MTS Series 793 Utility Software

User Information and Software Reference

100-147-132 P be certain.
© 2014 MTS Systems Corporation. All rights reserved.

Trademark Information
MTS, FlexTest, RPC, Temposonics, and TestWare are registered trademarks of MTS Systems
Corporation; MPT, Station Builder, Station Manager, and Profile Editor are trademarks of MTS Systems
Corporation within the United States. These trademarks may be protected in other countries.Microsoft
and Windows are registered trademarks of Microsoft Corporation. All other trademarks or service
marks are property of their respective owners.

Proprietary Software
Software use and license is governed by MTS’s End User License Agreement which defines all rights
retained by MTS and granted to the End User. All Software is proprietary, confidential, and owned by
MTS Systems Corporation and cannot be copied, reproduced, disassembled, decompiled, reverse
engineered, or distributed without express written consent of MTS

Software Verification and Validation

MTS software is developed using established quality practices in accordance with the requirements
detailed in the ISO 9001 standards. Because MTS-authored software is delivered in binary format, it
is not user accessible. This software will not change over time. Many releases are written to be
backwards compatible, creating another form of verification.The status and validity of MTS’s 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’s exacting quality standards when initially installed and will
continue to perform as intended over time
 Table of Contents

Table of Contents
Technical Support
How to Get Technical Support.........................................................................................................7
Before You Contact MTS.................................................................................................................7
If You Contact MTS by Phone..........................................................................................................9
Problem Submittal Form in MTS Manuals.....................................................................................10
Preface
Before You Begin...........................................................................................................................11
Documentation Conventions..........................................................................................................11

HWI-File-Editor Overview
About .hwi files...............................................................................................................................16
About the Hwi File Editor Application.............................................................................................16
Starting Hwi File Editor .................................................................................................................16
Hwi File Editor Controls.................................................................................................................17
About Multiple .hwi Files ...............................................................................................................20
Saving Multiple .hwi Files in a Controller Directory........................................................................21
Selecting .hwi Files in a Controller Directory.................................................................................21

Create and Edit an HWI File

Create a New File..........................................................................................................................24
Create New hwi File for Single Box System.......................................................................24
Hardware Resources.....................................................................................................................24
Hardware Resources Listed in .hwi File..............................................................................24
About Detect Hardware Feature.........................................................................................24
Use Detect Hardware Feature............................................................................................25
About .hwi Miscellaneous Hardware...................................................................................25
Manually Add VME Board to .hwi File.................................................................................25
Manually Add Mezzanine Card to .hwi File.........................................................................26
Manually Add Transition Board to .hwi File.........................................................................26
Configure Hardware Resource Settings........................................................................................26
Valve Driver Settings...........................................................................................................26
Digital Universal Conditioner (DUC) Settings.....................................................................26
Analog Input Filter Settings.................................................................................................27
Encoder Type Settings........................................................................................................27
Hydraulic Interface Settings................................................................................................27
Optional Hardware Resource Name Changes....................................................................28
VME Board Address Settings..............................................................................................28

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Table of Contents

About Actuator Movement When the Servovalve is Clamped.......................................................29

Where to Find Valve Balance Procedures.....................................................................................30

HWI Hardware Settings

About Hwi File Editor Default Settings...........................................................................................34
Edit Hwi Default Settings...............................................................................................................34
Apply Hwi Default Settings.............................................................................................................35
Export HWI Defaults......................................................................................................................37
Import HWI Defaults.......................................................................................................................38
System Options Settings................................................................................................................38
VME Bus Board Settings...............................................................................................................38
About Processor Boards.....................................................................................................39
Reconfigure Processor Functions.......................................................................................40
Processor Hwi Settings.......................................................................................................41
Model 493.50 ADDA II Board Settings................................................................................42
Model 498.71 GRES II Board Settings................................................................................44
Model 49x.43 Multibox I/O Board Settings..........................................................................45
Model 49x.40 I/O Carrier Board HWI Settings....................................................................45
Model 494.41 Single-Station System Board Settings.........................................................47
Model 494.42 Single-Station System Board Settings.........................................................49
Model 494.44 Two-Station System Board Settings.............................................................52
Model 493.42 System Board Settings ................................................................................55
Model 498.65 ADDA Board Settings...................................................................................57
Model 498.70 Digital I/O Board Settings.............................................................................58
Model 498.71 GRES II Board Settings................................................................................59
Model 493.40 I/O Carrier Mezzanine Cards .................................................................................59
Mezzanine Card Compatibility............................................................................................60
Model 493.1x Valve Driver Settings....................................................................................61
Model 493.2x DUC Card Settings.......................................................................................62
How to Add Accelerometer Compensation to a Model 493.21B/493.25 DUC....................62
How to Add a DI/O Load Washer to a Model 493.21B/493.25 DUC...................................63
How to Add a Serial Load Washer to a Model 493.21B/493.25 DUC.................................63
Model 493.45 Six-Channel A/D Card Settings....................................................................64
Model 493.46 Six-Output D/A Card Settings......................................................................64
Model 493.47 Encoder Card Settings.................................................................................65
SSI/Gurley Encoder Application Settings............................................................................66
Model 493.48 Accelerometer Input Card Settings..............................................................67
Model 493.50 ADDA II Mezzanine Cards......................................................................................68
Model 493.55/493.57 8-Channel A/D Card Settings...........................................................68
Model 493.56 8-Channel D/A Card Settings.......................................................................68
Model 493.59x Encoder Card Settings...............................................................................69
Model 494.40 I/O Carrier Mezzanine Cards..................................................................................70

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 Table of Contents

High Speed Data Acquisition Settings................................................................................70

Model 494.16 VD/DUC HWI Settings..................................................................................70
Model 494.21 Multi-Range DUC with Acceleration Compensation Card HWI Settings......72
How to Enable Acceleration Compensation on the Model 494.21 Card.............................74
How to Add a DI/O Load Washer to a Model 494.21 Card.................................................74
How to Add a Serial Load Washer to a Model 494.21 Card...............................................74
Model 494.25/494.26 DUC HWI Settings...........................................................................75
Model 494.45 8-Input A/D Converter HWI Settings............................................................76
Model 494.46 8-Output D/A Converter Card HWI Settings.................................................76
Model 494.47 Dual UART/Encoder/External Clock HWI Settings......................................78
SSI/Gurley Encoder Application Settings............................................................................81
Model 494.49 Quad Encoder Interface HWI Settings.........................................................83
Model 498.65A-10 Eight-Channel Card Settings...........................................................................83
Model 498.65A-11 D/A Card Settings............................................................................................84
Model 498.65A-12 Encoder Card Settings....................................................................................84
Transition Board Settings...............................................................................................................85
Model 493.72 Digital I/O Transition Board Settings............................................................85
Model 493.73 HPU Transition Board Settings....................................................................85
Model 493.74 HSM Transition Board..................................................................................86
Model 494.74 HSM Transition Board..................................................................................88
FlexTest IIm Chassis Settings .......................................................................................................89
Miscellaneous Device Settings......................................................................................................90
Temperature Controller Settings.........................................................................................90
How to Add Temperature Controllers ......................................................................91
Temperature Controller Settings..............................................................................92
Remote Station Control (RSC) Settings..............................................................................92
How to Add Remote Station Controls (RSC) .....................................................................93
Model 494.05 Handset Settings..........................................................................................93
Model 494.05 Handset Hwi File Editor Settings..................................................................94
CAN Bus Interface..............................................................................................................94
CAN Bus Interface Requirements............................................................................94
CAN Bus Interface Setup ........................................................................................95
Modbus Interface Settings..................................................................................................95
About EtherCAT..................................................................................................................96
EtherCAT Settings....................................................................................................97
About Read-Only HSMs......................................................................................................99
How to Configure a Read-Only HSM..................................................................................99
Read-Only HSM Control Logic............................................................................................99
Uninterruptible Power Supplies (UPS)..............................................................................100
How to Add an Uninterruptible Power Supply (UPS).............................................100
How to Set Model 493.40 I/O Carrier Address (FlexTest GT/SE, TestStar IIm)...........................102
How to Set ADDA II Board Address (FlexTest GT, TestStar IIm, FlexTest IIm)...........................102
How to set the Model 494.40 I/O Carrier Board Address ...........................................................103

