items are done before you begin tuning the force control mode e Hydraulic pressure is off e The specimen is not installed e You have created a station configuration file e You have created a station parameter set Tuning procedure Refer to Tuning Force in Chapter 5 Tuning of the Model 793 00 System Software manual for a detailed tuning procedure Model 493 10 793 00 Controller Service 255 Auto tuning Auto tuning 256 Purpose How auto tuning works Accepting the auto tuning values The auto tuning feature automatically calculates tuning values for PIDF control modes Note Auto tuning is only available for PIDF control modes There are two levels of auto tuning Basic and Advanced The Basic auto tuner disregards your current PIDF gain settings It 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 The majority of tests will run adequately with the settings calculated through basic auto tuning however advanced auto tuning may be used to optimize the results obtained through basic auto tuning The Advanced auto tuner performs basic auto tuning and then uses a sine sweep to exercise the actuator to 20 of the auto tuning limits with frequencies be
166. he Display menu on the Station Manager window select Meters and then set up to monitor displacement feedback 5 Click the Channel Input Signals icon to open the Inputs panel and then click the Calibration tab 6 On the Inputs panel enter Fullscale Min Max values that conform with your sensor specifications Typically you should set the fullscale min max values according to the dynamic stroke rating of your actuator The DYN STROKE rating is usually printed on a nameplate on the side of the actuator For example if the dynamic stroke rating of your actuator is 102 mm you should set your full scale min to 51 mm and your full scale max to 51 mm 7 Set Excitation to 10 volts 8 Adjust Post amp Gain for a 5 volt readout on the meter 9 Adjust Phase for the maximum output voltage on the meter 10 Adjust Post amp Gain for a 9 5 volt readout on the meter 11 Check to ensure that the polarity of the servovalve signal set correctly See Setting the Servovalve Polarity on page 115 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 Check the valve polarity setting If you do not know what polarity to use for your servovalve click Normal default E bd K o 150 Model 493 10 793 00 Controller Service Calibrating an LVDT 12 From Station Setup click the Cha
167. he Inner loop Zero the Spool Position Signal Inner Loop Signals 120 This task matches the electronic null of the spool position signal with the mechanical null position of the servovalve pilot spool During inner loop tuning it may be necessary to complete this procedure if the spool position signal voltage is not approximately equal though opposite polarity at opposite endcaps of a servovalve 1 On the Drive panel click the Valve tab 2 Set the Valve Balance to zero 3 On the Drive panel click the Conditioner tab 4 Ensure that the Offset control is set to zero 5 Apply hydraulic pressure a Do not remove the LVDT adjustment locknut or assembly when adjusting the servovalve LVDT spool position If it is removed hydraulic fluid will spray from the servovalve at full pressure You should refer to the servovalve product manual to identify the main stage LVDT spool adjustment 6 Loosen but do not remove the LVDT locknut 7 Adjust the LVDT in or out of the servovalve to provide a zero spool position signal 8 Tighten the locknut while holding the LVDT in position For detailed information about monitoring inner loop signals on TestStar Im and FlexTest GT Controllers see Inner Loop Signals in Chapter 5 Tuning of the Model 793 00 System Software manual Model 493 10 793 00 Controller Service Chapter 5 Sensors This chapter describes sensor signals connections and cabling Shunt cali
168. hell to the chassis J24 E STOP In is a 15 pin type D female connector e 15 contact type D male EMI connector e Backshell EMI metallized plastic 66 Model 493 10 793 00 Controller Service Emergency Stop Connections e Cable 24 AWG 4 connector with overall foil shield Belden 9534 or equivalent with drain wire connected to metallized plastic backshell at the chassis and to ground at the emergency stop station Jumper plug required If connector J24 is not used you must install a jumper plug to maintain the integrity of the interlocks Use jumper plug 397132 01 or jumper pins 5 and 7 8 and 13 Model 493 10 793 00 Controller Service 67 Hydraulic Power Unit Connection Hydraulic Power Unit Connection Service LED Cable specification Jumper plug required 68 Connector J25 HPS on the Model 493 73 HPU transition board controls the hydraulic power unit HPU e The module produces 24 V logic signals to control the HPU e The Model 493 07 HPU Converter Box allows any MTS HPU to be connected to the chassis with the following exceptions 506 52 92 HPUs 24 volt PLC compatible All Series 505 HPUs The converter box is used with other configurations see Hydraulic Configurations on page 259 for more information E Control voltages for hydraulic power units vary between models The HPU interface between the Model 493 73 HPU transition board and an HPU is 24 volt logic signals Connecting J25
169. hows how to cable hydraulic terminals on three 407 controllers in a master dependent daisy chain Note that the last dependent controller in any daisy chain must have jumper plugs installed in its Hyd Out and Intlk In terminals Master 407 Controller Dependant 407 Controller No Connection Last Dependant 407 Controller No Connection Jumper Plug PN 049 635 901 Jumper Plug PN 049 635 901 Model 493 10 793 00 Controller Service 99 Cabling and Programming External Controllers Setting Up a 407 to Receive and Send Signals After cabling the 407 you must configure it to receive and send signals from the Model 493 10 793 00 controller The tables below list typical menu settings Refer to the 407 Controller Product Information Manual for more information 407 Configuration Menu Eng Units EOC Act CYC Src PROGRAM SetPt R 150 s or highest Span R 300 s or highest Hyd Cnfg Intik Cnfg MASTER P V Sens Span Cnfg 1X CMD Sel EXT IN Prog Out Always designate one 407 in a station as a MASTER If there are other 407s in the same station daisy chain their interlocks designate them as DEPENDENT 100 Model 493 10 793 00 Controller Service Cabling and Programming External Controllers 407 Function Generator Menu PARAMETER SETTING Wvform EXTERN Freq Setpnt _ Span a Preset 407 Amplitude Control Menu PARAMETER SETTING
170. hree 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 Go to Tuning the Inner loop on page 119 for help Getting started When you set out to tune your system it is best to run auto tuning first Auto tuning establishes reasonable tuning levels that will be adequate for most control modes See Auto tuning on page 256 for more information If the results from auto tuning are not satisfactory you should create a tuning function and then manually tune each control mode Model 493 10 793 00 Controller Service 235 About Tuning Control Mode Characteristics A control mode uses a program command and sensor feedback to control the servovalve The controller uses a group of gain controls proportional integral derivative and feed forward gain These controls are called PIDF The PIDF controller can also incorporate stabilization gain and an adjustable forward loop filter Valve Driver Compensated Command Stab Filter2 T S me Active Stabilization Feedback Delta P 1 FL Filter on the Tuning Menu Sets filter frequency and select filter type 2 Stabilization Filter on the Tuning Menu Sets filter frequency and select filter type Each control mode has different tuning characteristics This section describes the characteristics of
171. hwi file see The HWI File on page 283 e Transducer connections require a conditioner daughter board be installed in the I O Carrier module The following conditioners can be installed Model 493 21B Digital Universal Conditioner Model 493 25 Digital Universal Conditioner Model 493 47 Encoder Model 493 48 Acceleration Conditioner See Transducer Connections on page 127 for more details e Valve connections require a valve driver daughter board be installed in the I O Carrier module The following valve drivers can be installed Model 493 14 Valve Driver Model 493 15 3 Stage Valve Driver e Analog I O connections require an A D or D A daughter board be installed in the I O Carrier module The following analog daughter boards can be installed Model 493 45 A D Converter Model 493 46 D A Converter Model 493 10 793 00 Controller Service 45 I O Carrier Connections Valve Connections The following types of valve connections are supported e Single or dual Series 252 Servovalve s can be controlled with a Model 493 14 Valve Driver daughter board e A Series 256 Servovalve can be controlled with a Model 493 15 3 Stage Valve Driver daughter board e A Series 257 Servovalve can be controlled with a Model 493 15 3 Stage Valve Driver daughter board and a Model 448 16C Power Driver chassis Cable specification 15 contact type D male EMI connector e Backshell EMI metallized pl
172. ial indicator or other readout device shows that the actuator s physical retraction equals your retraction command S bd K o 166 Model 493 10 793 00 Controller Service Calibrating an LVDT 4 If applicable repeat steps 1 and 2 for all ranges Example Suppose you have an actuator with a full scale capacity of 10 cm and ranges of 10 cm 5 cm 2 cm and 1 cm In this case you would repeat this process and calibrate retraction at 80 of each range 8 cm 4 cm 1 6 cm and 0 8 cm Note Some systems do not provide or require multiple ranges such as those using full range conditioners e g Model 493 25 DUC module In this case only one range is used typically 100 Note This procedure assumes a positive command extends the actuator and a negative command retracts the actuator If not use the opposite polarity for any values given Calibrate actuator 5 Apply an extension command that is 80 of the range s full scale extension Do this by adjusting the Manual Cmd slider on the Manual Command window then verify that the Station Signals panel reads what you applied with the slider During the initial calibration and tuning of your system it may take repeated adjustment for the two values to match Note Ifthe actuator response is sluggish and or the signal value does not match the command you will need to adjust the tuning of this contro mode Increase the proportional gain P Gain on the
173. iguration of your system accelerometers In the example shown below the Acceleration Conditioner supports three accelerometers The indicated three jumpers must be set on the I O Carrier module x101 Andag Bus 1 9 DUC X103 75 AndogBus 2 X1045 7 Analog Bus i Extemal Sum Input Analog Bus 5 Ertemel Sum Input Ertemel Sum Input Accel cn zAcea Out ran ie Daughter cn 3Acca Out HADS a Transition ean ee Card ws 2 eee a o t 3 jumpers Model 493 10 793 00 Controller Service 57 Encoder Connections Encoder Connections 1 0 Carrier Module For an ADDA configuration using an I O Carrier module each encoder Configuration requires installation of a Model 493 47 Encoder Interface daughter board on the Model 493 40 I O Carrier board The I O Carrier connector is based on the location of the daughter board installed on the board of the I O Carrier module See Determine installed location on page 204 lt 3 p 0000000 o o o o o o o o 00000000 0000000 J7 VO 00000000 0000000 al 58 Model 493 10 793 00 Controller Service Encoder Connections Optional ADDA II For the optional ADDA II configuration using the Model 493 50 ADDA Configuration II module each encoder require
174. ime N 1 lt i lt lt O i c n e The polarity of any servovalve is generally set when the valve is installed Important The combination of the conditioner polarity and the servovalve polarity affects the final output signal The conditioner polarities should be set before the servovalve polarity because they do not need hydraulics to be turned on In general you will set the conditioner and servovalve polarity the same Procedure This procedure allows you to determine servovalve polarity by observing actuator movements while applying a positive Setpoint command to the actuator Refer to How to Set Servovalve Polarity in Chapter 5 Tuning of the 793 00 System Software manual for a detailed procedure Model 493 10 793 00 Controller Service 115 Getting Things Ready Getting Things Ready If you plan to perform any of the procedures described later in this chapter be sure that you get the hydraulic fluid up to temperature Be sure that both the hydraulic fluid and the servovalve are at operating temperature Remove any specimen and run the system in displacement control for at least 30 minutes using an 80 full scale length command at about 0 1 Hz Refer to How to Warm Up the System Hydraulics in Chapter 5 Tuning of the Model 793 00 System Software manual for a detailed procedure 2 i ih Ez gt i gt k nn 116 Model 493 10 7
175. ines the input channel to represent a portion of the sensor s physical capacity With this type of sensor conditioner you may create a range for any portion of the sensor s capacity Typical ranges are Range 1 100 Range 2 50 Range 3 20 and Range 4 10 Each sensor can be calibrated for different ranges A range redefines the input channel to represent a portion of the sensor s physical capacity You can create a range for any portion of a sensor s capacity eii ie ge EET a a h z Ta Ta east lites Mero aa 5 mm S a E eel ener 1112227 i as Suppose a displacement sensor has a full scale capacity of 10 mm A 5 mm range can operate across the full scale range of the sensor 5 mm A 2 5 mm range of the same sensor can operate across half the capacity of the sensor this redefines full scale to be 2 5 mm Be sure you select a range large enough to accommodate the maximum sensor output expected during a test om cm tcm oom fon 2 om Example Suppose your test requires a 2 0 cm displacement A 6 cm or 3 cm range functions properly but a 2 cm range provides the best resolution Model 493 10 793 00 Controller Service 123 Sensor Signals When setting up a test it is good practice to select a range slightly larger than the largest value expected for the test The smaller the range the better the resolution of the sensor s signal Initial limit detectors for When you select a range the
176. ing are true e The Fine Zero adjustment on the Calibration tab is 0 e The Manual Offset on the Offset Zero tab is 0 e The Electrical Zero adjustment on the Offset Zero tab is 0 1 Mount the displacement measuring device Mount the measuring device to measure the distance between the end of the actuator s piston rod and a stationary point such as the actuator s upper endcap There are a variety of ways to measure actuator displacement e Dial Indicator e Tape Measure Ruler e Optical Detector e Encoder E bd K o 162 Model 493 10 793 00 Controller Service Calibrating an LVDT El e You may need to place the dial indicator on a block to measure the mid displacement position AL AA e Be sure to zero the dial indicator after IA you position it properly e 2 In the Station Controls panel s toolbar click the Manual Command button to display the Manual Command window In the Manual Command window A Select the appropriate Channel associated with the LVDT signal you are calibrating B For the Control Mode select Displacement C Click Enable Manual Command 3 Evaluate the mid displacement position for the actuator A Move the Manual Cmd slider to apply a positive command extend the actuator B Adjust the Manual Cmd slider to fully extend the actuator and note the displacement signal value in the S
177. ion at 80 of each range 8 kN 4 KN 1 6 kN and 0 8 kN Note Some systems do not provide or require multiple ranges such as those using full range conditioners e g Model 493 25 DUC module In this case only one range is used typically 100 Record data points The accuracy tolerance of your data depends on the manufacturer of your sensor Your sensor should include a calibration data sheet that shows the data point tolerance Sensors from MTS include a sensor calibration data sheet that shows the data points as it was calibrated 1 Record the data points for compression A Adjust the Manual Cmd slider on the Manual Command window to achieve a load standard readout of zero B Adjust the Manual Cmd slider between zero and full compression three times This exercises the force sensor to remove hysteresis C Establish the zero reference Using a load standard e Adjust Manual Cmd slider for 0 kN Then zero the load standard readout S bd K o 188 Model 493 10 793 00 Controller Service Calibrating a Force Sensor Using dead weights e Remove all dead weights On the Inputs panel click on the Offset Zero tab and then adjust Manual Offset for a signal value of 0 kN on the DVM or Station Signals panel D Adjust the Manual Cmd slider to achieve a load standard reading of 20 compression and record the meter reading Repeat this step for 40 60 80 and 100 compression 2 Record the data
