Document Outline

• Contents
• Technical Support
  • How to Get Technical Support
  • Before You Contact MTS
  • If You Contact MTS by Phone
  • Problem Submittal Form in MTS Manuals
• Preface
  • Before You Begin
  • Conventions
    • Documentation Conventions
• Safety Information
  • Intended Use of MTS Series 494 Controllers
  • EC Declaration of Conformity for MTS Models 494.04 (FlexTest 40), 494.06 (FlexTest 60), 494.10 (FlexTest 100) and 494.20 (FlexTest 200)
  • Waste Electrical and Electronic Equipment (WEEE) Considerations
  • Safety Circuits
    • Shock Hazards
    • Input/Output Verification
    • E-Stop Circuits
    • E-Stop Circuit Testing
    • Hardware Interlocks
    • E-Stop and Hardware Interlocks
• FlexTest Controller Configurations
  • FlexTest Controller Overview
    • About MTS FlexTest Models 40/60/100/200 Controllers
    • Typical Series 494 Chassis Connections (FT60, FT100, FT200)
  • Installation
    • Controller Installation Procedure
    • Installation Requirements–Series 494 Hardware
    • Environmental Requirements—Series 494 Hardware
    • Ventilation Requirements–Series 494 Chassis
    • Rack-Mounting Requirements–Series 494 Chassis
    • Grounding Requirements–Series 494 Chassis
    • AC Power Disconnect Requirements–Series 494 Chassis
    • Cable Requirements–Series 494 Hardware
    • UPS System Requirements
      • UPS Systems for FlexTest 60, 100, 200, and GT Controllers
      • UPS Systems for FlexTest 40 and FlexTest SE Servocontrollers
      • Specifications–UPS Systems Used with MTS Controllers
      • Controller P0 Interlock Check Utility
  • FlexTest 40 Controller Configuration
    • About the FlexTest 40 Controller
    • About the Model 494.04 Chassis
    • Specifications–Model 494.04 Chassis
    • Model 494.04 Chassis Boards
    • Typical Model 494.04 Chassis Connections
    • Model 494.41 Single-Station System Board
      • About the Model 494.41 Single-Station System Board
      • Model 494.41 System Board Specifications
      • J24 Emergency Stop Connections for the Model 494.41 System Board
      • J25 Hydraulic Power Unit Connections for the Model 494.41 System Board
      • J28 HSM Connections for the Model 494.41 System Board
      • J29 Emergency Stop Connections for the Model 494.41 System Board
      • J43 Interlock Connections for the Model 494.41 System Board
      • J49 Auxiliary Power Connections for the Model 494.41 System Board
      • J54 Digital Input Connections for the Model 494.41 System Board
      • J55 Digital Output Connections for the Model 494.41 System Board
      • Analog Output Connections for the Model 494.41 System Board
      • UPS Connections for the Model 494.41 System Board (FT40)
    • Model 494.42 Single-Station System Board
      • About the Model 494.42 Single-Station System Board
      • Model 494.42 System Board Specifications
      • J23 E-Stop/Run Output Connections for the Model 494.42 System Board
      • J24 Emergency Stop Connections for the Model 494.42 System Board
      • J25 Hydraulic Power Unit Connections for the Model 494.42 System I/O Board
      • J28 HSM Connections for the Model 494.42 System Board
      • J29 Load Frame Connections for the Model 494.42 System Board
      • J43 Interlock Connections for the Model 494.42 System Board
      • J49 Auxiliary Power Connections for the Model 494.42 System Board
      • J54 Digital Input Connections for the Model 494.42 System Board
      • J55 Digital Output Connections for the Model 494.42 System Board
      • J56 UPS Input Connections for the Model 494.42 System Board
      • Analog Output Connections for the Model 494.42 System Board
    • Model 494.44 Two-Station System Board
      • About the Model 494.44 Two-Station System Board
      • Model 494.44 System Board Specifications
      • J23 E-Stop/Run Output Connections for the Model 494.44 System Board
      • J24 Emergency Stop Connections for the Model 494.44 System Board
      • J25 Hydraulic Power Unit Connections for the Model 494.44 System I/O Board
      • J28 HSM Connections for the Model 494.44 System Board
      • J29 A/B Load Frame Connections for the Model 494.44 System Board