5
Table of Contents

Controller Management Tool

Controller Options Description.....................................................................................................106
Controller Attributes tab....................................................................................................107
User Files tab (FlexTest SE only)......................................................................................109
License Keys tab (FlexTest SE only).................................................................................110
Regional Settings tab (FlexTest SE only)..........................................................................110
Passwords tab (FlexTest SE only)....................................................................................112
Using the Controller Management Tool........................................................................................112
FlexTest SE multi Controller Considerations.....................................................................113
FlexTest SE Version Checking..........................................................................................113
How to put a FlexTest SE Controller in the Service boot mode........................................113
How to Install or Update System Files on FlexTest SE Controllers..................................114
How to Update or Backup User Files on FlexTest SE Controllers....................................114
How to Register a FlexTest SE Controller for Automation................................................115
How to Unregister a FlexTest SE Controller.....................................................................115
How to Set Controller Options on FlexTest SE Controllers...............................................115
How to Configure a FlexTest SE Controller to Boot in a Different Boot Mode..................116
How to Configure a New Aero ST Multi Controller System ..............................................116
About Rebooting Aero ST Controllers with CMT..............................................................116
User File Access for Registered Controllers.....................................................................117

Acumen System Setup

Acumen Hwi Setup......................................................................................................................120
Acumen Hwi Settings........................................................................................................120

6
Technical Support

How to Get Technical Support

Start with your manuals

The manuals supplied by MTS provide most of the information you need to use and maintain your equipment.
If your equipment includes software, look for online help and README files that contain additional product
information.

Technical support methods

MTS provides a full range of support services after your system is installed. If you have any questions
about a system or product, contact Technical Support in one of the following ways.

Web site www.mts.com > Contact Us (upper-right corner) > In the Subject field, choose
To escalate a problem; Problem Submittal Form

E-mail Worldwide: [email protected]

Europe: [email protected]

Telephone Worldwide: 1 800 328 2255 - toll free in U.S.; +1 952 937 4000 - outside U.S.
Europe: +800 81002 222, International toll free in Europe

Outside the U.S.

For technical support outside the United States, contact your local sales and service office. For a list of
worldwide sales and service locations and contact information, use the Global MTS link at the MTS web
site:
www.mts.com > Global Presence > Choose a Region

Before You Contact MTS

MTS can help you more efficiently if you have the following information available when you contact us for
support.

Know your site number and system number

The site number contains your company number and identifies your equipment type (such as material
testing or simulation). The number is typically written on a label on your equipment before the system
leaves MTS. If you do not know your MTS site number, contact your sales engineer.
Example site number: 571167

MTS Series 793 Utility Software | 7

Technical Support

When you have more than one MTS system, the system job number identifies your system. You can find
your job number in your order paperwork.
Example system number: US1.42460

Know information from prior technical assistance

If you have contacted MTS about this problem before, we can recall your file based on the:
• MTS case number
• Name of the person who helped you

Identify the problem

Describe the problem and know the answers to the following questions:
• How long and how often has the problem occurred?
• Can you reproduce the problem?
• Were any hardware or software changes made to the system before the problem started?
• What are the equipment model numbers?
• What is the controller model (if applicable)?
• What is the system configuration?

Know relevant computer information

For a computer problem, have the following information available:
• Manufacturer’s name and model number
• Operating software type and service patch information
• Amount of system memory
• Amount of free space on the hard drive where the application resides
• Current status of hard-drive fragmentation
• Connection status to a corporate network

Know relevant software information

For software application problems, have the following information available:
• The software application’s name, version number, build number, and (if available) software patch
number. This information can typically be found in the About selection in the Help menu.
• The names of other applications on your computer, such as:
— Anti-virus software
— Screen savers
— Keyboard enhancers
— Print spoolers

8 | MTS Series 793 Utility Software

 Technical Support

— Messaging applications

If You Contact MTS by Phone

A Call Center agent registers your call before connecting you with a technical support specialist. The agent
asks you for your:
• Site number
• Email address
• Name
• Company name
• Company address
• Phone number where you can be reached

If your issue has a case number, please provide that number. A new issue will be assigned a unique case
number.

Identify system type

To enable the Call Center agent to connect you with the most qualified technical support specialist available,
identify your system as one of the following types:
• Electrodynamic material test system
• Electromechanical material test system
• Hydromechanical material test system
• Vehicle test system
• Vehicle component test system
• Aero test system

Be prepared to troubleshoot
Prepare to perform troubleshooting while on the phone:
• Call from a telephone close to the system so that you can implement suggestions made over the phone.
• Have the original operating and application software media available.
• If you are not familiar with all aspects of the equipment operation, have an experienced user nearby to
assist you.

Write down relevant information

In case Technical Support must call you:
• Verify the case number.

MTS Series 793 Utility Software | 9

Technical Support

• Record the name of the person who helped you.

• Write down any specific instructions.

After you call

MTS logs and tracks all calls to ensure that you receive assistance for your problem or request. If you
have questions about the status of your problem or have additional information to report, please contact
Technical Support again and provide your original case number.

Problem Submittal Form in MTS Manuals

Use the Problem Submittal Form to communicate problems with your software, hardware, manuals, or
service that are not resolved to your satisfaction through the technical support process. The form includes
check boxes that allow you to indicate the urgency of your problem and your expectation of an acceptable
response time. We guarantee a timely response—your feedback is important to us.
You can access the Problem Submittal Form at www.mts.com > Contact Us (upper-right corner) > In the
Subject field, choose To escalate a problem; Problem Submittal Form

10 | MTS Series 793 Utility Software

Preface

Before You Begin

Safety first!
Before you use your MTS product or system, read and understand the safety information provided with
your system. Improper installation, operation, or maintenance can result in hazardous conditions that can
cause severe personal injury or death, or damage to your equipment and specimen. Again, read and
understand the safety information provided with your system before you continue. It is very important that
you remain aware of hazards that apply to your system.

Other MTS manuals

In addition to this manual, you may receive additional manuals in paper or electronic form.
You may also receive an MTS System Documentation CD. It contains an electronic copy of the manuals
that pertain to your test system.
Controller and application software manuals are typically included on the software CD distribution disc(s).

Documentation Conventions

The following paragraphs describe some of the conventions that are used in your MTS manuals.

Hazard conventions
Hazard notices may be embedded in this manual. These notices contain safety information that is specific
to the activity to be performed. Hazard notices immediately precede the step or procedure that may lead
to an associated hazard. Read all hazard notices carefully and follow all directions and recommendations.
Three different levels of hazard notices may appear in your manuals. Following are examples of all three
levels. (for general safety information, see the safety information provided with your system.)

Danger:
Danger notices indicate the presence of a hazard with a high level of risk which, if ignored,
will result in death, severe personal injury, or substantial property damage.

MTS Series 793 Utility Software | 11

Preface

Warning:
Warning notices indicate the presence of a hazard with a medium level of risk which, if ignored,
can result in death, severe personal injury, or substantial property damage.