178. ion 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 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 Know relevant software For software application problems have the following information 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 Itis also helpful if the names of other non MTS applications that are running on your computer such as screen savers keyboard enhancers print spoolers and so forth are known and available If you contact MTS Your call will be registered by a HELPLine agent if you are calling by phone 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 Model 493 10
179. is selected for the active control mode Note The most common use for these controls is to establish a zero position after a specimen has been installed Model 493 10 793 00 Controller Service Calibrating Encoders Abbreviated Procedure Online readers All procedure entries are hypertext links Click on any entry to jump to the corresponding page The following abbreviated procedure outlines an encoder calibration process More detailed calibration information is available on the pages listed Task 1 Get things ready on page 206 Task 2 Create a calibration file on page 207 Task 4 Turn on hydraulic pressure on page 208 Task 5 Set the zero position on page 209 Task 6 Save the calibration on page 209 iw 2 gt r i Model 493 10 793 00 Controller Service 205 Calibrating Encoders Task1 Get things ready Perform the following before you start encoder calibration 1 Locate relevant documentation When calibrating an encoder you will need information about the encoder such as the serial number model number and a specification called measuring step resolution 2 Open a station configuration file You need a station configuration file that includes a control channel and a control mode that uses the encoder you intend to calibrate On the File menu select Open Station to open the appropriate configuration file 3 Enter the Calibration password You m
180. its provides support for up to three bridge completion resistors as well as a shunt calibration resistor The bridge completion resistors can be installed into sockets on the I O Carrier printed wiring board The shunt calibration resistor sockets are accessible from the I O Carrier front panel The following figures show three typical bridge configurations for a DC conditioner installed on an I O Carrier module 4 Wire Full Bridge Bridge VO Carrier Conditioner FBR FB EXS EX a aD Model 493 10 793 00 Controller Service 141 Shunt Calibration 3 Wire Quarter Bridge Gauge VO Carrier Conditioner FBR o FB fy a RENNER EXS al Rg gt EX EXS I FB o FBR oF RCAL Rshunt 7 Wire Full Bridge Bridge VO Carrier Conditioner FBR FB 9 O EXS o X g EX o EXS o FB 3 FBR rt MAN ni J 142 Model 493 10 793 00 Controller Service Shunt Calibration Transducer Identification Modules Transducer ID modules located at the end of the sensor cable are optional components that can store sensor calibration information just like a sensor calibration file Since the calibration information stays with the sensors transducer ID modules make it easier to change sensors Calibration information can be stored in the transducer ID EEPROM or in a sensor calibration
181. iw gt f p Calibrating an Extensometer B Verify that your extensometer feedback signal is 80 of the full scale range 5 Record conditioner feedback readings at predetermined negative strain command points Note After shutting down system hydraulics you will enter these recorded readings on the Linearization Data window A Adjust the Manual Cmd slider on the Manual Command window for a 0 command B Record the calibrator s readout value and the corresponding conditioner feedback reading in the 0 row of your record sheet Adjust the Manual Cmd slider for a 2 strain command D Record the calibrator s readout value and corresponding conditioner feedback reading in the 2 row of your record sheet E Repeat steps C and D for other negative strain commands typically at 4 6 8 10 20 40 70 and 100 percent of full scale 6 Record conditioner feedback readings at predetermined positive strain command points A Adjust the Manual Cmd slider for a 2 positive strain command B Record the calibrator s readout value and corresponding conditioner feedback reading in the 2 row of your record sheet C Repeat steps A and B for other positive strain commands typically at 4 6 8 10 20 40 70 and 100 percent of full scale 7 Turn off system hydraulics 8 Open the Linearization Data window and enter the calibrator readout values and corresponding conditio
182. just the readout signal For a detailed description of readout signal configuration and adjustment refer to How to Configure a Signal for External Readout Chapter 3 in Station Manager of the Model 793 00 System Software manual Model 493 10 793 00 Controller Service 111 Cabling and Using External Readout Devices 112 Model 493 10 793 00 Controller Service Chapter 4 Servovalve Controls Contents Hydraulic systems Adjustment prerequisites When to adjust This chapter describes servovalve adjustments that optimize the interface between the controller and the servovalve Setting the Servovalve Polarity 115 Getting Things Ready 116 Adjusting Valve Balance 117 Dither 118 Tuning the Inner loop 119 Inner Loop Signals 120 Hydraulic systems use servovalves to control the actuator The following complement of valves have different Drive panels N 1 lt i lt lt O i c n e 252 Valve trepresents the MTS Series 252 Servovalve e Dual 252 Valve trepresents two MTS Series 252 Servovalves mounted to the actuator manifold e 256 257 Valve represents the MTS Series 256 and Series 257 Servovalves Although these valves are different they use the same adjustments These servovalves have inner control loops You should run a small program to warm up the system hydraulic fluid and servovalve before you adjust the valve balance dither or inner loop Refer to
183. k Jumper W3 selects a 4 or 8 wire transducer for negative feedback The setting of jumper W8 single ended excitation enable may affect your choices for these jumpers W2 and W3 Note excitation excitation is standard See R33 or XDCR ID W1 Default Default punt QB w2 EX10 FB shunt GHE D v2 in 4 wire config in 4 wire config EE D wv EE NE EX to FBR shunt E E W2 Exto FBR shunt in d Dw in 8 wire config E YA 8 wire config d EBD 130 Model 493 10 793 00 Controller Service Transducer Connections Excitation sense Jumpers W5 and W7 select the local on board or remote through a cable excitation sensor connection e The local selection is used with 4 wire transducer connections The remote selection is used with 8 wire transducer connections e Jumper W7 configures the excitation signal e Jumper W5 configures the excitation signal Both jumpers should be set for the same configuration d Bv GBD v d Bws B v5 Shunt cal The shunt calibration resistor can be installed on the Full Range Digital Universal Conditioner module or in the transducer ID module R33 assigns a positive or negative excitation to the shunt calibration resistor if installed on the Full Range Digital Universal Conditioner module not the transducer ID module R33 E ID Default No Resistor EE ID Ex Shunt EMD Ex Shunt Model 493 10 793 00 Controller Service 131 Transducer Connections 132 Single en
184. le specifications analog I O 55 digital I O 81 J24 E stop input 66 J25 HPU 68 J28 HSM solenoid 72 J29 load unit 74 J43 interlock 75 J44 run stop 77 J49 auxiliary power 78 J54 system I O 68 servovalve 46 cables CE ECM compliant 41 E stop 66 fabrication 41 HPU connector 68 part number list 43 sensor 44 133 317 cabling Eurotherm temperature controller 104 external controllers 106 front panel J4 J7 A D inputs 53 J4 J7 D A outputs 54 64 J4 J7 transducer 46 J4 J7 valve 46 interlock signals 458 103 low frequency ground loops 41 readout devices 110 rear panel J23 E stop output 66 J24 E stop input 66 J25 HPU 68 J28 HSM solenoid 72 J29 load unit 74 J3 In digital inputs 80 J4 Out digital outputs 81 J43 interlock 75 J44 run stop 76 J49 auxiliary power 78 J54 System I O 68 typical system layout 42 calibration AC conditioners displacement 149 DC conditioners force 176 encoders 204 gain controls 185 hydraulics turn on 159 182 208 213 LVDT 149 phase adjustment 161 shunt 136 shunt performing 137 Temposonics sensors 210 with full range conditioner 148 calibration file creating 157 180 resource assignment 158 181 207 CE EMC compliance cabling 41 chassis modules installing 30 command sources 236 conditioner defining in hwi file 303 polarity 115 conditioner jumpers DUC shunt cal 131 4 8 wire sensor cable 130 active guard 130 bridge balance 132 excitation sense 131 single ended excitation 132
185. lers I O Carrier Daughter Boards MODEL MODULE NAME FUNCTION 493 14 Valve Driver Produces the control signal for a Series 252 Servovalve 493 15 3 Stage Valve Driver Produces the control signal for a Series 256 or 257 Servovalve 493 21B Universal Conditioner Processes the signals from either an AC or DC type sensors 493 25 Universal Conditioner Processes the signals from either an AC or DC type sensors 493 45 A D Converts up to six external analog signals to digital signals for use by the controller 493 46 D A Converts up to six internal digital signals to analog signals for use by external devices 493 47 Encoder Processes the signals from an encoder or a Temposonics III transducer with an SSI interface 493 48 Acceleration Conditioner Processes the signals from an accelerometer Each 34 Acceleration Conditioner daughter board can support up to three accelerometers Before installing this board specific jumpers must be set on the I O Carrier module See I O Carrier jumper settings on page 52 for more information on jumper settings Model 493 10 793 00 Controller Service Installing the Plug in Modules ADDA II Daughter Boards MODEL MODULE NAME FUNCTION 493 55 A D Converts up to eight external analog signals to digital signals for use by the controller This board requires the optional ADDA II module 493 56 D A Converts up to eight internal digital signals to analog signals for use by external devices This
186. libration data sheet provided with the sensor A current shunt calibration value taken before a test should be compared to the shunt calibration reference value recorded when the sensor was last calibrated If the reference value and the current value differ too greatly the sensor conditioner pair should be recalibrated to establish a new shunt 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 It is possible to adjust excitation to compensate for small to moderate changes in the shunt calibration value You should perform a shunt calibration establish a new shunt reference value when the following occur e You start a new test e You move a sensor to a different DC conditioner e You swap a DC conditioner module e You recalibrate a DC sensor e You change the sensor cable resistance may differ Note Shunt calibration can not be used to compensate for different length cables Note You cannot check shunt calibration of a sensor being used with the active control mode when hydraulic pressure is on Note Shunt calibration does not compensate for changes in the sensor sensitivity over time Model 493 10 793 00 Controller Service Shunt Calibration How to perform a shunt Each resistive bridge type transducer DC sensor uses a shunt resistor calibration to check the calibration accuracy
187. loop can be tuned e Two stage servovalves such as the MTS Series 252 Servovalves do not have inner loop tuning requirements After initial system tuning and before final tuning the valve balance should be checked and adjusted if necessary Using specimens Specimens can be very expensive A dummy specimen is an inexpensive material that has similar characteristics to the specimen selected for testing The most important specimen characteristic is its spring rate The advantage of a dummy specimen is that it can simulate how your testing system reacts to real specimen You can establish a more precise level of tuning with a dummy specimen Tuning without dummy If you do not have a dummy specimen or if a dummy specimen is not specimens practical review the following recommendations if you must use a real specimen e Start your PIDF controls at minimum settings e Do not use a square waveform for a massive specimen or a specimen prone to vibrations e Adjust rate to minimize any oscillation overshoot or ringing in the waveform e Be very conservative by beginning with a ramp waveform to establish initial control Then use a waveform that resembles the test waveform to provide a precise level of control Model 493 10 793 00 Controller Service 249 About Tuning Tuning without a specimen A specimen is required to tune force and strain control modes Initial force tuning may be accomplished with the actuator up against
188. lug in modules and 24 VDC for hydraulic power and the chassis fan The power supplies have universal inputs and will adapt to any line voltage between 90 and 264 VAC The power supply is protected with an external circuit breaker in the On Off switch that trips at a 10 ampere overload An internal fuse in the power supply is not user accessible or repairable Cooling The chassis is cooled with a fan An overtemperature sensor is part of the standard power supply assembly If the internal chassis temperature exceeds 50 C this sensor will light an amber indicator located on the rear of the power supply module Hydraulic control Hydraulic control is handled with two transition modules The Model 493 73 HPU Transition module has a connection to control a hydraulic power unit It includes connections for an emergency stop button and digital I O for system communications Typically up to four Model 493 74 HSM transition modules can be used to support up to eight HSM stations Each HSM module includes connections to support two stations Each station supports an HSM a load unit run stop outputs auxiliary outputs and interlock controlled outputs Interlocks Two types of interlocks are supported the system wide interlock and station interlocks The system wide interlock shuts down the hydraulic power unit and all stations and the station interlock shuts down a single station leaving other stations running The emergency stop function on the
189. mage or endanger test integrity if the caution is ignored For example CAUTION 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 Model 493 10 793 00 Controller Service Preface 11 Conventions Other conventions Other conventions used in your manuals are described below Notes Notes provide additional information about operating your system or highlight easily overlooked items For example Note Resources that are put back on the hardware lists show up at the end of the list Special terms The first occurrence of special terms is shown in italics Illustrations 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 Electronic manual This manual is available as an electronic document in the Portable conventions Document File PDF format It can be viewed on any computer that has Adobe Acrobat Reader installed Hypertext links The electronic document has many hypertext links displayed in a blue font All blue words in the body text along with all contents entries and index page numbers are hypertext links When you click a hypertext link the application jumps to the corresponding topic 12 Prefac
190. mc hwi file that defines resources for a multi channel TestStar IIm system This system includes standard and optional hardware including 2 t e Four 2 stage valve drivers e One 3 stage valve driver e One encoder e One A D daughter board e One D A daughter board e Eight conditioners four DC four AC e GRES III module e A temperature controller e Four remote station controllers The file listing The following is an actual ftiim hwii file Both processor entries are needed for single processor systems PROCESSOR ADDRESS 0xC8000000 SLOT 1 FUNCTION SUPERVISOR PROCESSOR NUMBER 0 INTERRUPT LEVEL 2 FILENAME tsiismcsup o PORT ETHERNET IP ADDRESS 148 150 203 191 PROCESSOR ADDRESS 0x00000 SLOT 1 FUNCTION CONTROL PROCESSOR NUMBER 1 INTERRUPT LEVEL 5 FILENAME tsiismcdsp o SHARED MEMORY 0x700000 310 Model 493 10 793 00 Controller Service A Sample File HPU TRANSITION BOARD TRANSITION SLOT 9 NAME HPU MAIN POWER TRUE FIRST ON TRUE LAST OFF TRUE VISIBLE TRUE CONNECTOR J25 ay J SYSTEM OPTIONS VELOCITY LIMITER HSM TRANSITION BOARD TRANSITION SLOT 8 CHANNEL 1 NAME HSM 1 CONNECTOR J28A CONNECT TO MAIN TRUE TYPE PROPORTIONAL HSM RATE SLOW LOW PERCENT 50 HIGH PERCENT 100 CHANNEL 2 NAME HSM 2 CONNECTOR J28B CONNECT TO MAIN TRUE TYPE PROPORTIONAL HSM RATE SLOW LOW PERCENT 50 HIGH PERCENT 100 HSM TR