      • J43 A/B Interlock Connections for the Model 494.44 System Board
      • J49 Auxiliary Power Connections for the Model 494.44 System Board
      • J54 Digital Input Connections for the Model 494.44 System Board
      • J55 Digital Output Connections for the Model 494.44 System Board
      • Analog Output Connections for the Model 494.44 System Board
      • UPS Connections for the Model 494.44 System Board (FT40)
  • FlexTest 60 Controller Configuration
    • About the FlexTest 60 Controller
    • About the Model 494.06 Chassis
    • Specifications–Model 494.06 Chassis
  • FlexTest 100 Controller Configuration
    • About the FlexTest 100 Controller
    • About the Model 494.10 Chassis
    • Specifications–Model 494.10 Chassis
  • FlexTest 200 Controller Configuration
    • About the FlexTest 200 Controller
    • About the Model 494.20 Chassis
    • Transition Boards (Aero Structural Test Systems)
    • Specifications–Model 494.20 Chassis
    • Model 494.20 Chassis 24 V DC Output
• VME Bus Boards
  • VME Bus Board Overview
    • About VME Bus Boards
    • System Update Rates
    • How to Install and Remove a VME Bus Board
  • Processor Connections
    • Computer Workstation Connections
    • Wago Ethernet TCP/IP FieldBus Coupler Connections
  • Model 494.40 I/O Carrier Board
    • About the Model 494.40 I/O Carrier Board
    • How to Set Up a Model 494.40 I/O Carrier Board
    • Model 494.40 I/O Carrier Board Settings
    • How to Set the Model 494.40 I/O Carrier Board Address
    • How to Install a Shunt-Calibration Resistor on an I/O Carrier Board
    • How to Install a Bridge-Completion Resistor on an I/O Carrier Board
  • Model 494.43 Multibox Board
    • About the Model 494.43 Multibox Board
    • Specifications–Model 494.43 Multibox Board
    • J8 Interlock In Connections for the Model 494.43 Multibox Board
    • J9 Interlock Out Connections for the Model 494.43 Multibox Board
    • J51 Box In Connections for the Model 494.43 Multibox Board
    • J52 Box Out Connections for the Model 494.43 Multibox Board
• Mezzanine Cards
  • About Mezzanine Cards
  • How to Install a Mezzanine Card
  • How to Remove a Mezzanine Card
  • Digital Universal Conditioner Mezzanine Cards
    • About Digital Universal Conditioners
    • Digital Universal Conditioner (DUC) Features
    • Specifications–Digital Universal Conditioner (DUC)
    • Digital Universal Conditioner (DUC) Bridge Connections
    • Digital Universal Conditioner (DUC) LVDT Connections
    • How to Set Up a Digital Universal Conditioner (DUC)
    • Model 494.25 Single DUC Card
      • About the Model 494.25 Single DUC Card
      • Model 494.25 Single DUC Card Settings
      • Model 494.25 Single DUC Card Pin Assignments
    • Model 494.26 Dual DUC Card
      • About the Model 494.26 Dual DUC Card
      • Model 494.26 Dual DUC Card Settings
      • Model 494.26 Dual DUC Card Pin Assignments
    • Model 494.16 VD/DUC Mezzanine Card
      • About the Model 494.16 VD/DUC Card
      • Model 494.16 Valve Driver Features
      • Specifications–Model 494.16 Valve Driver Card
      • How to Set Up a Model 494.16 VD/DUC Card
      • Model 494.16 VD/DUC Card Settings
      • Model 494.16 VD/DUC Card Pin Assignments
      • Two-Stage Servovalve Connections for the Model 494.16 VD/DUC Card
      • Three-Stage Servovalve Connections for the Model 494.16 VD/DUC Card
    • Model 494.21 Multi-Range DUC with Acceleration Compensation Card
      • About the Model 494.21 Multi-Range DUC /Acceleration Compensation Card
      • Specifications–Model 494.21 Multi-Range DUC/Acceleration Compensation Card
      • Model 494.21 Multi-Range DUC/Acceleration Compensation Card Settings
      • Model 494.21 Multi-Range DUC/Acceleration Compensation Card Pin Assignments
      • Model 494.21 Multi-Range DUC/Acceleration Compensation Card Configuration
  • Model 494.45 8-Input A/D Converter Card
    • About the Model 494.45 8-Input A/D Card
    • Specifications–Model 494.45 8-Input A/D Card
    • Model 494.45 8-Input A/D Card Pin Assignments
    • Model 494.45 8-Input A/D Card Connections
  • Model 494.46 8-Output D/A Card