Caution:
Caution notices indicate the presence of a hazard with a low level of risk which, if ignored,
could cause moderate or minor personal injury or equipment damage, or could endanger test
integrity.

Other special text conventions

Important:
Important notices provide information about your system that is essential to its proper
function. While not safety-related, if the important information is ignored, test results may
not be reliable, or your system may not operate properly.

Note:
Notes provide additional information about operating your system or highlight easily
overlooked information.

Recommended:
Recommended notes provide a suggested way to accomplish a task based on what MTS
has found to be most effective.

Tip:
Tips provide helpful information or a hint about how to most efficiently accomplish a task.

Access:
Access provides the route you should follow to a referenced item in the software.

Examples show specific scenarios relating to your product and appear with a shaded
background.

Special terms
The first occurrence of special terms is shown in italics.

Illustrations
Illustrations appear in this manual to clarify text. They are examples only and do not necessarily represent
your actual system configuration, test application, or software.

12 | MTS Series 793 Utility Software

 Preface

Electronic manual conventions

This manual is available as an electronic document in the Portable Document File (PDF) format. It can be
viewed on any computer that has Adobe Acrobat Reader installed.

Hypertext links
The electronic document has many hypertext links displayed in a blue font. All blue words in the body text,
along with all contents entries and index page numbers, are hypertext links. When you click a hypertext
link, the application jumps to the corresponding topic.

MTS Series 793 Utility Software | 13

HWI-File-Editor Overview
Topics:

• About .hwi files..................................................................................................................................16

• About the Hwi File Editor Application................................................................................................16
• Starting Hwi File Editor .....................................................................................................................16
• Hwi File Editor Controls.....................................................................................................................17
• About Multiple .hwi Files ...................................................................................................................20
• Saving Multiple .hwi Files in a Controller Directory...........................................................................21
• Selecting .hwi Files in a Controller Directory.....................................................................................21

MTS Series 793 Utility Software | 15

HWI-File-Editor Overview

About .hwi files

Hwi files are text files that define the internal components—or resources—available to MTS Series 793
Controllers. Resource examples include conditioners, valve drivers, and digital inputs.
The text description of a resource in an .hwi file includes proximity information, such as the location of the
slot in the chassis in which the resource is installed, and the rear-panel connectors through which it may
be accessed.
Hwi files and Station Builder
You use the Station Builder application (one of the applications included with MTS 793.00 System Software)
to define test stations by allocating some or all of the resources listed in the .hwi file.
Initial .hwi files are typically created at MTS
The .hwi file associated with a given controller is typically created at MTS according to the resources
included with the controller. It may be necessary to edit this file if system resources are added, removed,
or repositioned in the controller chassis.

About the Hwi File Editor Application

The Hwi File Editor is a utility used to create and edit hardware interface (.hwi) files.

Starting Hwi File Editor

The typical path to the Hwi File Editor is as follows:

Start > Programs > MTS 793 System Software > Service Tools
Note:
You can also launch the application by typing hwieditor from the command line.

Supported MTS Controllers

• FlexTest 40/60/100/200
• FlexTest IIm (498.xx)
• FlexTest GT/TestStar IIm (493.10)
• FlexTest SE (493.02)
• TestStar IIs (493.01)
• Aero ST (493.20)

16 | MTS Series 793 Utility Software

 HWI-File-Editor Overview

Editing existing .hwi files with the Hwi File Editor

When you open an existing .hwi file with the Hwi File Editor, the Hwi File Editor minimizes the chance of
introducing syntax errors when making changes.
Creating new .hwi files with the Hwi File Editor
When you create a new .hwi file with the Hwi File Editor, the Hwi File Editor’s built-in logic streamlines the
process of adding new resources. For instance, when you add or remove analog resources from an .hwi
file, the Hwi File Editor has a fill-down function that automatically assigns proper channel numbers and
resource names.
The Detect Hardware feature automatically detects VME and transition bus hardware and adds those
resources to the current file opened in the Hwi File Editor application. This is the preferred method when
you create a new .hwi file.
Changing .hwi files at customer sites
While the primary use of the Hwi File Editor is to create .hwi files for systems before they leave MTS, it
can also be used to make modifications to .hwi files at customer sites.
For instance, if a system in the field adds new hardware because of a need for additional conditioning, the
Hwi File Editor can be used to reflect those changes in the system’s existing .hwi file.

Hwi File Editor Controls

Number callout in graphic - Item Description

1 - Menu File: Use the File menu commands to create, open, change,
save, and print files. You can also exit the application from this
menu.
Note:
Whenever you save an .hwi file that has been modified,
a backup copy is automatically created. The backup
filename will contain a date and time stamp in the

MTS Series 793 Utility Software | 17

HWI-File-Editor Overview

Number callout in graphic - Item Description

filename. For example:

FTIIM_YYYY-MM-DD_HH-MM-SS.HWI.

View: Use to show or hide the Toolbar and Status Bar.

Options: Use to rename resources or reconfigure processors.
Rename Resources: Selecting this option automatically renames
resources to eliminate name conflicts. You should only select
this option before you create a configuration using Station
Builder. Once you assign a resource to a configuration, renaming
that resource in the .hwi file will invalidate the configuration file.
When you select this option, the Hwi File Editor renames all of
the analog input/output, digital input/output (except on a GRES
card), and HPU and HSM resources using syntax that includes
the slot number and connector name in the resource name.
For example, a 493.25 DUC in the first mezzanine location on
an I/O Carrier in slot 5 is named 493.25 DUC S5-J4.
Conditioners and valve drivers assigned to A/Ds or D/As use
the conditioner/driver model, chassis and connector. For
example, a 497.22 dual DC conditioner in chassis 2, slot 10,
and channel 1 is named 497.22 DDC C2-J1001.
After selecting this option, review the new names to make sure
they are acceptable. When you create a station with these
renamed resources (with Station Builder) and open that station
(with Station Manager), the HPU and HSM resources will appear
on the Station Manager panel as they are saved in the .hwi file.
You can use Station Builder to assign logical display names
(such as load, displacement) to other types of resources when
allocating those resources to create a test station.

Reconfigure Processors: For Controllers equipped with the Time

History Playback (THP) option and two processors, this option
allows you to change the way the processors are initialized.
Note:
This option will be grayed-out if your controller is not
equipped for THP, or has only one or three processors.

Detect Hardware: This option automatically detects VME and

transition bus hardware and adds those resources to the Hwi
File Editor tree view pane.
Help: Selecting the Electronic Documentation option displays
the Hwi File Editor manual in the portable document file (PDF)
format. Selecting the About Hwi File Editor displays a window
identifying the Hwi File Editor’s release version and build
number.

2 - Toolbar Provides quick access to common commands and windows.

18 | MTS Series 793 Utility Software

 HWI-File-Editor Overview

Number callout in graphic - Item Description

3 - Tree view pane Shows icons of selected controller components in an expandable

hierarchical display.
The intended slot number for each board is shown in brackets
after the resource (type) name.
Displays icons of selected controller components in an
expandable hierarchical display.
Note:
You can right-click many of the tree-view icons to
perform/set features.

4 - Controller definition pane Contains tabbed pages of various controller components and
characteristics. You create an .hwi file by making selections in
these tabbed pages.
Contains tabbed pages of various controller components and
characteristics. You create .hwi files by making selections in
these tabbed pages.
Note:
Some tabs contain fields that contain dimmed or “grayed
out” values. These values are read only, and are provided
only for reference.

Properties tab Controller Type: The Hwi File Editor applies to several types of
MTS Series 793 Controllers. It is important to select the controller
type that pertains to your controller before you make any further
selections. The available hardware is dependent on the
Controller Type.