191. meter 4 If the extensometer signal value is above 8 cm cm adjust the Delta K control on the Calibration tab to achieve an 80 value 8 cm cm Record your final strain signal value from the meter for the 80 output If the extensometer signal is below 8 cm cm Delta K adjustment cannot be made Return the Delta K adjustment to its original setting Use the Post amp gain control to increase the calculated output to a value halfway between its present value and 8 cm cm this splits the difference between compression and tension 5 Repeat steps 1 4 for a 20 40 60 and 100 positive output Compare recorded Your sensor should include a calibration data sheet that shows the data data points to point tolerance calibration sheet 1 Compare your recorded output values to the calibration data sheet that accompanied your sensor 2 Make sure your current values fall with the permissible variation If they do not you must go back to recalibrate the extensometer negative and positive outputs S bd K o 222 Model 493 10 793 00 Controller Service Calibrating an Extensometer Task7 Gain Linearization Calibration Initial extensometer calibration If you are using Gain Linearization for your calibration type complete the following procedure If not complete Task 6 Gain Delta K Calibration on page 221 Important Using linearization data requires specific conditioner zeroing 1 practices Ensur
192. mmand and displacement values to match Note Ifthe actuator response is sluggish and or the displacement signal value does not match the command you will need to adjust the tuning of this control mode Increase the proportional gain P Gain on the Adjustments tab of the Tuning panel to correct sluggish actuator movement Increase the reset integration value I Gain to help the feedback match the command At this point unless the conditioner is already in calibration the actuator s physical retraction will not equal your commanded value You will adjust gain in the next step so that the actuator s physical retraction and your commanded retraction match E bd K o 172 Model 493 10 793 00 Controller Service Calibrating an LVDT Example Suppose your actuator has a 100 retraction of 10 cm In this step you would apply a 8 cm command and even though the station signals would read 8 cm of feedback the actuator may retract only 4 cm This shows the conditioner sensor pair are out of calibration 9 Adjust gain to retract the actuator until it equals your retraction command Adjust the Post Amp Gain control on the Calibration tab until your dial indicator or other readout device shows that the actuator s physical retraction equals your retraction command 10 Apply an extension command that is 80 of the full scale range A Adjust the Manual Cmd slider for an extension command that is 80 of the full
193. n Delta K for Cal Type on the Calibration tab of the Inputs panel 2 Apply a retraction command that is 80 of the range s full scale Do this by adjusting the Manual Cmd slider on the Manual Command window then verify that the Station Signals panel reads what you applied with the slider During the initial calibration and tuning of your system it may require repeated adjustment for the two values to match Note _ f the actuator response is sluggish and or the signal value does not match the command you will need to adjust the tuning of this contro mode Increase the proportional gain P Gain on the Adjustments tab of the Tuning panel to correct sluggish actuator movement Increase the reset integration value I Gain to help the feedback match the command At this point unless the conditioner is already in calibration the actuator s physical retraction will not equal your commanded value You will adjust gain in the next step so that the actuator s physical retraction and your commanded retraction match Example Suppose your actuator has a 100 retraction of 10 cm In this step you would apply a 8 cm command and even though the station signals would read 8 cm of feedback the actuator may retract only 4 cm This shows the conditioner sensor pair are out of calibration 3 Adjust gain to retract the actuator until it equals your retraction command Adjust the Post Amp Gain control on the Calibration tab until your d
194. n helps the servo control loop react quickly to an abrupt change in the command e Is needed when testing a soft specimen in force control Stabilization Stabilization gain allows a second signal to be integrated into the gain S composite command signal as a stabilizing factor It enhances stability for systems that move large masses at high speeds The second signal is generated by a special transducer such as AP differential pressure or accelerometer Stabilization controls will be available only if a stabilization resource was added to the control channel in the Station Builder program Delta P AP 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 Model 493 10 793 00 Controller Service 243 About Tuning 244 Acceleration Stabilization The servovalve 90 phase lag frequency can be found in the servovalve product literature The natural frequency can be approximated with the following formula Actuator Frequency WV Where C constant for English 2500 or metric units 1060 A actu
195. nalog Out panel located on your controller chassis If you do not have an Analog Out panel use the Meters window or Station Signals panel to monitor sensor output On the Station Manager Display menu select Station Setup In the navigation pane select Station Signals to display the Station Signals panel to monitor current values for user defined signals iw gt gt f i Model 493 10 793 00 Controller Service 211 S bd K ca Calibrating Temposonics Sensors Task 2 Create a calibration file Setting Temposonics Task 3 resolution This task creates a sensor calibration file and sets up any ranges you may want A Temposonics sensor does not require ranges its resolution is always the same See How to Create a Sensor File in Chapter 3 Station Manager of the Model 793 00 System Software manual for a detailed procedure In the Resolution box enter the Temposonics resolution supplied in the Temposonics documentation Note If want to use units different than those supplied in the sensor documentation enter the full scale and resolution in the supplied units first and then switch to the desired full scale units The units conversion will be calculated automatically Assign the calibration file 212 This task links a sensor calibration file created in Task 2 to a hardware resource effectively selecting one of the sensor ranges for the input signal definition
196. nd signal post PIDF correction The stabilized command signal is then sent to the valve driver Model 493 10 793 00 Controller Service About Tuning Forward loop FL filter adjustments compensate for noise in the servoloop which filter FL usually comes from sensor feedback FL filter adjustments establish a frequency bandwidth for the servo loop command signal Noisy Feedback D Gain Amplifies Noise Not All Noise is Removed Keep in mind e By default the FL filter is set to one half the system rate e The minimum FL filter frequency setting is 0 01 e Be sure the forward loop filter frequency is higher than any frequency in the test program Most testing occurs below 50 Hz 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 providing your test does not reach 100 Hz If additional adjustment is needed reduce the setting by 5 10 Hz at a time Stabilization Filter Some systems with a higher actuator frequency may benefit from changing the filter setting for the stabilization signal See How to Enable a Tuning Filter in Chapter 5 Tuning of the Model 793 00 System Software manual for a detailed procedure for changing the stabilization filter setting Model 493 10 793 00 Controller Service 245 About Tuning Creating a Tuning Program Auto tuning Command waveforms 246
197. nections for Master Dependent 407 Controllers 98 How to Connect Hydraulic Terminals on Master Dependent 407s 99 Setting Up a 407 to Receive and Send Signals 100 4 Model 493 10 793 00 Controller Service Connecting Interlock Signals to 458 Controllers 103 Eurotherm Temperature Controller Connection 104 Cabling for External Command Inputs 105 How to Enable and Run External Command Inputs 105 Cabling and Using External Readout Devices 108 How to Send Signals to External Readout Devices 110 Chapter 4 Servovalve Controls 113 Setting the Servovalve Polarity 115 Getting Things Ready 116 Adjusting Valve Balance 117 Dither 118 Tuning the Inner loop 119 Zero the Spool Position Signal 120 Inner Loop Signals 120 Chapter 5 Sensors 121 Sensor Signals 122 About Sensor Ranges and Detectors 122 Transducer Connections 127 Full Range Digital Universal Conditioner FRDUC Jumpers 130 Sensor Cables 133 Specifications 133 Sensor Cable Part Numbers 134 Shunt Calibration 136 Shunt Calibration Bridge Completion 140 I O Carrier Module 140 Transducer Identification Modules 143 Model 493 10 793 00 Controller Service Chapter 6 Calibration 145 Before You Begin 147 Calibrating an LVDT 149 Abbreviated Procedure 154 Calibrating a Force Sensor 176 Abbreviated Procedure 177 Calibrating Encoders 204 Abbreviated Procedure 205 Calibrating Temposonics Sensors 210 Abbreviated Procedure 210 Calibrating an Extensometer 215 How To
198. ner feedback readings for all command points previously recorded on a separate sheet Click Linearization Data on the Calibration tab S bd K o 224 Model 493 10 793 00 Controller Service 9 Calibrating an Extensometer E Linearization Data x Fullscale Min Max 10 000 10 000 cm cm Data Range er To 100 Recommended Standard Conditioner 080000 ETO ETO 060000 0 60000 0 60000 om ci 040000 ERT ETO 0 20000 ETRY ERO Tr 0 00000 0 00000 omic 0 20000 OTT ATO 0 40000 0 40000 0 40000 om cd oe0000 0 60000 0 60000 om cd 0 80000 TIT RTT 1 0000 RUT MRT Turn on system hydraulics Extensometer If the extensometer has been previously calibrated use the following recalibration procedure 1 2 Locate the calibration data sheet for the appropriate conditioner Turn off system hydraulics Click Linearization Data on the Calibration tab to open the Linearization Data window Transfer Standard and Conditioner data from the conditioner s calibration data sheet to corresponding data entries on the Linearization Data window Turn on system hydraulics Verify linearization data A Adjust the Manual Cmd slider for each strain command point on the Linearization Data window B At each command point verify both the calibrator readout value Standard and its corresponding conditioner feedback value Conditioner by comparing them with the corresp
199. neral safety information see the Safety manual included with your system Danger notices 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 DANGER 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 procedures 10 Preface Model 493 10 793 00 Controller Service Conventions Warning notices 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 WARNING Hazardous fumes can accumulate in the test chamber as a result of testing Breathing hazardous fumes can cause nausea fainting or death Ensure that the chamber is properly ventilated before you open the chamber door or put your head or hands into the chamber To do this ensure that the temperature controller is off and allow sufficient time for the ventilation system to completely exchange the atmosphere within the chamber Caution notices Caution notices indicate the presence of a hazard which will or can cause minor personal injury cause minor equipment da
200. ng a 10 kN range exercise the actuator between 0 and 10 volts To calibrate the same force sensor for a different range such as 5 kN exercise the load standard between 0 and 5 volts 9 Apply a tensile force command that is 80 of the range s full scale A Adjust the Manual Cmd slider for a tensile force command that is 80 of the full scale range iw gt f p Model 493 10 793 00 Controller Service 193 S bd K o Calibrating a Force Sensor B Verify that your force transducer feedback signal is 80 of the full scale range During the initial calibration and tuning of your system it may require repeated adjustment for the tensile force command and feedback values to match Note _ f the actuator response is sluggish and or the signal value does not 10 11 194 match the command you will need to adjust the tuning of this contro mode Increase the proportional gain P Gain on the Adjustments tab of the Tuning panel to correct sluggish actuator movement Increase the reset integration value I Gain to help the feedback match the command At this point unless the conditioner is already in calibration the tensile force applied to the force transducer will not equal your commanded value You will adjust gain in the next step so that the actual tensile force and your commanded tensile force match Example Suppose your actuator has a 100 tensile force rating of
201. ng a sensor 144 description 143 saving calibration data to 144 transition bus 20 transition panels description 37 installing 36 tuning about 232 auto tuning 256 checklist 234 compensation 232 control modes 236 control range adjust 239 controls 239 creating a program 246 displacement 254 force control modes 255 guidelines 233 innerloop 119 monitoring waveforms 250 pre calibration LVDT 150 prerequisites 235 proportional gain 240 selecting amplitude 248 selecting frequency 248 specimens changing 232 tuning with 249 tuning without 250 waveforms 246 when to tune 234 Model 493 10 793 00 Controller Service V valve balance adjustment 117 valve driver definitions hwi file 298 valves polarity check 151 VME bus 20 VMEbus installing modules 31 VMEbus modules description 34 installing 31 W waveforms 246 250 areas of interest 250 error signal 251 monitoring 250 workstation connection 83 Z zero setting displacement sensor 220 encoders 204 209 force sensor 184 LVDT 162 Temposonics sensor 214 Model 493 10 793 00 Controller Service 323 324 Model 493 10 793 00 Controller Service
202. nge is used typically 100 Record data points The accuracy tolerance of your data depends on the manufacturer of your sensor Your sensor should include a calibration data sheet that shows the data point tolerance Sensors from MTS include a sensor calibration data sheet that shows the data points as it was calibrated 1 Record the data points for LVDT extension A Adjust the Manual Cmd slider to achieve zero command B Adjust the dial indicator for a zero reference C Adjust the Manual Cmd slider to 20 extension and record the dial indicator reading Repeat this step for 40 60 80 and 100 actuator extension 2 Record the data points for LVDT retraction A Adjust the Manual Cmd slider to achieve zero command B Adjust the dial indicator for a zero reference C Adjust the Manual Cmd slider to 20 retraction and record the dial indicator reading Repeat this step for 40 60 80 and 100 actuator retraction S bd K o 168 Model 493 10 793 00 Controller Service Calibrating an LVDT Task9 Gain Linearization Calibration If you are using Gain Linearization for your calibration type complete the following procedure If not complete Task 8 Gain Delta K Calibration on page 165 Important Using linearization data requires specific conditioner zeroing practices Ensure that Electrical Zero Lock on the Offset Zero menu is set to Locked Adjusting electrical zero after calibration may invalidate
203. nnections A Temposonics HI transducer requires a DC conditioning daughter board Force and strain sensors require a DC conditioning daughter board oO N EX 5 24V I I i i T 6 com 9 I o gt I J 2 I i i ii ii Data l i t ii 1 FROM mi TT J TEMPOSONICS III i i i 3 SENSOR II ota 13 ma Ww By fig OUTER BRAID XJ 2 I mM l 1 1 i 2 I LJ Model 493 10 793 00 Controller Service 129 Transducer Connections Full Range Digital Universal Conditioner FRDUC Jumpers The following jumpers are for the Model 493 25 Full Range Digital Universal Conditioner The jumpers are labeled W instead of X the W jumpers are solder pads The following jumper descriptions are from the 493 XX Module Setup configuration drawing PN 493363 01 Active guard Jumper W1 enables or disables an active guard for the sensor cable e A passive guard drive is the default Enable Disable Short to Ground Cap to Ground Ss v aD Default 4 or 8 Wire Jumpers W2 and W3 establish the correct shunt calibration connections sensor cable for 4 wire and 8 wire sensor cables The length of the sensor cable determines which type of cable is used Short cables are typically 4 wire cables while long cables are typically 8 wire cables Jumper W2 selects a 4 or 8 wire transducer for positive feedbac