    • About the Model 494.46 8-Output D/A Card
    • Specifications–Model 494.46 8-Output D/A Card
    • Model 494.46 8-Output D/A Card Pin Assignments
    • Model 494.46 8-Output D/A Connections
  • Model 494.47 Dual UART/Encoder Interface Card
    • About the Model 494.47 Dual UART/Encoder Card
    • Specifications–Model 494.47 Dual UART/Encoder Card
    • UART Pin Assignments for the Model 494.47 Dual UART/Encoder Card
    • UART Connections for the Model 494.47 Dual UART/Encoder Card
    • Incremental Encoder/Counter Pin Assignments for the Model 494.47 Card
    • Incremental Encoder Connections for the Model 494.47 Card
    • Counter Connections for the Model 494.47 Card
    • SSI Encoder Pin Assignments for the Model 494.47 Card
    • SSI Encoder (Temposonics R) Connections for the Model 494.47 Card
    • Pulse-Width-Modulated Output Pin Assignments for the Model 494.47 Card
    • Pulse-Width-Modulated (PWM) Connections for the Model 494.47 Card
    • External Clock Connections for the Model 494.47 Card
  • Model 494.49 Quad Encoder Interface Card
    • About the Model 494.49 Quad Encoder Interface Card
    • Specifications–Model 494.49 Quad Encoder Interface Card
    • Model 494.49 Quad Encoder Interface Card Connections
    • Incremental Encoder/Counter Pin Assignments for the Model 494.49 Card
    • Incremental Encoder Connections for the Model 494.49 Card
    • Counter Connections for the Model 494.49 Card
    • SSI/Gurley Encoder Pin Assignments for the Model 494.49 Card
    • SSI/Gurley Encoder (Temposonics R) Connections for the Model 494.49 Card
    • PWM Input Pin Assignments for the Model 494.49 Quad Encoder Card
    • Temposonics G Connections for the Model 494.49 Quad Encoder Card
    • External Clock Connections for the Model 494.49 Quad Encoder Card
  • TEDS Transducer ID Module
    • About the TEDS Transducer ID Module
• Digital I/O and Transition Boards
  • Digital I/O Hardware Devices
    • About Digital I/O Hardware
    • Model 493.72 Digital I/O Board
      • About the Model 493.72 Digital I/O Board
      • Specifications–Model 493.72 Digital I/O Board
      • How to Change the Debounce Settings on the Model 493.72 Digital I/O Board
    • Model 493.31 16-Channel Low-Current DI/O Breakout Box
      • About the Model 493.31 DI/O Breakout Box
      • Digital I/O Connections for the Model 493.31 DI/O Breakout Box
      • Digital Input Connections for the Model 493.31 DI/O Breakout Box
      • Digital Output Connections for the Model 493.31 Breakout Box
    • Model 494.31 16-Channel High-Current DI/O Breakout Box
      • About the Model 494.31 DI/O Breakout Box
      • Specifications–Model 494.31 DI/O Breakout Box
      • Digital I/O Connections for the Model 494.31 DI/O Breakout Box
      • Digital Input Connections for the Model 494.31 DI/O Breakout Box
      • Digital Output Connections for the Model 494.31 Breakout Box
    • Model 494.32 8-Channel DI/O Breakout Box
      • About the Model 494.32 DI/O Breakout Box
      • Specifications–Model 494.32 DI/O Breakout Box
      • Power Connections for the Model 494.32 DI/O Breakout Box
      • Digital Input Connections for the Model 494.32 DI/O Breakout Box
      • Digital Output Connections for the Model 494.32 DI/O Breakout Box
    • Model 494.33 Digital I/O Power Supply
      • About the Model 494.33 Digital I/O Power Supply
      • Specifications–Model 494.33 DI/O Power Supply
      • Fuse Replacement—Model 494.33 DI/O Power Supply
      • Circuit Breaker Reset—Model 494.33 DI/O Power Supply
      • Overtemperature Reset—Model 494.33 DI/O Power Supply
      • Power Connections for the Model 494.31 DI/O Breakout Box
      • Power Connections for the Model 494.32 DI/O Breakout Box
  • Transition Boards
    • About Transition Boards
    • Model 493.73 HPU Interface Board
      • About the Model 493.73 HPU Interface Board
      • Specifications–Model 493.73 HPU Interface Board
      • J23 E-Stop Output Connections for the Model 493.73 HPU Interface Board
      • J24 E-Stop Input Connections for the Model 493.73 HPU Interface Board
      • J25 HPU Connections for the Model 493.73 HPU Interface Board