Board tab Board Slot n: Allows you to select the desired VME board (the
available boards vary with controller type) for the selected slot.

Chassis tab (FlexTest IIm only) Chassis n: Allows you to select an Analog Chassis or Hydraulic
Control Panel for the selected chassis.

Transition tab (FlexTest GT, TestStar Transition Slot n: Allows you select a DIO, HPU, or HSM
IIm, Aero ST, FlexTest 60/100/200 only) transition board for the selected slot.

Miscellaneous tab Use the drop-down lists in the Miscellaneous tab to add various
external devices to the .hwi file. The devices listed here are not
automatically added by the Hardware Detect option.

MTS Series 793 Utility Software | 19

HWI-File-Editor Overview

Number callout in graphic - Item Description

5 - Hwi text pane The selections you make in the tabbed pages of the controller
definition pane are automatically reflected as text in this pane.
The selections you make in the tabbed pages of the controller
definition pane are automatically reflected as text in this pane.

About Multiple .hwi Files

You can create multiple .hwi files that contain different hardware settings and save them in the same
controller directory. This allows you to create custom .hwi settings for different tests. Custom settings may
include different input filtering settings, DUC settings, and external hardware settings.
You can use the Project Manager application to select different .hwi files for use with a controller.

Caution:
For proper operation, the hardware resources specified in a configuration (.cfg) file must match
those in the .hwi file.
Changing the hardware resources in an .hwi file can cause the system load operation to fail.
When using multiple .hwi files with the same controller, make sure that your .hwi files all have
identical hardware resources.

20 | MTS Series 793 Utility Software

 HWI-File-Editor Overview

Saving Multiple .hwi Files in a Controller

Directory

You can create multiple .hwi files that contain different hardware settings and save them in the same
controller directory. This allows you to create custom .hwi settings for different tests.
1. Shut down any test and quit all Series 793 applications.

Caution:
For proper operation, the hardware resources specified in a configuration (.cfg) file must
match those in the .hwi file.
Changing the hardware resources in an .hwi file can cause the system load operation to
fail.
When using multiple .hwi files with the same controller, make sure that your .hwi files all
have identical hardware resources.

2. Use the HWI File Editor application to create a new .hwi file with a new name and custom settings.
3. From the File menu, click Save As.
4. In the Save As window, select the new controller directory and click Save. The following window appears:

If you click Yes, the file is saved in the controller directory and the controller.793settings file is modified
to point to the new .hwi file. The next time you start a controller application, it will use the new .hwi file.
If you click No, the file is saved in the controller directory but the controller.793settings file is not modified.
Note:
You can now use the Project Manager application to switch between the multiple .hwi files that
you saved in the controller directory.

Selecting .hwi Files in a Controller Directory

You can use the Project Manager application to select different .hwi files for use with a controller.
1. Shut down any test and quit all Series 793 applications.

MTS Series 793 Utility Software | 21

HWI-File-Editor Overview

Caution:
For proper operation, the hardware resources specified in a configuration (.cfg) file must
match those in the .hwi file.
Changing the hardware resources in an .hwi file can cause the system load operation to
fail.
When using multiple .hwi files with the same controller, make sure that your .hwi files all
have identical hardware resources.

2. Start the Project Manager application.

3. From the Tools menu, click Controller Settings.
4. In the controller list, click the Hwi file.
5. In the Hwi File text box, type the name of the .hwi file that you want to use.

6. Click OK.
The controller.793settings file is modified to point to the .hwi file. The next time you start a controller
application, it will use the .hwi file that you defined above.

22 | MTS Series 793 Utility Software

Create and Edit an HWI File
Topics:

• Create a New File..............................................................................................................................24

• Hardware Resources.........................................................................................................................24
• Configure Hardware Resource Settings............................................................................................26
• About Actuator Movement When the Servovalve is Clamped...........................................................29
• Where to Find Valve Balance Procedures.........................................................................................30

MTS Series 793 Utility Software | 23

Create and Edit an HWI File

Create a New File

Create New hwi File for Single Box System

Only qualified personnel should create or edit .hwi files.

Recommended:
An incorrect .hwi file can result in improper system response and unexpected actuator
movements.
Unexpected actuator movements may result in personal injury or damage to equipment.
Before operating your system, ensure the .hwi file you are using is valid for your situation.

1. From the File menu, click New.

2. Click the Controller icon in the tree view pane.
3. Click the Properties tab, and select a Controller Type from the drop-down list.

Hardware Resources

Hardware Resources Listed in .hwi File

The hardware resources listed in the .hwi file must exactly match the physical location and address settings
for each board used in the system. There are two methods to add hardware resources to an .hwi file:
• Use the Detect Hardware feature to detect VME and transition bus hardware and add those resources
to the current file opened in the Hwi File Editor application.
• Use the Hwi File Editor application to manually add hardware resources.

About Detect Hardware Feature

The Detect Hardware feature automatically detects VME and transition bus hardware and adds those
resources to the current file opened in the Hwi File Editor application. This is the preferred method when
you create a new .hwi file. The Detect Hardware feature will also remove hardware resources from an
existing .hwi file if that hardware was physically removed from the chassis.
The Detect Hardware feature will not detect a Model 498.70 board, Model 497 chassis tab, or any hardware
added through the Miscellaneous tab (such as temperature controllers, RSCs, and handsets). You must
manually add those hardware resources for any system that uses those hardware types.

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Use Detect Hardware Feature

1. Open either a new or existing .hwi file.
2. From the Options menu, click Detect Hardware.
The detect hardware process adds and removes hardware resources based on what hardware was
detected.

3. All detected hardware appears in the hardware resource tree. (Slot numbers for each board appear in
brackets.)
4. Manually add any hardware that appears in the Miscellaneous tab (such as, temperature controllers,
RSCs, and handsets).

About .hwi Miscellaneous Hardware

Any hardware listed in the Miscellaneous tab must be added manually using the HWI Editor application.

The Detect Hardware feature will not detect or add any hardware listed in the Miscellaneous tab.

Manually Add VME Board to .hwi File

The Hwi File Editor application includes a tree structure and drop-down lists that allow you to manually
add hardware resources.
1. Select the Controller icon in the tree view pane.
2. Click the Board tab, and select the VME board for each board slot used in the system.

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Create and Edit an HWI File

Manually Add Mezzanine Card to .hwi File

The Hwi File Editor application includes a tree structure and drop-down lists that allow you to manually
add hardware resources.
1. Select the Model 49x.40 I/O Carrier or Model 493.50 ADDAII board in the tree view pane.
Empty I/O Carrier and ADDA II boards are not supported. At least one mezzanine card must be specified.

2. Click the Mezzanines tab, and select the mezzanine card type for each mezzanine location.
You can also right-click a resource and select a mezzanine card from the pop-up menu.

Manually Add Transition Board to .hwi File

The Hwi File Editor application includes a tree structure and drop-down lists that allow you to manually
add hardware resources.
1. Select Controller in the tree view pane.
2. Click the Transition tab, and select the appropriate DIO, HPU or HSM transition boards for each
transition slot.

Configure Hardware Resource Settings

Valve Driver Settings

Each valve driver has settings that may include valve mode (single/dual), current range, and clamp mode
settings.
In addition, any combination card (Model 494.16 VD/DUC) must be configured as either a two-stage or
three-stage valve driver.

Digital Universal Conditioner (DUC) Settings

Each DUC card requires a number of hardware settings that you must configure before attempting to use
the system.

DUC Mode Settings (AC/DC)

Each DUC card must be configured as either an AC or a DC conditioner (Default=DC).

Bridge Type Settings

Model 494.xx DUCs include settings that define the bridge type (full, half, quarter).