204. nnel Tuning icon and then click the Adjustments tab 13 Set P Gain to 0 5 14 On the Station Controls panel perform the following setup A Click the Manual Command button to open the Manual Command window B Inthe Channel selection box ensure that the desired control channel is selected C In the Control Mode selection box ensure that the displacement control mode is selected D Click on the Enable Manual Command check box to enable manual command E Ensure that the Master Span is set for 100 F If the 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 15 Check the movement of the actuator 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 extend the actuator Actuator fully retracted e If the actuator is fully extended and applying a negative or extended 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 13 and increase the gain setting e Ifthe actuator is fully retracted and applying a positive Manual Cmd
205. not calibrated the sensor before e The hydraulics are warmed up see System warm up below e Gain is set to 1 on the Drive panel Conditioner tab 3 stage servovalves only e You know your signal polarity see Signal polarity below Be sure that both the hydraulic fluid and the servovalve are at operating temperature before calibration Remove any specimen and run the system in displacement control for at least 30 minutes using a 80 full scale length command at about 0 1 Hz Refer to How to Warm Up the System Hydraulics in Chapter 5 Tuning of the Model 793 00 System Software manual for a detailed procedure Some test systems are configured to extend the actuator in response to a positive command while other test systems are configured to retract the actuator in response to a positive command Conditioner polarity determines feedback polarity You must know how your test system is configured so you can determine the appropriate polarity for the values used in this chapter The valve polarity is established first see Setting the Servovalve Polarity on page 115 Model 493 10 793 00 Controller Service 147 iw gt f p S bd K o Before You Begin Full range vs Multi range conditioners 148 Consider the following differences when calibrating sensors that use full range conditioners such as the 493 25 DUC instead of multi range conditioners e Full range c
206. nsor cable to the rear panel of the controller chassis CABLE DESCRIPTION ID MODULE W CABLE System CABLE MODULE CONNECTOR ADT 120 525435 XX 561258 XX 493 40 J4 J7 300 524436 XX 561259 XX 493 40 J4 J7 Extensometer 633 capacitive 525434 XX 525443 XX 493 40 J4 J7 Force Transducer w PT connector 525425 XX 525442 XX 493 40 J4 J7 w PC connector 525426 XX 525442 XX 493 40 J4 J7 w MS connector 525427 XX 525442 XX 493 40 J4 J7 LVDT 52543 1 XX 525442 XX 493 40 J4 J7 AP control 525432 XX 525442 XX 493 40 J4 J7 Pressure Control Sensotec 525433 XX 525442 XX 493 40 J4 J7 Strain w Amphenol connector 525429 XX 525442 XX 493 40 J4 J7 w PT connector 525430 XX 525442 XX 493 40 J4 J7 Temposonics 525437 XX 561260 XX 493 40 J4 J7 Temposonics II low power conditioner 525438 XX 525442 XX 493 40 J4 J7 RVDT w MS connector 527508 XX 525442 XX 493 40 J4 J7 1 XX specifies cable length 01 through 09 represent 10 50 ft in 5 ft increments Higher numbers represent custom cable lengths Model 493 10 793 00 Controller Service 135 Shunt Calibration Shunt Calibration When to use shunt calibration 136 You can verify the calibration accuracy of a DC sensor conditioner pair through shunt calibration Shunt calibration works 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 ca
207. ntroller chassis If you do not have an Analog Out panel use the Meters window or Station Signals panel to monitor strain feedback On the Station Manager Display menu select Station Setup In the navigation pane select Station Signals to display the Station Signals panel to monitor current values for user defined signals 6 Mount the extensometer to the calibrator Review the extensometer product manual for mounting information and calibrator requirements E bd K o 216 Model 493 10 793 00 Controller Service Calibrating an Extensometer Task 2 Create a sensor calibration file This task creates a sensor calibration file and sets up any ranges you may want If you already have a sensor calibration file skip this task The following steps provide an overview of sensor file creation For a more detailed description of this procedure refer to How to Create a Sensor File in Chapter 3 Station Manager of the Model 793 00 System Software manual 1 On Station Manager Tools menu select Sensor File Editor 2 On the Sensor File Editor toolbar click the Open button and then New 3 From the Conditioner Type list select the type Model of conditioner that is connected to the extensometer you are calibrating Note Until you select conditioner type all conditioner entries are disabled 4 Enter a sensor name 5 Specify the signal Dimension 6 Enter any additional information 7 Under Range
208. ntrols have the following functions e Proportional gain P Gain increases system response e Integral gain I Gain increases system accuracy during static or low frequency operation and maintains the mean level at high frequency operation e Derivative gain D Gain improves the dynamic stability when high proportional gain is applied e Feed forward gain F Gain increases system accuracy during high frequency operation e Forward loop filter FL Filter adjustments establish a frequency bandwidth for the servoloop command signal Changing adjustment It is possible that the amount of adjustment for a control is too coarse ranges or inadequate Click the adjustment button such as P Gain and use the Range Select window to change the range of the adjustment Reducing the range produces smaller steps between values higher resolution while increasing the range produces larger steps between values Example Suppose the default range for the Proportional Gain adjustment is 50 Assume you are adjusting the gain and you reach the maximum adjustment 50 Clicking the P Gain slider label displays the P Gain range window where you can change the range of the adjustment Change the range by typing a new value in the maximum entry field Model 493 10 793 00 Controller Service 239 About Tuning Tuning Channel 1 Displacement Adjustments Fitter Range Min 1 0e 012 PIDF Max 100000000 Resolution Min 0 0000 P Gaim
209. nts See GRES III on page 309 for more information on adding a GRES III module to your system Model 493 10 793 00 Controller Service 85 Service Connections Service Connections Chassis service 86 The Model 493 10 Chassis can have several service connectors There are two types of connectors e The chassis connection monitors the power supply e The connection on the I O Carrier module monitors the output of each daughter board The J39 Power Monitor connector is located on the rear panel of the chassis It functions as test points for a service technician It allows you to check all of the power supply voltages along with the status of the over temperature sensor and the power fail circuit From Power Supply J39 5 Volts 2 12 Volts 3 12 Volts 4 15 Volts 5 15 Volts 6 24 Volts 7 Ground 8 2 5 Volts Reference 9 Ground 11 Temperature 14 Power Fail 15 Model 493 10 793 00 Controller Service Service Connections 1 0 Carrier service The J3 Service connector on the Model 493 40 I O Carrier module provides the monitor output from each of the four I O option cards installed It is an 8 pin RJ 45 connector From To Daughter J3 External Boards Device gt 1 Slot 1 Monitor TTT 2 Slot 1 Ground 2 3 Slot 2 Monitor ST 4 Slot 2 Ground p 5 Slot 3 Monitor 6 Slot 3 Ground Zoo 7 Slot 4 Monitor Eo 8 Slot 4 Ground Important The signals at the
210. nual Cmd slider for a 2 retraction command Record dial indicator value and conditioner feedback at the 2 row of your record sheet F Repeat steps D and E for other retraction commands typically at 4 6 8 10 20 40 70 and 100 percent of full scale 6 Record dial indicator and conditioner feedback readings at predetermined extension command points A Adjust the Manual Cmd slider for a 2 extension command S bd K o 170 Model 493 10 793 00 Controller Service Calibrating an LVDT B Record the dial indicator value and conditioner feedback at the 2 row of your record sheet C Repeat steps A and B for other extension commands typically at 4 6 8 10 20 40 70 and 100 percent of full scale 7 Turn off system hydraulics 8 On the Linearization Data window enter the dial indicator and conditioner feedback readings for all command points previously recorded Click Linearization Data on the Calibration tab to open the Linearization Data window E Linearization Data x Fullscale Min Max 1 0000 1 0000 cm Data Range Recommended Standard Conditioner 0 080000 OREN TTT 0060000 0 05000 0 05000 om _ 0 080000 ETI EET 0 020000 TT ERE 00000 TT 020000 ORE ACRE 0040000 0 05000 0 04000 om _ 0 060000 STN MCR 0 080000 0 08000 0 08000 cm_ 9 Turn on system hydraulics LVDT recalibration If the LVDT has been previ
211. o So So So Ch2Ain ch2 ch2 0 KO 93 93 93 93 a o o o o ca SY RIT KS LY o J is 38 gQ YO oo J44A Run Stop J44B J44A Run Stop J44B Chain chs chs chs O Ko KO HIRO z 059 a roy FG FOX gg 399 z lt 8 38 A s3 oe 809 E STOP IN 08 oo 26 oo ge Ch 1B In cha cha 290 o o o o 2o Go 28 EJI eS eI ET O z Q SY S9 LY Le ze O og o O 38 O KO O oO 2 28 ee So J49A AuxPwr J49B J49A AuxPwr J49B o S chs chs o s 7 a a S IO o 9 ONEI z 2 G 8a eSI fa ea ea fea Hes D z 090 2 80 So go So fo o o o o 308 99 99 og 08 En ch6 che 090 n 20 s 25 Sig O gt SS XY NY MY 2 lt 0 A O J25 HPS O KO ge ss 350D J29A Load Unit 3298 J29A Load Unit J29B 28 a o a lal Q GE 11281 sy Ba 3 229 39 og o9 og Ch3B In o o o o ool 08 se 98 98 269 o 26 oo 26 0 08 o o o 8 ag ga 9e Co o o o A 20 95 20 So wo ke 9 88 JT SERIAL EN K O k 98 as J Jan m m J28AHSM sans o se Ky fier fea ea o 23 gel neu I I So oG se ST E 38 O 32 i ji L o o o 4 o So o ge L 12 312 e ag J28B HSM 288HsM o u ZB Out hss 8S hss o o 32 ge o o O o oO 2 O Ea O 9 Note Other transition modules may be used contact MTS Systems Corporation for additional information
212. o Zero button on the Offset Zero tab Inputs panel Note When you change the encoder resolution on the Calibration tab it immediately changes the resolution of signal values displayed on the Station Signals Meters and Scope windows Task6 Save the calibration It is important that you save your sensor calibration values On the Station Setup window Inputs panel click the Calibration tab and then Save This saves current calibration values on the Calibration Sensor and Shunt tabs to the sensor calibration file S bd K o 214 Model 493 10 793 00 Controller Service Calibrating an Extensometer Calibrating an Extensometer Extensometers are usually calibrated such that the maximum strain represents 100 of the full scale capacity of the extensometer To calibrate you extensometer you will need e An extensometer calibrator e A digital voltmeter DVM How To Calibrate an Extensometer Online readers All procedure entries are hypertext links Click on any entry to jump to the corresponding page Task 1 Get things ready on page 216 Task 2 Create a sensor calibration file on page 217 Task 3 Assign a sensor calibration file on page 218 Task 4 Turn on hydraulic pressure on page 219 Task 5 Adjust offset on page 220 Task 6 Gain Delta K Calibration on page 221 Task 7 Gain Linearization Calibration on page 223 Task 8 Establish the sh
213. o perform as intended over time Manual Part Number Publication Date 100 068 901 E June 2003 Contents Preface 9 Conventions 10 Technical Support 13 Chapter 1 Introduction 17 Functional Description 20 Specifications 23 Chapter 2 Installation 25 Installing the Chassis 26 Connecting Electrical Power 27 Installing the Plug in Modules 30 VMEbus Modules 31 Transition Panels 36 Model 493 10 793 00 Controller Service Chapter 3 Cabling 39 CE EMC Compliant Cabling 41 Typical Cabling 42 Cable Part Numbers 43 I O Carrier Connections 45 Valve Connections 46 Multiple Universal Driver Connections 50 Analog I O Connections 52 Accelerometer Connections 56 Encoder Connections 58 Remote Setpoint Adjust Connections 60 ADDA II Connections 61 Emergency Stop Connections 66 Hydraulic Power Unit Connection 68 Station Connections 71 J28 HSM 72 J29 Load Unit 74 J43 Interlock 75 J44 Run Stop 76 J49 Auxiliary Power 78 Digital I O Connections 79 Workstation Connection 83 Remote Station Controller Connection 84 Service Connections 86 Cabling and Programming External Controllers 88 How to Program an External Controller 89 Connecting Interlock Signals to 407 Controllers 94 Single 407 Controller Interlock Connections 94 How to Jumper the Hydraulic Terminal on a Single Station 407 95 Multiple 407 Controller Interlock Connections 96 How to Connect Hydraulic Terminals on Multiple Station 407s 97 Interlock Con
214. o you connect the oscilloscope and what signal do you monitor Read Monitoring Waveforms on page 250 234 Model 493 10 793 00 Controller Service About Tuning What to do first The following are tasks that should be completed before you tune It is 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 under complete recalibration 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 Connect an oscilloscope to your system or use the controller scope You need to monitor the sensor signal or error signal for the control mode you intend to tune Go to Monitoring Waveforms on page 250 for help e Balance the servovalve The electrical valve balance adjustment compensates for minor mechanical imbalance it is an intermediate adjustment Go to Adjusting Valve Balance on page 117 and perform the electrical valve balance adjustment procedure e Calibrate each sensor used for a control mode or data acquisition Perform the appropriate calibration procedure 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 See Shunt Calibration on page 136 e If you have a t
215. of hardware your hwi file When any of these components are added to your system you must 1 Remove the comment markers definition from either side of the component definition 2 Edit the definition for required board ID slot information channel number and other necessary information e g baud rate master clock definition 3 Move the edited definition to the appropriate section of the file This appendix describes how each component definition must be formatted This information is provided so you can edit the tsiismec hwi file for your system See A Sample File on page 310 for an example of an hwi file for a typical system 284 Model 493 10 793 00 Controller Service Processor Processor This block defines the processor modules installed in the 493 10 Chassis The information shown is the same for all systems using the 498 93 1 and 498 93 2 Processor modules Do not change the information in this block ay J r PROCESSOR ADDRESS 0xC8000000 SLOT 1 FUNCTION SUPERVISOR PROCESSOR NUMBER 0 INTERRUPT LEVEL 2 PC Interface FILENAME tsiismcsup o Processor PORT ETHERNET Functions IP Do not change the ADDRESS 148 150 203 1913333 information in this block PROCESSOR ADDRESS 0x00000 SLOT 1 FUNCTION CONTROL PROCESSOR NUMBER 1 INTERRUPT LEVEL 5 FILENAME tsiismcdsp o SHARED MEMORY 0x700000 Model 493 10 793 00 Controller Service 285 2 i
216. of the actuators when applying hydraulic pressure 1 On the Station Manager Display menu select Station Setup 2 In the Station Setup navigation pane locate and select the channel associated with the sensor signal you are calibrating 3 In the Station Controls panel s toolbar click the Manual Command button to display the Manual Command window In the Manual Command window A Select the Channel associated with the sensor signal you are calibrating B For the Control Mode select the displacement associated with the sensor signal you are calibrating C Click Enable Manual Command 4 On the Station Controls panel ensure the Master Span is set for 100 5 If the Interlock indicator is lit click Reset If the indicator lights again you must determine the cause and correct it before proceeding 6 In the power selection box click the Power Low button and then Power 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 7 If an HSM is present click the Power Low button and then Power High for the appropriate HSM iw gt f p i Model 493 10 793 00 Controller Service 159 Calibrating an LVDT Task 5 Verify the conditioner polarity This task checks the polarity of the conditioner Different types of test systems are configured with different conditioner polarities Th