      • J54 DI/O Connections for the Model 493.73 HPU Interface Board
      • UPS Connections for the Model 493.73 HPU Board (FT60, FT100, FT200, FTGT)
    • Model 493.74 Two-Station HSM Interface Board
      • About the Model 493.74 Two-Station HSM Interface Board
      • Specifications–Model 493.74 Two-Station HSM Board
      • J28 HSM Connection for the Model 493.74 HSM Board
      • J28 Proportional HSM Output Configuration
      • J29 Load Frame Connections for the Model 493.74 HSM Board
      • J43 Interlock Connections for the Model 493.74 HSM Board
      • J44 Run/Stop Connections for the Model 493.74 HSM Board
      • J49 Auxiliary Power Connections for the 493.74 HSM Board
    • Model 493.80 Encoder Interface Board
      • About the Model 493.80 Encoder Interface Board
      • Specifications–Model 493.80 Encoder Interface Board
      • Power Settings for the Model 493.80 Encoder Interface Board
      • Jumper Settings and Locations for the Model 493.80 Encoder Interface Board
      • Mode Settings for the Model 493.80 Encoder Interface Board
    • Model 494.74 Two-Station HSM Interface Board
      • About the Model 494.74 Two-Station HSM Interface Board
      • Specifications–Model 494.74 Two-Station HSM Interface Board
      • J3 Interlock Connections for the Model 494.74 HSM Board
      • J28 HSM Connections for the Model 494.74 HSM Board
      • J49 Auxiliary Power Connections for the Model 494.74 HSM Board
    • Model 494.75 8-Input BNC Transition Board
      • About the Model 494.75 8-Input BNC Transition Board
    • Model 494.76 8-Output BNC Transition Board
      • About the Model 494.76 8-Output BNC Transition Board
    • Model 494.79 8-Channel Valve Driver Board
      • About the Model 494.79 8-Channel Valve Driver Board
      • Specifications–Model 494.79 8-Channel Valve Driver Board
      • Model 494.79 8-Channel Valve Driver Board Pin Assignments
      • Two-Stage Servovalve Connections for the Model 494.79 Valve Driver
  • Model 493.07 HPU Converter Box
    • About the Model 493.07 Converter Box
    • Connections for the Model 493.07 Converter Box
• Cables
  • Series 494 Cable Part Numbers
  • How to Identify Series 494 RJ-50 Connectors
  • Series 494 Cable Connections
• Troubleshooting and Maintenance
  • Chassis Troubleshooting
    • J39 Service Test Points
    • Overcurrent Protection for Series 494 Hardware
    • How to Reset the Chassis Circuit Breaker
    • How to Correct Over Temp Conditions
    • Service Connections
      • About Service Connections
  • Chassis Maintenance
    • How to Clean the Chassis
    • How to Clean the Air Filter
• Optional Station Configurations
  • About Optional Station Configurations
  • Six-Station Configurations
  • Eight-Station Configurations
• Aero Multibox Systems
  • Aero Multibox Overview
    • About Multibox Systems
    • Multibox Hardware
    • Processor Memory Module Compatibility
    • AeroPro Workstation Requirements
    • Add HPU and HSM Boards to the Master Controller Box
    • Reflective Memory Module Node Address Jumper Settings
    • Multibox Processor Settings
    • Multibox Chassis Address Settings
    • Verify the I/O Carrier Address Settings
    • Connect Multibox Hardware (dual processors)
    • Connect Multibox Hardware (single 7100 processor)
    • Single-Box Multibox Chassis Connections
    • Multibox Network Address Settings
    • Delete the Old Single-Box Controller Folder
    • Install System Controller Files
    • Use the CMT to Configure the Controller
    • Reboot the Controllers
    • Use the CMT to Register Multiple Controllers
    • Select a Controller and run the Detect Hardware Feature to Help Build an Hwi file
    • Define the VME Slot Locations
    • About Servovalve Drive Outputs for Aero Applications
    • Configure Servo Valve Outputs
    • Configure the Model 494.79 Multiple Universal Driver (MUD) Board
    • Configure Each Model 493.25 / 494.26 DUC
    • Configure the Model 493.73 HPU Options
    • Save the Hwi File in the Correct Folder
• Model 793 Multibox Systems
  • Model 793 Multibox System Connections
  • Use the CMT to Register Multiple Controllers
  • Use the CMT to Configure the Controller
• Index