Shunt Settings
Model 494.xx DUCs include settings that define where the shunt calibration resistor is applied.

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Analog Input Filter Settings

Mezzanine cards that include analog inputs (DUCs, A/D Converter, Encoder, and conditioners) includes
filter settings that you may want to change for custom applications.

Encoder Type Settings

Each Encoder card requires a number of hardware settings that you must configure before attempting to
use the system.

Hydraulic Interface Settings

Various HSM, HPU, and system boards have hydraulic interface settings that you must define before
attempting to run the system. These settings vary with each board and may include first on/last off,
proportional-on/off solenoid operation, and proportional rate settings.
The drawing shows examples for the following hydraulic interface settings:

Number callout in graphic - Item Description

1 - HPU with HSM Hydraulic Power Unit (HPU) with Hydraulic Service Manifold
(HSM)

2 - HPU Only Hydraulic Power Unit (HPU) only

3 - Controller Controller chassis

4 - HPU with HSM This setting is available for the HPU transition and system
boards (494.41, 494.42, 494.44, 493.42).

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Number callout in graphic - Item Description

TRUE–indicates the system’s HPU supplies one or more

HSMs.
FALSE–used for HPU only systems (makes HPU selection
available in Station Builder).

5 - Connect to HPU This setting is available for various HSM transition boards.
TRUE–indicates that the HPU must be started (either manually
or as “first on”) before you can activate an HSM.
FALSE–indicates the HSM can be activated without an HPU
activation.

Optional Hardware Resource Name Changes

If you change the name of a hardware resource, you may invalidate existing configuration files. This is
because an existing configuration file depends on the names of the resources in the current .hwi file
matching the names of the resources with which the configuration was created. (These are the names
displayed in the Hardware Resources lists in the Station Builder application.)
If the names do not match, the configuration will not load into Series 793.00 System Software applications.

Resource naming convention

Hwi files typically use the following resource naming convention for valve driver and conditioner resources:
Convention: Resource model; Slot number; Connector number.
Example 1: 493.14 2SVD S5-J5.
Explanation: An MTS Model 493.14 2-Stage Servovalve Driver Board located in Slot 5 of the chassis
whose output is available from Connector J5.
Example 2: 493.21B DUC S3-J4.
Explanation: An MTS Model 493.21B Digital Universal Conditioner Board located in Slot 3 of the chassis
whose input is available at Connector J4.

VME Board Address Settings

If you use the Hardware Detect feature to add hardware resources, the board addresses are correct and
no further action is required.
If you manually added the hardware resources to the .hwi file, you must make sure that the address setting
in the .hwi file matches the physical address switch settings on the 493.40 I/O Carrier board, 494.40 I/O
Carrier Board, and the ADDA II board.

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About Actuator Movement When the Servovalve

is Clamped

If an unbalanced servovalve (two-stage or three-stage) is clamped by Series 793 software, it may act
unpredictably. In addition, if a three-stage servovalve is clamped when its third stage is not properly tuned,
it may act unpredictably.

Servovalve balance
To balance a servovalve, you must first perform a mechanical adjustment on the servovalve to achieve
gross mechanical balance. You can then use the Series 793 software Valve Balance to perform an electrical
adjustment to fine-tune the mechanical adjustment.

Mechanical balance
The mechanical adjustment must be performed before the electrical adjustment, and is typically performed
at the following times:
• At system installation
• When a new servovalve is installed in an existing system
• If the servovalve cannot be electrically balanced
• At regular service intervals

Electrical balance
The electrical adjustment is performed with the Valve Balance control, which adjusts the electrical input
to the servovalve to compensate for minor mechanical imbalances. When the valve-balance adjustment
is complete, there should be no (or minimal) hydraulic fluid flow when the servovalve output signal is at
null.
Note:
The electrical adjustment is typically performed much more frequently than the mechanical
adjustment.

Inner-loop tuning
In addition to mechanical and electrical valve-balance adjustments, three-stage servovalves also have
inner-loop tuning controls that may affect clamping behavior. The inner loop is similar to a displacement
control mode for the outer-loop.
The inner control loop resides inside the test system’s primary, or outer control loop. So in addition to the
pilot spool, three-stage servovalves include a third stage (or main) spool, that is driven by the pilot spool.
The inner loop (like the outer loop), has gain and rate controls that can be adjusted to optimize performance.
The inner-loop is tuned at system installation, and requires periodic fine tuning when the outer-loop becomes
sluggish.

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Number callout in graphic Item

Feedback
1

2 Outer Loop

3 Inner Loop

4 Hydraulic Service Manifold (HSM)

5 Hydraulic Power Supply

6 Control Signal

7 493.15 Valve Driver

8 Program Command

The innerloop (proportional) gain and rate (derivative) adjustments are the same types of adjustments as
the proportional and derivative gain adjustments of the outer-loop tuning controls.

Where to Find Valve Balance Procedures

Mechanical valve-balance procedures

For two-stage servovalves, the mechanical valve balance procedure is included in the Series 252 Servovalve
Product Manual (PN 011-182-906), which is typically included in the system documentation set.
For three-stage servovalves, the mechanical valve balance procedure involves the procedure for the pilot
spool (which is the same as the procedure for two-stage servovalves), and a procedure to adjust the LVDT

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mechanical null for the third-stage spool. These procedures are included in the Series 256 Servovalve
Product Manual (PN 011-209-602), which is typically included in the system documentation set.

Electrical valve-balance and inner-loop tuning procedures

Electrical valve balance procedures and inner-loop tuning procedures for three-stage servovalves are
included in the Series 793 Tuning and Calibration manual (PN 100-147-134).

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HWI Hardware Settings
Topics:

• About Hwi File Editor Default Settings...............................................................................................34

• Edit Hwi Default Settings...................................................................................................................34
• Apply Hwi Default Settings................................................................................................................35
• Export HWI Defaults..........................................................................................................................37
• Import HWI Defaults..........................................................................................................................38
• System Options Settings...................................................................................................................38
• VME Bus Board Settings...................................................................................................................38
• Model 493.40 I/O Carrier Mezzanine Cards .....................................................................................59
• Model 493.50 ADDA II Mezzanine Cards..........................................................................................68
• Model 494.40 I/O Carrier Mezzanine Cards......................................................................................70
• Model 498.65A-10 Eight-Channel Card Settings..............................................................................83
• Model 498.65A-11 D/A Card Settings................................................................................................84
• Model 498.65A-12 Encoder Card Settings........................................................................................84
• Transition Board Settings..................................................................................................................85
• FlexTest IIm Chassis Settings ..........................................................................................................89
• Miscellaneous Device Settings..........................................................................................................90
• How to Set Model 493.40 I/O Carrier Address (FlexTest GT/SE, TestStar IIm)..............................102
• How to Set ADDA II Board Address (FlexTest GT, TestStar IIm, FlexTest IIm)...............................102
• How to set the Model 494.40 I/O Carrier Board Address ...............................................................103

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HWI Hardware Settings

About Hwi File Editor Default Settings

The Hwi Defaults feature allows you to change the default HWI settings for most VME- and transition-bus
hardware. When Show HWI Defaults is selected, Hwi Default settings appear in an editable resource tree
that appears above the Controller resources.

To change Hwi Default values, edit the hardware properties pages in the HWI Defaults tree. Once you edit
the default settings, you can:
• Apply the new default settings to hardware resources in the current hwi file.
• Use the Export HWI Defaults function to save the settings to a file and change the HWI File Editor
application defaults.
• Use the Import HWI Defaults function to import default settings from a file and change the HWI Editor
application defaults.