217. off system hydraulics 15 On the Linearization Data window enter the calibrator values Standard and its corresponding conditioner feedback readings Conditioner for all command points previously recorded on a separate sheet 16 Verify linearization data A Adjust the Manual Cmd slider for each strain command point on the Linearization Data window B At each command point verify both the calibrator readout value Standard and its corresponding conditioner feedback value Conditioner C Check validity before entering each pair of values on a new Calibration Data sheet Model 493 10 793 00 Controller Service 227 iw gt f p E bd K o Calibrating an Extensometer Task8 Establish the shunt calibration reference Each DC conditioner supports a shunt resistor To establish the shunt reference value perform the following tasks 1 Disable hydraulic pressure and remove the calibrator 2 Activate hydraulic pressure and zero the strain sensor output Adjust the Manual Cmd slider for a 0 cm cm output The sensor output must be 0 000 cm cm for a proper shunt calibration If not review Task 5 Adjust offset on page 220 3 On the Manual Command window change your control mode to displacement 4 Determine the shunt calibration resistor from the following table BRIDGE RANGE RESISTOR RESISTANCE SENSITIVITY FULL SCALE VALUE 350 2 2 mV V 100 49 9 k
218. ogram on the Model 493 10 793 00 controller via its Model 493 74 HSM transition module Use the specified four channel master dependent interlock cable PN 564489 XX to make these connections for each 407 controller station P28 CPC 4P 24V o 24V OW HYD INTLK J4 INPUT gg y EVENT PROGRAM INTLK INPUT OFF INTLK 1 2 y lel Law P43 D 9P 1 Jumper 2 3 Jumper 4 24v own 5 6 7 Jumper 5 8 Master Dependent Interlock Cable PN 564489 XX Digital I O Connector A Hydraulic DIGIT Interlock 4 p a IN re Active Low To 407 Controller 2 l o1citat Run Stop Station 1 out 1 f Active High Master 10 FT TS Hydraulic 3 EN K DIGITAL Interlock To 4 Active Low 407 Controller 5 L ommal Run Stop ee 1 s our 1 f Active High ave RJ Hydraulic 3 Interlock DIGITAL p K N1 f Active Low To 3 407 Controller 5 oroita Run Stop Station 2 A 6 J ouT f Active High Slave ol 10 FT Hydraulic BME oicitat Interlock 4 IN1 J Active Low To 407 Controller 3 1 nisita Run Stop Station 3 6 J ouT 1 f Active High Slave XJ Model 493 10 793 00 Controller Service Cabling and Programming External Controllers How to Connect Hydraulic Terminals on Master Dependent 407s The following figure s
219. oint e During calibration Manual Offset should always be set to zero e When calibrating sensors that use a full range conditioner e g 493 25 DUC ensure that Electrical Zero Lock is checked on the Offset Zero tab of the Inputs panel e After completing force sensor calibration do not change the electrical zero adjustment Readjustment of electrical zero after calibration will change the point at which linearization takes place disturbing other calibration settings especially delta k You will need the following items to calibrate a a force sensor All calibration tools should also be calibrated to an industry standard e A load standard can be a calibrated force sensor with its own electronics or it can be a calibrated set of dead weights Note This calibration procedure calibrates the DC conditioner for a force sensor of 10 kN You will need to adjust the procedure to accommodate your force sensor e A DVM to monitor the output of the load standard Model 493 10 793 00 Controller Service Calibrating a Force Sensor Abbreviated Procedure Online Readers Al procedure entries are hypertext links Click on any entry to jump to the corresponding page The following abbreviated procedure outlines a force sensor load cell calibration process More detailed calibration information is available on the pages listed Task 1 Get things ready on page 178 Task 2 Create a calibration file on page 180 Task 3
220. ommand points previously recorded on a separate sheet 15 Turn on system hydraulics 16 Verify linearization data A Adjust the Manual Cmd slider for each retraction and extension command point on the Linearization Data window B At each command point verify both the dial indicator value Standard and its corresponding conditioner feedback value Conditioner C Check validity before entering each pair of values on a new Calibration Data Sheet S bd K o 174 Model 493 10 793 00 Controller Service Calibrating an LVDT Task 10 Save the calibration It is important that you save your sensor calibration values Click Save on the Calibration tab to save the current calibration values to the sensor calibration file Task 11 Calibrate additional ranges This task describes how to calibrate additional ranges Each sensor calibration file can have calibration data for four ranges If you have a need for additional ranges simply create another sensor calibration range e Use the calibration values from the previous range as a starting point e If you adjust the zero reference it may affect the other ranges Note Some systems do not provide or require multiple ranges such as those using full range conditioners e g Model 493 25 DUC module In this case only one range is used typically 100 Adding a range If the sensor calibration file must have additional ranges defined perform the foll
221. ommand source perform the following 1 Cable the controllers on page 106 2 Allocate external command resources in Station Builder on page 106 3 Adjust the command signal with Station Manager on page 107 4 Start the External Command on page 107 Model 493 10 793 00 Controller Service 105 Cabling for External Command Inputs Task 1 Cable the controllers Cable the external programmer analog out connector to a Model 493 75 Analog In module BNC connector External Analog Source e 2 e SO From 1 0 Carrier Module cr 3 J m Pl Task 2 Allocate external command resources in Station Builder Using Station Builder allocate controller resources to receive programming from an external controller Refer to Enabling External Command Inputs in Chapter 2 Station Builder in the Model 793 00 System Software manual for more detailed information 106 Model 493 10 793 00 Controller Service Cabling for External Command Inputs Task 3 Adjust the command signal with Station Manager Refer to How to Enable and Run External Command Inputs in Chapter 3 Station Manager in the Model 793 00 System Software manual for more detailed information Task 4 Start the External Command Refer to How to Enable and Run External Command Inputs in Chapter 3 Station Manager in the Model 793 00 Syst
222. omponents defined in the hwi file include e processor modules e hydraulic control resources e valve drivers conditioners e analog inputs and outputs e digital inputs and outputs e temperature controllers e remote station controllers e global interlock resources e encoder resources Your test system comes equipped with one of the following hardware interface files depending on your system controller e tsiisme hwi file This file represents the actual components installed in your TestStar IIm test controller e ftgt hwi file This file represents the actual components installed in your FlexTest GT test controller Model 493 10 793 00 Controller Service 283 If a module is added removed or repositioned in your chassis you must revise your hwi file to reflect the new configuration You can edit the hardware interface file with a text editor ee Do not edit your hwi file unless you know what you are doing 2 i t Your system software will not function if the required file structure is not followed Be sure to create a back up copy of your hwi file before revising it The file format of the hwi file is critical An errant or misplaced space comma period or character can make the file nonfunctional A misspelling can also cause the file to be nonfunctional ee ______ _ __ __ __ __________i Adding optional Definitions for optional supported hardware are included at the end
223. on Manager of the Model 793 00 System Software manual When you go from a larger range to a smaller range limit detector do not automatically change so they may not apply to your new range When this occurs the controller will display the following message The range selected for signal signal name has left one or more of the signal s detectors outside of the new range Please verify that the detectors limit and error associated with this signal are adjusted as necessary For example suppose you have a configuration in which Range 1 spans 10 kN with limits set at 9 kN and 5 kN as shown below in the figure to the left Both limits are viable for Range 1 Model 493 10 793 00 Controller Service 125 Sensor Signals 9 kl Next suppose you select Range 2 which spans 6 kN as shown below in the figure to the right In this case the 9 kN limit would not be applicable to Range 2 and the application would display the message However the 5 kN limit still falls within the span of Range 2 Limit Range 1 O Ppa EEN ee 5 KN Limit 9 kN Limit Range 1 Range 2 Pec scecoss v 6kN v 10 kN 5 kN Limit When you select a new range review the limits you have defined for the selected signal to ensure they are appropriate for your new range 126 Model 493 10 793 00 Controller Service Transducer Connections Transducer Connections Transducer connections require a condition
224. on configuration can provide eight channels of control A typical 8 Channel 8 Station configuration requires 16 Digital Universal Conditioners and 8 two stage valve drivers HSM power current is limited to 1 5 A per HSM For 8 station configurations the hwi file must contain the line INTERLOCKS 8 This line must be a discrete entry not part of any other hwi section Cross head interlocks with solenoid power are not supported for 8 station configurations Remote Station Control RSC is not supported for 8 station configurations Only one set of six A D analog inputs is supported for 8 station configurations This is an example of a ftgt hwi file that defines resources for an 8 station 8 channel FlexTest GT system This system includes standard hardware including e seven 2 stage valve drivers e One 3 stage valve driver e One A D daughter board e One D A daughter board e Sixteen Universal Conditioners 8 AC and 8 DC i gz i gt n st i iar i y K i i 7 The file listing The following is an actual ftgt hwii file Both processor entries are needed for single processor systems PROCESSOR ADDRESS 0xC8000000 SLOT 1 FUNCTION SUPERVISOR PROCESSOR NUMBER 0 INTERRUPT LEVEL 2 FILENAME tsiismcsup o PORT ETHERNET IP ADDRESS 148 150 203 191 PROCESSOR ADDRESS 0x00000 SLOT 1 FUNCTION CONTROL PROCESSOR NUMBER 1 INTERRUPT LEVEL 5 FILE
225. onding conditioner feedback reading at 0 command C Adjust the Manual Cmd slider for a 2 tensile force command D Record the force standard s readout value and its corresponding conditioner feedback reading in the 2 row of your record sheet iw 2 gt r i Model 493 10 793 00 Controller Service 191 S bd K o Calibrating a Force Sensor 192 E Repeat steps E G for other tensile force commands typically at 4 6 8 10 20 40 70 and 100 percent of full scale 7 Record conditioner feedback readings at predetermined compressive force command points A Adjust the Manual Cmd slider for a 2 compressive force command B Record the standard s readout signal and corresponding conditioner feedback reading in the 2 row of your record sheet C Repeat steps A and B for other compressive force commands typically at 4 6 8 10 20 40 70 and 100 percent of full scale 8 Turn off system hydraulics 9 On the Linearization Data window enter the force standard values and corresponding conditioner feedback readings for all command points previously recorded on a separate sheet Click Linearization Data on the Calibration tab to open the Linearization Data window E Linearization Data x m Fullscale Min Max 1000 0 1000 0 DaN r Data Range J te po From Recommended standard Conditioner 20 000 ETT BET 80 000 TT TET 40 000 OTT
226. onding values on the Calibration Data sheet If the data is valid Stop this procedure If the data is not valid Proceed to the next step Model 493 10 793 00 Controller Service 225 iw gt f p i Calibrating an Extensometer 7 Click Reset on the Linearization Data window to return to default values 8 Use the Manual Cmd slider to adjust the calibrator between zero and 100 of the extensometer s full scale range three times This exercises the extensometer to remove any hysteresis 9 Apply a negative strain command that is 80 of the negative full scale range A Adjust the Manual Cmd slider for a negative strain command that is 80 of the full scale range B Verify that your extensometer feedback signal is 80 of the full scale range During the initial calibration and tuning of your system it may require repeated adjustment for the negative strain command and feedback values to match At this point unless the conditioner is already in calibration the negative strain applied to the extensometer will not equal your commanded value You will adjust gain in the next step so that the actual strain and your commanded strain match 10 Adjust gain until the actual strain equals your strain command Adjust the Post amp Gain control on the Calibration tab to increase the negative strain reading on the calibrator until it equals your negative strain command 11 Apply a positive strain command th
227. onditioners allow you to set up a linearized data table for a gain linearization calibration of a sensor See How to Create a Sensor File in Chapter 3 Station Manager of the Model 793 00 System Software manual for detailed information e When using linearized data you must retain copies of the initial calibration report containing non linearized data and the calibration report after applying linearization e When calibrating sensors that use a full range conditioner the Electrical Zero Lock must be checked on the Offset Zero tab of the Inputs panel Readjustment of electrical zero after calibration will change the point at which linearization takes place disturbing other calibration settings Model 493 10 793 00 Controller Service Calibrating an LVDT Calibrating an LVDT Prerequisites What you will need Important Notes Model 493 10 793 00 Controller Service 149 An LVDT is calibrated with a dial indicator or some other displacement measuring device Displacement is usually calibrated such that the maximum extension and retraction represent 100 of the full scale capacity of the LVDT with mid displacement set at zero Displacement can also be calibrated to any range within the full scale capacity of the sensor Also ranges do not have to be centered on zero Be sure the items described in Before You Begin on page 147 are true An LVDT requires a digital universal conditioner DUC in AC mode to process the fee
228. ously calibrated use the following procedure 1 Locate the calibration data sheet for the appropriate conditioner 2 Turn off system hydraulics 3 Click Linearization Data on the Calibration tab to open the Linearization Data window Model 493 10 793 00 Controller Service 171 iw gt f p i Calibrating an LVDT 4 Transfer Standard and Conditioner data from the conditioner s calibration data sheet to corresponding data entries on the Linearization Data window 5 Turn on system hydraulics 6 Verify the linearization data A Adjust the Manual Cmd slider for each retraction and extension command point on the Linearization Data window B At each command point verify both the dial indicator value Standard and its corresponding conditioner feedback value Conditioner with the corresponding values on the Calibration Data sheet If the data is valid Stop this procedure If the data is not valid Proceed to the next step 7 Click Reset on the Linearization Data window to return to default values 8 Apply a retraction command that is 80 of the range s full scale A Adjust the Manual Cmd slider on the Manual Command window for 80 of the full scale range B Use the Station Signals panel to verify that your LVDT displacement signal equals 80 of the full scale range During the initial calibration and tuning of your system it may require repeated adjustment for the retraction co
229. outputs and the valve driver daughter board define analog outputs If the analog output channels define output channels 1 through 6 then the valve driver must be assigned channel 7 An additional D A board would define channels 8 9 10 and so on DAUGHTER 3 ADDRESS 0x20000 TYPE 493 46 FILENAME D2A_53 OUT outputs CHANNEL 1 NAME Analog Output 1 I O 1 CONNECTOR J6 CHANNEL 2 NAME Analog Output 2 I O 1 CONNECTOR J6 CHANNEL 3 NAME Analog Output 3 I O 1 CONNECTOR J6 CHANNEL 4 NAME Analog Output 4 I O 1 CONNECTOR J6 CHANNEL 5 NAME Analog Output 5 I O 1 CONNECTOR J6 CHANNEL 6 NAME Analog Output 6 I O 1 CONNECTOR J6 DAUGHTER 4 ADDRESS 0x30000 TYPE 493 14 FILENAME DVD_53 OUT outputs CHANNEL 7 NAME 493 14 2SVD 1 I O 1 CONNECTOR J7 RANGE 25 MODE SINGLE Model 493 10 793 00 Controller Service I O Carrier The same is true for analog inputs For example the A D daughter board and the conditioner daughter boards are analog inputs If the conditioner daughter boards define input channels 1 2 the A D daughter board must be defined as channels 3 8 and so on DAUGHTER 1 ADDRESS 0x00000 TYPE 493 21B FILENAME DUCB_53 0OUT CHANNEL 1 NAME 493 21B DC Slot 3 1 CONNECTOR J4 MODE DC FILTER 1000 DAUGHTER 2 ADDRESS 0x10000 TYPE 493 21B FILENAME DUCB_53 0UT CHANNEL 2 NAME 493 21B AC Slot 3 2 CONNECTOR J5 MODE AC FILTER 1000 DAUGHTER 3 ADDRESS 0x20000 TYPE 493 45 FILENAME A2D_53 0OUT CHANNEL