Edit Hwi Default Settings

You can apply default Hwi settings to new and existing controller hardware.
1. On the View menu, click Show HWI Defaults. When Hwi Defaults are displayed, Hwi Default settings
appear in an editable tree structure located above the Controller resources.

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2. Change the default HWI Settings in the HWI Defaults tree.

You can also use the Import HWI Defaults function to change the default settings based on a previously
exported HWI Defaults file.
Note:
When you import a previously created Hwi Default file, the Hwi Editor application will use those
default values for any subsequent .hwi files that you create.

3. Once the default settings are changed, you can apply the settings to the controller resources.
Note:
Optional–Use the Export HWI Defaults function to save the default setting in a file. The export
function also changes the Hwi Editor application defaults. The Hwi Editor application will use the
exported default values for any subsequent Hwi files that you create.

Apply Hwi Default Settings

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

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HWI Hardware Settings

• Right-click the I/O Carrier icon and click Apply HWI Defaults. HWI defaults are applied to the hardware
resources in the I/O carrier.

• Right-click a hardware resource in the Controller tree and click Apply HWI Defaults.
The HWI default settings are only applied to that hardware resource.
In this example, the default HWI values will only be applied to the selected 494.26 hardware resource.

• Right-click a specific hardware resource in the HWI Defaults tree and click Apply HWI Defaults.
The HWI default is applied to any instance of that particular hardware resource that appears in the
Controller tree.

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In this example, the default values for the 494.16 VD/DUC will be applied to all instances of the 494.16
in the Controller tree.

Use one of the following methods to apply Hwi defaults to new hardware that you add to an Hwi file:
• On the Options menu, click Detect Hardware. Any hardware detected will use the default Hwi settings.
• Manually add hardware to the Controller tree. Any new hardware that is added will use the default Hwi
settings.

Export HWI Defaults

Default Hwi values can be exported to a file for future use. After HWI Defaults are exported, the Hwi Editor
application will use those default values for any subsequent Hwi files that you create.
Note:
Hwi Default files use a “.hwidef” file extension.

Use one of the following methods to export an HWI Defaults file that includes all the default settings from
the Hwi Defaults tree view:
• On the File menu, click Export HWI Defaults.
OR
• Right-click the HWI Defaults icon and click Export HWI Defaults.
OR
• Right-click the Controller icon and click Export HWI Defaults.

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HWI Hardware Settings

Import HWI Defaults

Previously exported Hwi Defaults files can be imported. After HwiDefaults are imported, the Hwi Editor
application will use those default values for any subsequent Hwi files that you create.
Note:
Hwi Default files use a “.hwidef” file extension.

Use one of the following methods to import a previously exported Hwi Defaults file.
• On the File menu, click Import HWI Defaults.
OR
• Right-click the HWI Defaults icon and click Import HWI Defaults.
OR
• Right-click the Controller icon and click Import HWI Defaults.

System Options Settings

System Options icon

Velocity Limiter: When enabled (true), limits actuator movement to a maximum of 10 mm/sec. when
displacement is commanded from the RSC or handset. This feature provides compliance to CE requirements.
When Velocity Limiter=True, the manual command control is locked.
Interlocks: When the Hwi File Editor reads existing .hwi files, this value represents the number of interlock
chains in the file. If you are creating a new .hwi file, enter the desired number of interlock chains.

VME Bus Board Settings

VME Board FlexTest FlexTest Aero ST FlexTest FlexTest FlexTest

IIM GT, (493.20) SE 40 60/100/200
(498.xx) Teststar (493.02) (494.04)
(494.06/.10/.20)
IIM
(493.10)

Processor X X X X X X

Model 493.40 I/O Carrier X X X

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VME Board FlexTest FlexTest Aero ST FlexTest FlexTest FlexTest

IIM GT, (493.20) SE 40 60/100/200
(498.xx) Teststar (493.02) (494.04)
(494.06/.10/.20)
IIM
(493.10)

Model 494.40 I/O Carrier X X

Model 493.50 ADDA II X X X

Model 49x.43 Multi-Box I/O X

Model 498.71 GRES II X

Model 498.71 GRES III X X X

Model 498.65 ADDA X

Model 498.70 Digital I/O X

Model 493.42 System Board X

Model 494.41 System Board X

Model 494.44 System Board X

About Processor Boards

Each controller requires one or more processor boards that are installed in the VME chassis. Each processor
board includes at least one CPU (core).

Core functions
Each core performs predefined CPU functions such as, Supervisor (SUP), Digital Signal Processing (DSP),
and Time History Playback (THP). The function(s) assigned to each core depends on the number of
processor boards and the types of options installed.

One processor board

The single core performs SUP and DSP functions.

Two processor boards

By default, the core in Processor [1] performs the SUP and optional THP functions, while the core in
Processor [2] performs the DSP function.

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HWI Hardware Settings

Note:
If necessary, use the Reconfigure Processors option window to reconfigure the core functions for
existing two-processor systems.

Three processor boards

The core in Processor [1] performs the SUP function (and THP if the Hybrid Simulation option is installed),
and the core in Processor [2] performs the DSP function.
The core in Processor [3] performs the THP function (if that option is installed) or the hybrid simulation
(SIM) function (if that option is installed).

Dual-Core Processor
Although these boards occupy one slot, they contain two cores that perform different CPU functions:
Core 1 - performs SUP and THP functions.
Core 2 - performs the DSP function.
Note:
Controllers can only have one dual-core processor with no other processor boards.

Reconfigure Processor Functions

For controllers with the Time History Playback (THP) option and two processors, this option allows you to
change the way the processors are initialized.
Note:
This option will be grayed-out if your controller is not equipped for THP, or has only one or three
processors.

1. From the Options menu, click Reconfigure Processors.

The Reconfigure Processors window shows how your controller is currently configured.

2. If necessary, change the processor setting.

Default Setting: The Shared SUP/THP on 1 and DSP on 2 default setting is recommended for configuring
new controllers.
Existing Settings: Some existing systems may require the “SUP on 1 and shared DSP/THP on 2” OR
“Shared SUP/DSP on 1 and THP on 2” settings.

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Important:
If an existing HWI file uses one of the other settings, do not change the setting.

Processor Hwi Settings

Item Description

Processor circuit board icon Address: Describes the proximity of the circuit board within the chassis.
Processor properties This value is generated during initialization, and should be changed only if
the value read in from an existing .hwi file is wrong.
Slot: Specifies which slot the circuit board occupies in the chassis. More
than one function (such as SUP, DSP, THP, or SIM) may occupy the same
slot.
Application Attribute: Not applicable
# of Cores: (applies to dual-core processors only): If a dual-core processor
(such as the 7100) is used, set the number of cores to two. All other
single-core processors should be set to one.
Note:
This setting cannot be changed if you use the HWI Detect Hardware
feature.

Core icon Each processor board includes at least one core that represents the CPU
on that board.

Function icon Under each Core icon are Function icons that specify what functions are
performed by the CPU (core).
Name: shows the function assigned to that CPU (core). The function(s)
assigned to each core depends on the number of processor boards and
the types of options installed.
SUP = Supervisor
DSP = Digital Signal Processing
THP = Time History Playback
SIM = Hybrid Simulation (option)

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HWI Hardware Settings

Item Description

Processor Number: Not applicable

Interrupt Level: Not applicable

SIM Function icon (optional) The hybrid simulation (SIM) function for internal models is an option that
requires a license key. Once the license key is installed, you must add the
SIM function to the appropriate processor core.
To configure a processor to run the Hybrid Simulation (SIM) option:
1. Right-click the processor Core icon and click Add Simulation Function.
2. Click the SIM Function icon and define the number of input and output
ports.
Note:
Hybrid Simulation is set up by MTS personnel only. This is
described in an internal MTS document.