230. owing 1 On the Tools menu select Sensor File Editor 2 Open the sensor file for the sensor you have just calibrated 3 Click Add under Range Definition 4 Select the units for the range and then enter the absolute value of the range 5 Save the new range to the calibration file 6 Calibrate the added range Note Ranges can also be added on the Sensor tab and calibrated on the Calibration tab iw gt f p i Model 493 10 793 00 Controller Service 175 E bd K o Calibrating a Force Sensor Calibrating a Force Sensor Prerequisites Initial calibration Recalibration Important notes What you will need 176 A force sensor also called a load cell is calibrated with a load standard It is calibrated such that the maximum compression and tension represent 100 of the full scale capacity of the force sensor with zero force set at midcapacity Be sure the items described in Before You Begin on page 147 are true A force sensor requires a Digital Universal Conditioner DUC configured for the DC mode that processes a DC feedback signal You must know which conditioner is connected to the sensor If you are calibrating a sensor for the first time you may find it necessary to e Perform an initial tuning of the sensor channel before calibration e Perform the procedure twice If you are recalibrating a sensor use the existing calibration values as a starting p
231. p Control 1 ADDRESS 0x1 RSC NAME RSC 2 HOST PORT GRES COM 2 FILENAME POD HEX INTERLOCK 2 NAME RSC 3 HOST PORT GRES COM 3 FILENAME POD HEX INTERLOCK 3 NAME RSC 4 HOST PORT GRES COM 4 FILENAME POD HEX INTERLOCK 4 316 Model 493 10 793 00 Controller Service Index Numerics 252 servovalve I O carrier connection 47 256 servovalve I O carrier connection 48 257 servovalve I O carrier module connection 49 407 controller hydraulic terminal jumper 94 95 96 programming to receive send signals 100 407 hydraulic terminal cabling multiple station 407 97 single station 407 94 95 96 493 01 chassis digital universal conditioner DUC jumpers 130 493 07 HPU Converter 263 493 10 chassis 27 AC grounding 28 functional description 20 grounding 27 installing 26 power connections 28 specifications 23 493 46 D A 493 76 Analog Out connection 54 64 A AC conditioners calibration 149 polarity 160 183 acceleration conditioner definitions hwi file 304 acceleration stabilizing with 244 accelerometer I O carrier connection 56 actuator determine natural frequency 244 analog I O cable specifications 55 analog I O definitions hwi file 301 auto tuning 246 256 advanced 256 basic 256 control panel 257 displacement 257 force 257 improving results 257 Model 493 10 793 00 Controller Service balance adjust valve 117 bridge completion I O carrier module 141 ID module 144 C cab
232. per 24V www 5 gt 6 Re Meu ee OFF INTLK Jumper v Interlock Cable PN 56455 0XX P28 Digital CPC 4P I O Connector HSM LO N a acu 24vo i 3 yaraulic M DIGITAL Interlock 2 J 4 ActiveLow T VY Fer 5 407 2 5 L nmal Run Stop Controller LS J 6 TT f ActiveHigh Station 2 YU P43 AI To D 9P 493 74 HSM 24V OW 1 Transition gt Jumper HYD INTLK T a NPU 3 Jumper 24V oOwW 5 gt 6 e Wa PE 7 j OFF INTLK Jumper Vv Interlock Cable PN 56455 0XX 96 Model 493 10 793 00 Controller Service Cabling and Programming External Controllers How to Connect Hydraulic Terminals on Multiple Station 407s The following figure shows how to cable hydraulic terminals on multiple station 407 controllers where each 407 controller can run an independent test program Repeat this scheme for each additional 407 controller 407 Controller No Connection Jumper Plug PN 049 635 901 No Connection Jumper Plug PN 049 635 901 No Connection Jumper Plug PN 049 635 901 No Connection Jumper Plug PN 049 635 901 Model 493 10 793 00 Controller Service 97 To 493 74 HSM Transition 98 HSM LO Cabling and Programming External Controllers Interlock Connections for Master Dependent 407 Controllers The following figure shows how to cable interlocks when a master 407 controller is daisy chained with three other dependent 407 controllers to run a single test pr
233. ration differences 148 full range conditioners 122 function generator random 248 G gain derivative d gain 242 feed forward F gain 243 forward loop filter FL filter 245 integral I gain 241 proportional P gain 240 stabilization S gain 243 gain delta K calibration calibrate compression 187 calibrate tension 186 extensometer 221 force sensor 185 LVDT 165 gain linearization calibration force sensor 190 initial calibration 190 recalibration 193 LVDT 169 initial calibration 169 recalibration 171 319 grounding chassis AC power 28 low frequency ground loops 41 hardware interface file hwi file accel conditioner definitions 304 analog I O definitions 301 conditioner definitions 303 digital I O definitions 297 encoder definitions 295 306 processor definitions 285 Temposonics sensor definitions 296 306 valve driver definitions 298 HPU HPU transition board connection 68 system I O connector 70 HPU transition board E stop cable specifications 66 E STOP connectors 66 E STOP Out J23 66 HPU cable specifications 68 HPU connector J25 68 system I O connector J54 70 HSM proportional output 72 HSM transition board J28 HSM connector 72 J29 load unit connection 74 J43 interlock connection 75 J43 interlock connecto 75 J44 run stop connection 76 J49 auxiliary power connector 78 hydraulic terminals cabling master slave 407s 99 multiple 407s 97 single 407 94 95 96 I gain See integral gain
234. rected universal input Input voltage 100 240 V AC Input frequency 47 63 Hz Input surge lt 100 A Power lt 1000 W Insulation over Category II voltage Pollution degree 2 Power supply 1 maximum draw is 400 W total gt 5 VDC 40 A S 15 VDC 75 A S Power supply 2 maximum draw is 400 W total S 12 VDC 4A 24 VDC 10 A Weight approximately 45 kg 100 Ib in stand alone configuration The specification shown conforms to CE Low Voltage Directive requirements The specification allows for 10 of the values stated The actual voltage the 493 10 chassis can operate is 90 264 V AC Model 493 10 793 00 Controller Service 23 Specifications i gz d p 24 Model 493 10 793 00 Controller Service Chapter 2 Installation This section describes how to install the Model 493 10 Chassis and connect it to your system components Contents Installing the Chassis 26 Connecting Electrical Power 27 Installing the Plug in Modules 30 5 a mp D gt Model 493 10 793 00 Controller Service 25 Installing the Chassis Installing the Chassis The chassis can be installed in an equipment rack console or in a stand alone configuration CAUTION The Model 493 10 Chassis weighs about 45 kg 100 Ib in stand alone configuration Improper lifting techniques can cause strained muscles and back injuries When lifting this chassis take the appropriate precautions to prevent injuries
235. ress specifies the CONNECTOR2 identifies the I O Carrier rear panel front panel connector connector that is available for MUD board output DAUGHTER 3 ADDRESS 0x20000 TYPE 2493 A JLENAME D2A_53 0UP CHANNEL 1 NAME 493 79 MUD T5 1 CONNECTOR J6 DRIVER TYPE 493 79 SLOT 5 CHANNEL 1 RANGE 25 INTERLOCK 1 CHANNEL 2 NAME 493 79 MUD T5 2 CONNECTOR J6 DRIVER TYPE 493 79 SLOT 5 CHANNEL 2 RANGE 50 INTERLOCK 1 CHANNEL 3 NAME 493 79 MUD T5 3 CONNECTOR J6 DRIVER TYPE 493 79 SLOT 5 CHANNEL 3 RANGE 75 INTERLOCK 1 CHANNEL 4 NAME 493 79 MUD T5 4 CONNECTOR J6 DRIVER TYPE 493 79 SLOT 5 CHANNEL 4 RANGE 0 INTERLOCK 1 CHANNEL 5 NAME 493 79 MUD T5 5 CONNECTOR J6 DRIVER TYPE 493 79 SLOT 5 CHANNEL 5 RANGE 25 INTERLOCK 1 CHANNEL 6 NAME 493 79 MUD T5 6 CONNECTOR J6 DRIVER TYPE 493 7 OT 5 CHANNEL 6 RANGE 25 INTERLOCK 1 The name in quotes appears RANGE identifies the utput in INTERLOCK indicates the in the Station Builder application mA of the valve driver itself The status of cable loss detection as a system resource You can settings are 0 25 50 or 75 The 0 disables 1 enables edit this if you want 0 setting requires an on board userselectable resistor 300 Model 493 10 793 00 Controller Service Analog Output The analog output definition describes the D A Analog Output daughter board ay J e The CONNECTOR specification identifies the rear panel
236. rity 160 gain delta K 165 gain linearization 169 initial values 157 mouniting dial indicator 162 pre calibration tuning 150 prerequisites 149 setting offset 162 setting zero 162 signal monitoring 156 what you need 149 millivolt volt calibration 197 monitor innerloop signals 120 monitoring waveforms 250 areas of interest 250 error signal 251 using controller scope 253 using oscilloscope 253 mV V calibration 197 0 offset setting displacement sensor 220 force sensor 184 LVDT 162 oscilloscope tuning use 253 Model 493 10 793 00 Controller Service P plug in modules installing 30 polarity conditioner 115 displacement sensors 160 183 force sensors 183 servovalve 115 setting servovalve signal 115 power connections 493 10 chassis 28 processor definition hwi file 285 proportional gain 240 random functions 248 ranged 122 ranged conditioners 123 ranges in sensors 122 ranges sensor 123 readout channel creating 111 readout signal adjust 111 remote station controller hwi file 85 308 serial interface connection J50 84 S save tuning parameters 233 sensor assigning with transducer ID 144 cables 133 connections 127 create calibration file 157 180 ranges 123 signals 122 147 sensor cables 4 8 wire jumpers 130 active guard jumper 130 part numbers 134 specifications 133 with ID module 135 without ID module 134 sensor calibration saving data to ID module 144 shunt calibration
237. rm for the initial tuning If the required results cannot be achieved change to a square waveform e If gain is too low the system may be sluggish or unresponsive with large static offsets Model 493 10 793 00 Controller Service 237 About Tuning Strain control Strain control uses an extensometer or strain gage bonded to the specimen as the controlling feedback source e Tune for each type of specimen or any changes in the force train e Strain control requires a specimen to be installed you may choose to use a broken specimen e Use a ramp waveform for the initial tuning e Do not use a square waveform for tuning A square wave can cause the extensometer to move or fall off the specimen which can cause the system to go unstable e If gain is too low the system may be sluggish or unresponsive with large static offsets Or it may be uncontrollable 238 Model 493 10 793 00 Controller Service About Tuning How the Tuning Controls Work The controller system software includes five tuning controls You do not need to use all of the controls to properly tune your system In fact most testing can be accomplished with just the proportional gain adjustment The other adjustments introduce a signal to the command to compensate for specific situations Note Throughout this chapter the terms gain rate and reset represent proportional gain rate derivative and reset integration respectively The five available tuning co
238. rm 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 communicate problems you are experiencing with your MTS software hardware manuals or service This form includes check boxes that allow you to indicate the urgency of your problem and your expectation of an acceptable response time We guarantee a timely response your feedback is important to us Model 493 10 793 00 Controller Service Chapter 1 Introduction The Model 493 10 Chassis is a multi station multi channel VMEbus chassis which houses up to ten MTS VMEbus modules in its front panel and up to ten transition modules in its rear panel The chassis supports up to four stations and eight channels in a standard configuration Optional six and eight station models are available Contents Functional Description 20 Specifications 23 h i a iv i Model 493 10 793 00 Controller Service 17 i T gz i i pz 18 2 9 OK Temp 139 Power Monitor
239. rol for multi station configurations a 8 5 cl o5555 SEER Gl O Remote Station Control x OMK J 00000 0000 00000 o a Cm a E ama aae Jan 8 00000 00000 00000 Pi 556342 xx E Stop or 556343 xx Station Stop Model 493 10 793 00 Controller Service Remote Station Controller Connection HWI file additions In order to use one or more RSCs with your Model 493 10 Chassis two sections must be added to your hwi file an RSC section and a GRES III section Note Remote Station Controllers are not available with the optional 6 or 8 station system configurations Note Ifyou specified RSC support when you ordered your test system these sections will be added to your hwi file at the factory Note For information on editing your hwi file to accommodate RSCs contact MTS The RSC definition is always the same A GRESIII module is needed to support an RSC in your system For information on adding a GRES III module see GRES III section on page 85 RSC section See Remote station controller on page 308 for more information on the RSC section of the hwi file GRES III section The Model 498 71 GRES III module supports both the Remote Station Controller RSC and the Temperature Controller and must be added to your system when using either of these compone
240. rror signal in engineering units The error is the difference between the command signal and the sensor feedback signal Abs Error Displays the absolute value of the error signal in engineering units Model 493 10 793 00 Controller Service 109 Cabling and Using External Readout Devices How to Send Signals to External Readout Devices To send station signals to an external readout device you must 1 Cable your controller to the readout device on page 110 2 Create a readout channel with Station Builder on page 111 3 Adjust the readout signal in Station Manager on page 111 Task 1 Cable your controller to the readout device Cable your FlexTest IIm CTC analog output connector to the readout device Analog I O connectors are located on the rear of the test processor chassis Connect an external readout device analog input to a BNC connector on a Model 493 76 Analog Out module Om An on Analog Monitor r I 6 G2 ona cha cna chs TI From I O Carrier Module il nanc 110 Model 493 10 793 00 Controller Service Cabling and Using External Readout Devices Task 2 Create a readout channel with Station Builder Refer to How to Create a Readout in Chapter 2 Station Builder of the Model 793 00 System Software manual for a detailed procedure Task 3 Adjust the readout signal in Station Manager Use Station Manager to ad
241. s installation of a Model 493 59 Universal Encoder daughter board on the Model 493 50 ADDA II module The Model 493 80 Encoder Transition module provides up to four channels of encoder interface between the Model 493 50 ADDA II module and various incremental Temposonics or other digital and serial data tranducers omor z A A Daughter Board 1 be JER Board 2 i ee Front Rear a EE e e ki 493 10 Chassis Daughter Board 3 e o Daughter Board 4 DETOUR OCUEEUEUEEIECEIII LEE R Ens Front Rear Cable Conduit Model 493 10 793 00 Controller Service 59 Remote Setpoint Adjust Connections Remote Setpoint Adjust Connections 60 A Remote Setpoint Adjust RSA control is an optional stand alone hardware device that uses an incremental or absolute encoder to control actuator setpoints Each RSA control pod requires installation of a Model 493 47 Encoder Interface daughter board on the Model 493 40 I O Carrier board The I O Carrier connector is based on the location of the daughter board installed on the board of the I O Carrier module See Determine installed location on page 204 See Setting Up Remote Setpoint Adjust in the Station Builder chapter of the 793 00 Software manual for more information on configuring your system for RSA use Remote Setpoint Pod es
242. s the defined clock type CLOCK TYPE SLAVE Model 493 10 793 00 Controller Service 1 0 Carrier daughter boards Daughter board ID I O Carrier The I O Carrier daughter boards plug into the Model 493 40 I O Carrier module Each daughter board described below can be assigned to one of the I O Carrier module rear panel connectors J4 J7 I O Transducer connections require a conditioner daughter board be installed in the I O Carrier module The following conditioners can be installed Model 493 21B Digital Universal Conditioner Model 493 25 Digital Universal Conditioner Model 493 47 Encoder Model 493 48 Acceleration Conditioner e Valve connections require a valve driver daughter board be installed in the I O Carrier module The following valve drivers can be installed Model 493 14 Valve Driver Model 493 15 3 Stage Valve Driver e Analog I O connections require an A D or D A daughter board be installed in the I O Carrier module The following analog daughter boards can be installed Model 493 45 A D Converter Model 493 46 D A Converter Each type of daughter board has an identification code labeled as TYPE FILENAME For example e The digital universal conditioner DUC daughter board is identified as TYPE 493 21B FILENAME DUCB_53 OUT e The encoder daughter board is identified as TYPE 493 47 FILENAME ENC_53 OUT e The acceleration conditioner daughter board is identified as
243. s with Station Manager Adjust Program Signal Adjust Feedback Signals Cabling and Programming External Controllers Adjust the outgoing program signal for the required external controller channel Refer to How to Adjust Program Output Signals in Chapter 3 Station Manager of the Model 793 00 System Software manual If you will monitor sensor feedback for data acquisition or control feedback adjust the incoming feedback signals Refer to How to Configure an Externally Conditioned Feedback Signal in Chapter 3 Station Manager of the Model 793 00 System Software manual for more detailed information Task 4 Set up your program Using Function Generator Using Basic TestWare Using MultiPurpose TestWare Define a program with the Function Generator Basic TestWare or Multipurpose TestWare applications Refer to How to Program with the Function Generator in Chapter 3 Station Manager of the Model 793 00 System Software manual The Basic TestWare application allows you to create simple test programs that do not require complex signal management or mode switches for station configuration files Refer to Defining the Test Command in Chapter 4 Basic TestWare of the Model 793 00 System Software manual Note Itis good practice to use tapered wave shapes to apply the program command to the external controller slowly To create more sophisticated test programs use the optional MultiPurpose TestW
244. scale range B Verify that your LVDT displacement signal feedback is approximately equal to 80 of the full scale range 11 Record dial indicator and conditioner feedback readings at predetermined retraction command points Note After shutting down system hydraulics you will enter these recorded readings on the Linearization Data window A Adjust the Manual Cmd slider for a 0 command Record the dial indicator value at 0 command C Record the corresponding conditioner feedback reading at the 0 row of your record sheet D Adjust the Manual Cmd slider for a 2 retraction command Record the dial indicator and conditioner feedback values at the 2 row of your record sheet F Repeat steps D and E for other retraction commands typically at 4 6 8 10 20 40 70 and 100 percent of full scale iw gt f p Model 493 10 793 00 Controller Service 173 Calibrating an LVDT 12 Record conditioner feedback readings at predetermined extension command points A Adjust the Manual Cmd slider for a 2 extension command B Record the dial indicator value and conditioner feedback at the 2 row of your record sheet C Repeat steps A and B for other extension commands typically at 4 6 8 10 20 40 70 and 100 percent of full scale 13 Turn off system hydraulics 14 On the Linearization Data window enter the dial indicator and conditioner feedback values for all c
245. sensor includes one cable with a transducer ID module and a system extension cable A system cable is required between the transducer ID cable and the 493 10 Chassis Model 493 10 793 00 Controller Service 133 Transducer Connections Sensor Cable Part Numbers Sensor cables See the System Cable Jumper Plug 493 Package Selection drawing PN without ID Module 700 000 656 for the most current sensor cable part numbers CABLE DESCRIPTION CABLE MODULE CONNECTOR ADT 120 562348 XX 493 40 J4 J7 300 562531 XX 493 40 J4 J7 Extensometer 633 capacitive 516495 XX 493 40 J4 J7 Force Transducer w PT connector 464402 XX 493 40 J4 J7 w MS connector 464406 XX 493 40 J4 J7 w PC 562529 XX 493 40 J4 J7 LVDT 464403 XX 493 40 J4 J7 AP control 479276 XX 493 40 J4 J7 Pressure Control Sensotec 562530 XX 493 40 J4 J7 Strain w Amphenol connector 562336 XX 493 40 J4 J7 w PT connector 501200 XX 493 40 J4 J7 Temposonics 491532 XX 493 40 J4 J7 Temposonics II low power conditioner 562532 XX 493 40 J4 J7 Temposonics III 563167 XX 493 40 J4 J7 RVDT w MS connector 512028 XX 493 40 J4 J7 134 Model 493 10 793 00 Controller Service Transducer Connections Sensor cables with ID See the System Cable Jumper Plug 493 Package Selection drawing PN Module 700 000 656 for the most sensor cable current part numbers Each sensor includes a cable with an ID module built into it Use a system cable to bridge the se
246. sonics Sensors Temposonics sensors require a Model 493 47 Encoder Interface daughter board to be installed in a Model 493 40 Carrier I O board The Carrier I O connector used depends on the installed location of the daughter board on the board of the Carrier I O module Determine installed To determine the installed location of the Model 493 47 Encoder location Interface use the Hardware tab on the Station Signals window Access Station Signals on the Station Setup window navigation panel Defining an input Defining a Temposonics sensor input signal is no different from any other input signal Use the Station Builder application to allocate a Temposonics sensor to the station configuration file The Station Builder application also assigns units to the signal Feedback Resources labeled Temposonics Input or Temposonics II Input indicate that the optional Temposonics daughter board Model 493 47 Encoder Interface is installed in the Model 493 40 Carrier I O board Abbreviated Procedure Online readers All procedure entries are hypertext links Click on any entry to jump to the corresponding page The following abbreviated procedure outlines a Temposonics sensor calibration process More detailed calibration information is available on the pages listed Task 1 Get things ready on page 211 Task 2 Create a calibration file on page 212 Task 4 Turn on hydraulic pressure on page 213 Task 5 Set th
247. sponse during static or low frequency operation and maintains the mean level at high frequency operation It can offset a DC or steady state error such as that caused by valve imbalance p n Fe ab Droop Reset Too Low Mean Level Stability Reset Too High Excessive Reset A ramp and hold waveform illustrate different levels of reset The I Gain adjustment determines how much time it takes to improve the mean level accuracy Integral gain e Improves mean level response during dynamic operation e Corrects feedback droop caused by the spring characteristic of the servovalve in static and very low frequency test programs e Minimizes the amount of time the system needs to recover from transitions or transients Keep in mind e Higher integral gain settings increase system response e Too much integral gain can cause a slow oscillation hunting e You may want to use the max min display to monitor the mean level reset the display and check it again Model 493 10 793 00 Controller Service 241 About Tuning Derivative gain D Derivative gain is used with dynamic test programs It introduces a derivative of the feedback signal This means it anticipates the rate of change of the feedback and slows the system response at high rates of change Overshoot a Ira TT y iow Needs Rate Optimum Rate Too Much Rate Excessive Rate Derivative gain e Reduces ringing e Provides stability and reduces noise at higher proportional
248. such as those using full range conditioners e g Model 493 25 DUC module In this case only one range is used typically 100 Note Sensor calibration and range information can be edited on the Sensor tab located on the Station Setup window Inputs panel See How to Create a Sensor File in Chapter 3 Station Manager of the Model 793 00 System Software manual for a detailed procedure For force sensor calibration set the following initial conditioner calibration values Control Setting Polarity Normal Pre amp Gain 250 480 for Model 493 25 conditioner Post amp Gain 2 1 for Model 493 25 conditioner Total Gain 500 Excitation 10 volts Fine Zero 0 Zero Balance 0 Delta K 1 Model 493 10 793 00 Controller Service Calibrating a Force Sensor Task3 Assign a calibration file This task links a sensor calibration file created in Task 2 to a hardware resource The purpose for this is to select one of the sensor ranges for the input signal definition See How to Assign a Sensor File in Chapter 3 Station Manager of the Model 793 00 System Software manual for a detailed procedure iw gt gt f i Model 493 10 793 00 Controller Service 181 Calibrating a Force Sensor Task 4 Turn on hydraulic pressure AN 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
249. tation Signals panel C Adjust the Manual Cmd slider to fully retract the actuator and note the displacement signal value in the Station Signals panel The noted signal values should be within 1 of each other iw gt gt f Model 493 10 793 00 Controller Service 163 Calibrating an LVDT If not you can evaluate the following procedures to establish the zero reference e Use the Fine Zero adjustment on the Calibration tab to shift the sensor conditioner s zero reference position Note Some conditioners have two zero adjustments coarse and fine Try to calibrate zero using only the Fine Zero control whenever possible Using the Coarse Zero control affects the signal before the post amp stage of the conditioner and may require additional Gain adjustments e In some cases a mechanical adjustment may be necessary to center the LVDT for instructions see the actuator product manual S bd K o 164 Model 493 10 793 00 Controller Service Calibrating an LVDT Task8 Gain Delta K Calibration If you are using Gain Delta K for your calibration type complete the following procedure If not complete Task 9 Gain Linearization Calibration on page 169 Calibrate actuator LVDTs can be retraction calibrated so that a ees positive output Indicated output JAY AK et represents actuator i extension and a negative output represents actuator retraction or vice versa me
250. ters following the list of valve command signals CHANNEL 13 NAME Analog Input 1 CONNECTOR J14 lt q This block defines an analog input signal It will always be listed as a channel in an A D The name in quotes This connector is daughter board appears in the Station located on the ADDA II Builder application as a front panel system resource This block defines an analog output signal It will always CHANNEL 5 NAME Analog Output 1 CONNECTOR J18 be listed as a channel ina D A daughter board DSPAD The Model 493 57 DSPAD daughter card available for installation on ADDA II modules provides 8 channels of A D with digital filtering A DSPAD hwi definition is shown below Note that for DSPAD cards the FILTER should be set to ON Filter cut off frequency DAUGHTER 2 ADDRESS 0x2 TY PE 493 57 FILTER ON CHANNEL 9 NAME Analog Input 56k 1 CONNECTOR J13 FILTER ELLIP4 500 CHANNEL 10 NAME Analog Input 56k 2 CONNECTOR J13 FILTER ELLIP4 1000 CHANNEL 11 NAME Analog Input 56k 3 CONNECTOR J13 FILTER ELLIP4 1500 CHANNEL 12 NAME Analog Input 56k 4 CONNECTOR J13 FILTER ELLIP4 2000 CHANNEL 13 NAME Analog Input 56k 5 CONNECTOR J14 FILTER OFF CHANNEL 14 NAME Analog Input 56k 6 CONNECTOR J14 FILTER OFF CHANNEL 15 NAME Analog Input 56k 7 CONNECTOR J14 FILTER OFF CHANNEL 16 NAME Analog Input 56k 8 CONNECTOR J14 FILTER OFF 294 Model 493 10 793 00 Controller Service ADD
251. the Plug in Modules Installing the Plug in Modules 30 This section describes how to install the plug in modules into the chassis The modules plug into a backplane connector and are secured to the chassis with a screw at the top and at the bottom of the module faceplate A hardware interface file hwi defines each type of module and maps each module location for the system software The hwi file and the physical locations for each type of module must match Recommended standard module locations are described in the following sections For more information on the hwi file see The HWI File on page 283 A The plug in modules contain static sensitive components Improper handling of the module can cause component damage Be sure to follow these precautions when handling modules e Turn off electrical power before installing or removing a module e Use a static ground strap to ground yourself to the chassis ground before touching the chassis or a module e Keep unused modules in conductive bags Also be sure you are grounded when removing a module from a conductive bag e Handle modules with their front panel or circuit card edges Do not touch any circuit card components pins or circuit connection points EE Model 493 10 793 00 Controller Service Installing the Plug in Modules VMEbus Modules The VMEbus compatible modules should be installed in the front panel chassis slots according to the following guidelines
252. the following control modes e Displacement control e Force control e Strain control Command sources The program command source can come from an internal source such as the Function Generator or the MultiPurpose TestWare application or from an external device such as an external profiler or function generator 236 Model 493 10 793 00 Controller Service About Tuning CLC control mode Channel limited channel CLC control modes are used for specimen installation and removal Channel limited channels require two feedback signals See How to Tune a CLC Control Mode in Chapter 5 Tuning of the Model 793 00 System Software Manual for a detailed CLC tuning procedure Displacement control A length control mode also called displacement or stroke control uses the LVDT sensor in the actuator as the controlling feedback source e The length control mode only needs to be tuned once e Does not need a specimen installed for tuning e Displacement control uses a square wave when tuning an LVDT but not when tuning a displacement gage e If gain is too low there may not be any actuator movement e If gain is too high the actuator will move quickly and noisily Force control Force control uses a force sensor also called a load cell as the controlling feedback source e Tune for each type of specimen or any changes in the force train e Force control requires a specimen to be installed e Force control uses a ramp wavefo
253. tion as a system ae The board address determines resource You can edit this if you want the connector that must be specified here Model 493 10 793 00 Controller Service 303 Acceleration conditioner signals Acceleration conditioner signals On systems affected by acceleration induced errors an optional acceleration conditioner board can be linked to a DC conditioner DUCB only to perform load washing 2 x t e The acceleration conditioner definition specifies a list of auxiliary inputs that the DUC conditioners can use on the acceleration daughter board Each DUC daughter board definition is enhanced to allow an auxiliary input to be defined e The load washer configuration will be identified by additional text following the desired DUC definition The first entry is RANGES It must be placed after the FILTER definition or after the MODE definition if no filter selection is specified It can also be placed after the AUXILIARY INPUT definition if acceleration conditioning is used e Following the RANGES entry the digital outputs to be controlled are listed They will be strings prefaced with RANGE rangeName The rangeName can be any string but must match the range name given to the range in the sensor file 304 Model 493 10 793 00 Controller Service Acceleration conditioner signals DAUGHTER 2 ADDRESS 0x00000 TY PE 493 48 FILENAME NONE Defines the _ W CHANNEL 1 NAME 493 48 Accel 1 CONNECT
254. to a non compliant HPU can damage the module DO NOT connect 24 V DC relay circuitry or 115 V AC circuitry to the HPU connector J25 The Service LED turns on when electrical power is applied and it turns off when the chassis makes contact with the personal computer J25 HPS is a 15 pin type D male connector e 15 contact type D female EMI connector e Cable 24 AWG 10 conductor with overall foil shield Carol C0745 or equivalent with drain wire connected to metallized plastic backshell to the chassis If connector J25 HPS is not used you must install a jumper plug to maintain the integrity of the interlocks Use jumper plug 397133 01 or jumper pins 1 7 2 3 5 6 9 8 10 11 12 Model 493 10 793 00 Controller Service Hydraulic Power Unit Connection To From J25 To From Chassis HPU HPSOn Sense T 9 me i fv ee 10 P gt ZX QverTemp Ia nm i N Low Level 12 la X HPS 24 Vdc o 1 SER Bee Een is i CRM X Start mie gt 2 Os Lo 3 Seo SE ERE NE eee Motor i i Relay Wy 1 1 High Hi Pressure TE RE gt 4 Sie Solenoid To J24 pin 13 5 O 24Vdc E stop 5 HPS Interlock To J29 pin8 6 CRM TER YZ Controller 24 Vdc O gt 7 HPS Defeat Voltage not connected in HPS S Model 493 10 793 00 Controller Service 69 Hydraulic Power Unit Connection Syst