Reflective memory icon Some options, such as Hybrid Simulation (external model), require a
optional) reflective memory module that is mounted on the processor card.
To add reflective memory to a processor, right-click the DSP Function icon
and click Add Reflective Memory.
Note:
Hybrid Simulation is set up by MTS personnel only. This is described
in an internal MTS document.

Input/Output Port icons Input and output ports are user-defined portions of memory associated with:
(optional)
• Reflective memory (external simulation model). When you add reflective
memory to the DSP core function, you will see a port icon for each import
and export port specified in the Reflective Memory properties.
OR
• The memory on a processor board that is running the hybrid simulation
(SIM) function (internal simulation model). The input/output port icons
appear when you add the hybrid simulation (SIM) function to a processor
and define the number of input/output ports.
Note:
Hybrid Simulation is set up by MTS personnel only. This is
described in an internal MTS document.

Model 493.50 ADDA II Board Settings

This board is compatible with Aero ST, FlexTest GT, FlexTest IIm, and TestStar IIm controllers.

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Item Description

493.50 ADDAII circuit board icon When the optional Model 493.50 ADDA II board is being used,
the .hwi file describes this board and the A/D, D/A, DSPAD, and
encoder mezzanine cards that are installed on it.
The following ADDA II mezzanine cards can be installed:
• Model 493.55 8-A/D (8-Channel)
• Model 493.56 8-D/A (8-Channel)
• Model 493.57 8-A/D (8-Channel)
• Model 493.59-1 U2 Absolute
• Model 493.59-3 U2 Incremental
• Model 493.59-5 U2 Temposonics III

Each mezzanine card can be assigned to one of the four ADDA

II board rear panel connectors. Each mezzanine card definition
is followed by four or eight signal definitions.
The analog I/O definitions provide A/D channels and D/A
channels for analog inputs and outputs from the 498 Analog In
transition boards.
The channel numbers for the analog inputs represent the
available analog-to-digital converters following the list of AC and
DC conditioner signals.
The channel numbers for the analog outputs represent the
available digital-to-analog converters following the list of valve
command signals.

Properties tab Address: Describes the proximity of the circuit board within the
chassis. This value is generated during initialization, and should
be changed only if the value read in from an existing .hwi file is
in error.
Slot: Specifies which slot the circuit board occupies in the
chassis.
Clock Type: Master/Dependent.
For Master Clocks
System Rate: 1024, 2048, 4096 and 6144 Hz (binary).
Note:
The System Rate must be an integer multiple of the
Medium System Rate.

Medium System Rate: Must be an integer multiple of the Low

System Rate.

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HWI Hardware Settings

Item Description

Note:
The Low System Rate is always set at 25.6. The Medium
System Rate is typically 256.

Mezzanines tab Mezzanine: describes the mezzanine cards that are installed
on the ADDA board.

Model 498.71 GRES II Board Settings

This card is compatible with FlexTest IIm controllers.

Item Description

498.71 GRES II circuit board The Model 498.71 GRES II board supports both the Remote Station
icon Controller (RSC) and the temperature controller. It must be added to your
system when using either of these components before the components
are installed in the chassis. The GRES II board communicates to the RSC
or temperature controller via a serial transition card located to the rear of
the chassis.
Address: Describes the proximity of the circuit board within the chassis.
This value is generated during initialization, and should be changed only
if the value read in from an existing .hwi file is in error.
Slot: Specifies which slot the circuit board occupies in the chassis.
Clock Type: Master, Dependent.
For Master Clocks
Clock Mode: Decimal, Binary.
System Rate: 1024, 2048, 4096 and 6144 Hz (binary).
The System Rate must be an integer multiple of the Medium System Rate.
Medium System Rate: Must be an integer multiple of the Low System Rate.
The Low System Rate is always set at 25.6. The Medium System Rate is
typically 256.

Digital Input/Output icons Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Channel: Not applicable.

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Model 49x.43 Multibox I/O Board Settings

This board is used with Aero ST controllers.

Item Description

49x.43 Multi-box I/O circuit Slot: Specifies which slot the circuit board occupies in the chassis.
board icon
System Rate: 512, 1024, 2048, 4096 and 6144 Hz (binary).
Note:
The System Rate must be an integer multiple of the Medium System
Rate.

Medium System Rate: Must be an integer multiple of the Low System Rate.
Note:
The Low System Rate is always set at 25.6. The Medium System
Rate is typically 256.

Model 49x.40 I/O Carrier Board HWI Settings

These settings are for the Model 493.40 and 494.40 I/O Carrier boards.
The Model 493.40 board is compatible with Aero ST, FlexTest GT, FlexTest SE, and TestStar IIm controllers.
The Model 494.40 board is compatible with FlexTest 40/60/100/200 controllers.
Note:
When a 494.40 I/O carrier board is plugged in to a chassis, but the .hwi file does not include the I/O
board, the system load will generate a hardware interlock that you cannot clear.

Paddleboard considerations for the Model 494.40 I/O Carrier

To avoid system-load errors, the Model 494.40 I/O carrier that connects to the paddle board (a circuit
board with ribbon cables that connect the VME bus to the transition bus) must be configured as follows:
• The paddle board must connect to the 494.40 with the lowest VME address.
• The 494.40 board must be configured as Clock type=Master.

Item Description

49x.40 I/O Carrier circuit Describes each Model 49x.40 I/O Carrier board installed in the Chassis and
board icon their installed mezzanine cards. Each I/O Carrier board can support up to
four mezzanine cards.
The first I/O Carrier board in slot three (typical) provides the master clock
(Clock Type=Master) for all other I/O Carrier boards. If a GRES III board is

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HWI Hardware Settings

Item Description

added (typically in Slot 10), the clock type for this I/O Carrier board must
be changed to Clock Type=Dependent.
For FlexTest SE and FlexTest 40 controllers, the System Board provides
the master clock (Clock Type=Master) for the system, so all I/O Carrier
boards must be set to Clock Type= Dependent.

49x.40 Properties tab Address: Describes the proximity of the circuit board within the chassis.
This address setting must match the address switch settings on the 49x.40
board.
Note:
The Detect Hardware feature automatically detects the correct
address setting from the board and enters it in the .hwi file.

Slot: Specifies which slot the circuit board occupies in the chassis.
Application Attribute: an editable string that can be queried by a controller
application.
Clock Type: Master/Dependent.
For Master Clocks (Clock Type = Master):
Clock Mode: Binary/Decimal.
Note:
Changing the clock mode (from binary to decimal or from decimal to
binary) on systems with Series 494 hardware affects the calibration
of AC conditioners which can result in inaccurate readings. If you
want to run in a different clock mode, you must calibrate the
transducer/AC conditioner pair in the new clock mode and run your
tests in the same clock mode.

System Rate: 512 (single-box Aero systems), 1024, 2048, 4096 and 6144
Hz (binary).
Note:
The System Rate must be an integer multiple of the Medium System
Rate.

Medium System Rate: Must be an integer multiple of the Low System Rate.
Note:
The Low System Rate is always set at 25.6. The Medium System
Rate is typically 256.

49x.40 Mezzanines tab Mezzanine: describes the mezzanine cards that are installed on the I/O
Carrier board.

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Model 494.41 Single-Station System Board Settings

The Model 494.41 board is used with FlexTest 40 controllers.

Item Description

494.41 System Board circuit board The System Board defines digital and analog inputs and outputs, and
icon hydraulic power unit (HPU) and hydraulic service manifold (HSM)
functionality.

Properties tab Slot: 4.