255. to change conditioner polarity for example when moving a sensor to a different test system the sensor may need to be recalibrated Select Gain Linearization for Cal Type on the Calibration tab of the Inputs panel Exercise the force standard Use the Manual Cmd slider on the Manual Command window to cycle the load standard readout between zero and full tension three times This removes sensor hysteresis Example When calibrating a 10 KN range exercise the actuator between 0 and 10 volts To calibrate the same force sensor for a different range such as 5 kN exercise the load standard between 0 and 5 volts Apply a tensile force command that is 80 of the range s full scale A Adjust the Manual Cmd slider for a tensile force command that is 80 of the full scale range B Verify that your force transducer feedback signal is 80 of the full scale range During the initial calibration and tuning of your system it may require repeated adjustment for the tensile force command and feedback values to match Note _ f the actuator response is sluggish and or the feedback signal value does not match the command you will need to adjust the tuning of this control mode Increase the proportional gain P Gain on the Model 493 10 793 00 Controller Service Calibrating a Force Sensor Adjustments tab of the Tuning panel to correct sluggish actuator movement Increase the reset integration value I Gain to help the feedback
256. tuning when initially installing a system or fine tuning a system that employs 3 stage valve drivers The inner loop proportional gain and rate derivative adjustments are the same types of adjustments as used with the PIDF tuning controls Note During initial system installation inner loop gain and rate adjustments must be performed before tuning the servo outer loop For fine tuning an initial inner loop gain adjustment may be needed if the outer loop is sluggish The inner control loop is similar to a displacement control mode for the outer loop The Model 493 15 Three Stage Valve Driver module includes the electronics necessary to support the inner control loop Feedback Outer Loop Hydraulic Power Supply Signal Program Command 493 15 Valve Driver Always tune the inner loop without the hydraulics applied to the actuator Perform the inner loop gain adjustments with hydraulic pressure removed from the main spool while maintaining pressure at the pilot stage This prevents interaction between the inner and outer loops For a detailed inner loop tuning procedure refer to How to Tune the Inner Loop of Three Stage Valves in Chapter 5 Tuning of the Model 793 00 System Software manual Model 493 10 793 00 Controller Service 119 N 1 lt i lt lt O i z mh gt 2 i ih Ez gt i gt k nn Tuning t
257. tween 0 5 Hz and 20 Hz the upper frequency is user definable Note The advanced auto tuner will reduce the sweep amplitude if it detects the valve opening more than 50 The advanced tuner calculates the tuning parameters according to the tracking level you define In order to achieve a successful level of advanced auto tuning the sine sweep must create a phase shift between the command and compensated command of more than 90 for 0 tracking or more than 135 for 100 tracking You can monitor the advanced tuner command and compensated command on the scope The Current column displays your current PIDF gain values When auto tuning completes successfully the calculated tuning parameters are loaded into the New Values column on the Auto Tuning control panel You can click Accept to transfer the auto tuned values New Values to the Current column and the tuning Adjustments tab Model 493 10 793 00 Controller Service Auto tuning How to Auto Tune Control Modes Auto tune the displacement control mode Auto tune the force control mode How to improve auto tuning results First auto tune the displacement control mode Then install a dummy specimen and auto tune the force control mode See How to Auto Tune Control Modes in Chapter 5 Tuning of the Model 793 00 System Software manual for a detailed procedure See How to Auto Tune Control Modes in Chapter 5 Tuning of the Model 793 00 System Software manual
258. ues given Pre Amp gain is a selectable gain amplifier with predefined values Since changes in Pre Amp gain can cause spikes in the feedback signal Pre Amp gain can only be adjusted when hydraulics are off Post Amp gain is a finer operator defined gain control that can be adjusted when hydraulics are on The Total gain value is calculated by multiplying the Pre Amp and Post Amp gain values If the total desired gain amount is known from a calibration sheet you can enter the amount in the Total gain box Model 493 10 793 00 Controller Service 185 iw gt gt f i Calibrating a Force Sensor and the software will calculate the Pre Amp and Post Amp gain values automatically When you are calibrating an DC conditioner use the Post Amp gain control to increase gain If more gain is needed you must disable hydraulics and increase the Pre Amp gain You can then turn on hydraulics and continue to adjust the Post Amp gain slider 1 Exercise the force standard Use the Manual Cmd slider on the Manual Command window to cycle the load standard readout between zero and full tension three times This removes sensor hysteresis Example When calibrating a 10 kN range exercise the actuator between 0 and 10 volts To calibrate the same force sensor for a different range such as 5 kN exercise the load standard between 0 and 5 volts 2 Apply a tensile force command that is 80 of the range s full scale
259. umper plugs are required if a cable is not installed The connector is the 10 100 BaseT connector on the power PC module Sensor cables PART MODULE JUMPER NumseR CONNECTOR Plug Remote Station Control with E Stop 556342 XX 493 71 J50 556341 01 Remote Station Control with Station Stop 556343 XX 493 71 J50 556341 01 Workstation Link Ethernet cable 519968 XX 10 100 N A Remote Setpoint Adjust Control 100 051 058 493 40 J4 J7 N A XX specifies cable length 01 through 09 represent 10 50 ft in 5 ft increments Higher numbers See Sensor Cables on page 133 for sensor cable part numbers Sensor cables both with and without ID modules are described Also see the System Cable Jumper Plug 493 Package Selection drawing PN 700 000 656 for the most current part numbers Model 493 10 793 00 Controller Service I O Carrier Connections 1 0 Carrier Connections Each Model 493 40 I O Carrier module can include up to four daughter boards Each installed daughter board is assigned a specific I O Carrier module front panel connector J4 J7 I O A hardware interface file hwi defines each type of module and their associated daughter boards and maps each module location for the system software The hwi file and the physical locations for each type of module and associated daughter boards must match Also the I O Carrier module address setting on the module must match the hwi file address For more information on the
260. un stop status of the controller to external devices e Two form C contacts provide the run stop status e The contacts are rated 1 0 A at 30 V AC or DC From J44 To Chassis External Devices A jt 2 L Run Stop 0 L 3 _ 4 v _ Interlock Status T gt K Output 5 A a e 7 Run Stop 1 8 Interlock status Connector J44 Run Stop also provides opto isolator outputs that indicate the interlock status of each station to an external device These interlock status outputs are normally on and will turn off when an interlock occurs See Digital outputs on page 81 for detailed circuit drawings Output specifications The specifications for the interlock status opto isolator outputs are as follows e Output Format open collector open emitter transistor e Maximum Voltage 26 Vdc e Minimum Guaranteed Output Current Drive 20 mA 30 mA typical 1 0 V max 76 Model 493 10 793 00 Controller Service Station Connections Jumper X9 Jumper setting X5 selects the source for interlock status output The following jumper settings select the indicated interlock source e X5 Jumpered HSM Board Interlocks Only e X5 Not Jumpered Station and HPU Interlocks Jumpers W8 W9 Jumper settings W8 W9 determine the output polarity of the opto isolators Cable specification e 9 contact type D female EMI connector e Backshell EMI metallized plastic e Cable shielded twisted pairs
261. unt calibration reference on page 228 Task 9 Save the calibration settings on page 230 Task 10 Calibrate any additional ranges on page 230 iw gt gt f i Model 493 10 793 00 Controller Service 215 Calibrating an Extensometer Task1 Get things ready 1 Review Before You Begin on page 147 2 Locate all relevant documentation including information about the extensometer such as the serial number model number etc 3 Open a station configuration file You need a station configuration file that includes a control channel with a control mode that uses the extensometer you intend to calibrate On the File menu click Open Station to open the appropriate configuration file 4 Enter the Calibration password You must access the Calibration user access level before you can perform any of the calibration procedures On the Station Manager toolbar select the Calibration user level on the Access Level list 5 Set up a signal monitor Note You cannot monitor the output of a new sensor until a sensor calibration file has been created and the sensor assigned to an input signal You will be monitoring strain feedback when making adjustments throughout this procedure You can monitor strain feedback in the same units that you are using for the calibration You can use an external DVM to monitor strain feedback from a BNC connector on the Analog Out panel located on your co
262. ust access the Calibration user access level before you can perform any of the calibration procedures On the Station Manager toolbar select the Calibration user level on the Access Level list Type the required password By default the password is Calibration however it can be changed during the software installation procedure 4 Set up a signal monitor Note You cannot monitor the output of a new sensor until a sensor calibration file has been created and the sensor assigned to an input signal You will be monitoring encoder output when making adjustments throughout this procedure You can monitor the encoder output in the same units that you are using for the calibration You can use an external DVM to monitor encoder output from a BNC connector on the Analog Out panel located on your controller chassis If you do not have an Analog Out panel use the Meters window or Station Signals panel to monitor sensor output On the Station Manager Display menu select Station Setup In the navigation pane select Station Signals to display the Station Signals panel to monitor current values for user defined signals S bd K o 206 Model 493 10 793 00 Controller Service Calibrating Encoders Task2 Create a calibration file Setting encoder resolution Note Ifyou already have a sensor calibration file skip this task This task creates a sensor calibration file and sets up any ranges you may want An encoder
263. value does not match the command you will need to adjust the tuning of this contro mode Increase the proportional gain P Gain on the Adjustments tab of the Tuning panel to correct sluggish actuator movement Increase the reset integration value I Gain to help the feedback match the command iw gt f p i Model 493 10 793 00 Controller Service 187 Calibrating a Force Sensor At this point unless the conditioner is already in calibration the compressive force applied to the force transducer will not equal your commanded value You will adjust Delta K in the next step so that the actual compressive force and your commanded compressive force match Example Suppose your actuator has a 100 compressive force rating of 10 kN In this step you would apply 8 kN of command and even though the station signals would read 8 kN of feedback the force standard may only read 4 kN This shows the conditioner sensor pair are out of calibration 3 Adjust Delta K until the actual compressive force equals your compressive force command Adjust the Delta K control on the Calibration tab to increase the compressive force reading on the load standard until it equals your compressive force command 4 Repeat steps 2 and 3 for all ranges Example Suppose you have an actuator with a full scale capacity of 10 kN and ranges of 10 kN 5 kN 2 kN and 1 KN In this case you would repeat this process and calibrate compress
264. ved without going unstable and the end levels are repeatable simply increase the command to achieve the desired end levels Monitoring the The error signal shows similar characteristics as a feedback signal The error signal error signal represents the difference between the command and sensor feedback The following diagrams show the error signal characteristics for each type of waveform A square waveform is best suited to view the overshoot and ringing characteristics that occur when tuning a system Review the following waveforms to determine the kind of characteristics that can be found in an error signal Model 493 10 793 00 Controller Service 251 About Tuning The error signal from a square wave should show the feedback ringing centered on the zero reference A static accuracy difference in the error signal can be corrected with reset The square wave shape of the error signal represents the phase lag of the feedback signal The error signal from a sine should be a small amplitude sine waveform that looks like a rounded square waveform 252 Command Feedback Static Zero i 4 Accuracy Fi Difference Error Signal Feedback D ra Following Error Zer tami Difference Error Signal Command rs Feedback Actuator P Friction Zero 3 AY zZ Error Signal Model 493 10 793 00 Controller Service About Tuning Using the If you do not have an oscilloscope use the controller
265. vice 89 Cabling and Programming External Controllers Single 407 Controller Connections Transition modules on the rear panel of the Model 493 10 chassis are used for analog inputs and outputs 493 76 Analog Out This module includes 6 BNC connectors that provide analog outputs from a Model 493 46 D A daughter card Six analog outputs are available with each D A daughter card installed on the Model 493 40 I O Carrier module 90 493 76 Analog Out PN 044 632 0XX 407 Controller FE 493 77 Filtered Analog Input This module includes 6 BNC connectors that provide filtered analog inputs to a Model 493 45 A D daughter card Six analog inputs are available with each A D daughter card installed on the Model 493 40 I O Carrier module Model 493 10 793 00 Controller Service Cabling and Programming External Controllers Multiple 407 Controller Connections Conditioner Conditioner Monitor Monitor 493 76 Analog Out Program In Aa ee E rom Conditioner Conditioner Monitor Monitor va Program In p es Conditioner Conditioner By Monitor Monitor R a SEE GM Model 493 10 793 00 Controller Service 91 Cablin
266. whenever any of the following events occurs e lt 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 Jfa 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 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 Checklist Use this checklist when you tune a system You need to determine the following e What type of control mode do you wish to tune Read Control Mode Characteristics on page 236 e What controls should you use Read How the Tuning Controls Work on page 239 e What kind of a tuning program should you use Read Creating a Tuning Program on page 246 e Do you have a dummy specimen Read Other Considerations on page 249 e Where d
267. y the following in the order given e Connect the system chassis ground of the external device directly to the controller chassis e Disconnect the overall shield from the metallized back shell at the external device and add a capacitor approximately 0 01 uf to one end of the cable between the shield and the metallized backshell e Disconnect the overall shield from the metallized back shell at the external device Model 493 10 793 00 Controller Service 41 Typical Cabling Typical Cabling Other cables are available see Cable Part Numbers on page 43 PU Workstation 397137 xx 519968 xx 397083 xx Servovalve 561265 xx Load Unit Control p a 561264 xx UI ar Actuator ea ee Manifold a s HSM 556342 xx E stop or 556343 xx Station Stop Front Rear Remote Station Control Connectors with Transducer ID modules 525431 xx LVDT 525442 xx Jame Force Sensor 525425 xx 525442 xx 42 Model 493 10 793 00 Controller Service Cable Part Numbers Cable Part Numbers System cables The following is a list of the most common cables see the System Cable Jumper Plug 493 Package Selection drawing MTS part number 700 000 656 for the most current and additional cable part numbers CABLE DESCRIPTION PART MODULE JUMPER NUMBER CONNECTOR pyuct

Model 493.10/793.00 Controller Service Manual

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