Slot 4 in the FT-40 chassis is reserved for the system board.
System Rate: 1024, 2048, 4096 and 6144 Hz (binary).
The System Rate must be an integer multiple of the Medium System
Rate.
Medium System Rate: Must be an integer multiple of the Low System
Rate.
The Low System Rate is always set at 25.6. The Medium System
Rate is typically 256.
Low System Rate: 25.6.

Digital Input/Digital Output icons Name: Describes this resource as it will appear in Station Builder
resource lists when opened against an .hwi file. The name includes
the connector number (for example: “Dig In 1-J54”).
Changing this name may invalidate existing station configurations.

Analog Output icons Name: Describes this resource as it will appear in Station Builder
resource lists when opened against an .hwi file.
Connector: Both Analog Outputs are available on the “DA Output”
connector (located on the front of the 494.04 chassis).
Changing this name may invalidate existing station configurations.

Hydraulic Interface icon (HPU) Connector: J25.

HPU with HSM: True: Indicates the system’s HPU supplies HSMs.
False: used for HPU only systems (allows HPU selection to be
available to Station Builder).
First On: True: Indicates that the first HSM turned on activates the
HPU.
False: Setting First On and Last Off to False allows the HPU to turn
on independent of HSM power.
Setting First On and Last Off to True allows HSM Low selection to
activate HPU High without pressing the HPU buttons.
Last Off: True: Causes the last HSM turned off to turn off the HPU.

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Item Description

The First On/Last OFF settings are only available if the HPU with
HSM setting is True.
Name: Describes this resource as it will appear in Station Builder
resource lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Visible: True: Indicates whether or not the HPU button is visible on
the control panel. Changing Visible to False turns off the HPU button
display on the Station Manager window, provided both First On and
Last Off are True.
The Visible setting is only available when both the First On and First
Off settings are set to True.

Hydraulic Interface icon (HSM) Connector: J28

Name: Describes the hardware resource as it will appear in Station
Builder resource lists.
Changing this name may invalidate existing station configurations.
(Should this be read only?)Type: Solenoid, Proportional, On/Off
Solenoid.
If you select On/Off Solenoid, only two HSM control buttons (Off/On)
will appear on the Station Manager Station Controls panel. For the
other types, three HSM control buttons will appear (Off/Low/High).
If you select Proportional, you configure the proportional output with
the controller software. The output signal can be ramped from 20 mA
(minimum) to 700 mA (maximum) which corresponds with 50 psi (0.4
MPa) and 3000 psi (21 MPa). By default, low pressure is factory set
at 750 psi (5.25 MPa) and high pressure is set at 3000 psi (21 MPa).
Low Percent: 25. HSM low pressure setting as a percentage of
full-scale.
High Percent: 100. HSM high pressure setting as a percentage of
full-scale.
HSM Rate: Slow = 4 seconds. Fast = 2 seconds.
Time to achieve low pressure from zero pressure = (Low Percent
value) x (HSM Rate value).
Time to achieve high pressure from low pressure = (High Percent
value x HSM Rate value) - (Time to achieve low pressure).
Example: If Low Percent value = 25, High Percent value = 100, and
HSM Rate = Slow (4 seconds):
Time to achieve low pressure = 0.25 x 4 = 1 second.
Time to achieve high pressure = (1 x 4) - (1) = 3 seconds.

Interlock Interface icon Connector: J43,J29.

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Item Description

Assign to Interlock: Set to 1.

Gate Interlock: True or False, True = the controller responds to the
gate interlock signal on pins 3 and 4 of J29. (Default=True.) False=J29
pins 3 and 4 are reserved for Program Stop interlock.

Caution:
Failure to enable the gate interlock option on systems
that can operate in Slow (low-flow) mode can result in
unexpected actuator movement when switching the
system from Slow mode to Fast mode.
Unexpected actuator movement can result in injury to
personnel or damage to the equipment.
Enable the gate interlock option for systems that include
a Slow (low-flow) mode for specimen installation.

Model 494.42 Single-Station System Board Settings

The Model 494.42 board is used with FlexTest 40 controllers.

Item Description

494.42 System Board circuit board icon The System Board defines digital and analog inputs and
outputs, and hydraulic power unit (HPU) and hydraulic
service manifold (HSM) functionality.

Properties tab Slot: 4.

Slot 4 in the FT-40 chassis is reserved for the system
board.
System Rate: 1024, 2048, 4096 and 6144 Hz (binary).
The System Rate must be an integer multiple of the
Medium System Rate.
Medium System Rate: Must be an integer multiple of the
Low System Rate.
The Low System Rate is always set at 25.6. The Medium
System Rate is typically 256.
Low System Rate: 25.6.

Digital Input/Digital Output icons Name: Describes this resource as it will appear in Station
Builder resource lists when opened against an .hwi file.

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HWI Hardware Settings

Item Description

The name includes the connector number (for example:

“Dig In 1-J54”).
Changing this name may invalidate existing station
configurations.

Analog Output icons Name: Describes this resource as it will appear in Station
Builder resource lists when opened against an .hwi file.
Connector: Both Analog Outputs are available on the
“DA Output” connector (located on the front of the 494.04
chassis).
Changing this name may invalidate existing station
configurations.
An Acumen system requires an Analog Output that
provides a motor command signal for the Elmo motor
drive. To designate an analog output for the motor
command signal (Elmo Drive), right-click on the Analog
Output icon and click Elmo Output. An Elmo Output icon
appears. Click on this icon to display a list of settings
required for the Acumen system.

Hydraulic Interface icon (HPU) Name: Describes this resource as it will appear in Station
Builder resource lists when opened against an .hwi file.
Changing this name may invalidate existing station
configurations.
Connector: J25.
HPU with HSM: True: Indicates the system’s HPU supplies
HSMs. False: used for HPU only systems (makes the
HPU selection available to Station Builder).
Type:
Off-high–only two HPU control buttons (Off/High) will
appear on the Station Manager Station Controls panel.
Off-low-high–three HPU control buttons (Off/Low/High)
will appear on the Station Manager Station Controls panel.
First On:
True: Indicates that the first HSM turned on activates the
HPU.
False: Setting First On and Last Off to False allows the
HPU to turn on independent of HSM power.
Setting First On and Last Off to True allows HSM Low
selection to activate HPU High without pressing the HPU
buttons.
Last Off: True: Causes the last HSM turned off to turn off
the HPU.

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Item Description

The First On/Last OFF settings are only available if the

HPU with HSM setting is True.
Visible:
True: the HPU button is visible on the Station Manager
control panel.
False: Removes the HPU button display from the Station
Manager control panel, provided both First On and Last
Off are True.
The Visible setting is only available when both the First
On and First Off settings are set to True.

Hydraulic Interface icon (HSM) Name: Describes the hardware resource as it will appear
in Station Builder resource lists.
Changing this name may invalidate existing station
configurations.
Connector: J28
(Should this be read only?)Type: Solenoid, Proportional,
On/Off Solenoid.

Solenoid: three HSM control buttons (Off/Low/High) will

appear on the Station Manager Station Controls panel.
On/Off Solenoid: only two HSM control buttons (Off/On)
will appear on the Station Manager Station Controls panel.
For the other types, three HSM control buttons will appear
(Off/Low/High).

Proportional: you configure the proportional output with

the controller software. The output signal can be ramped
from 20 mA (minimum) to 700 mA (maximum) which
corresponds with 50 psi (0.4 MPa) and 3000 psi (21 MPa).
By default, low pressure is factory set at 750 psi (5.25
MPa) and high pressure is set at 3000 psi (21 MPa).
Connect to HPU: True: Indicates the HSM requires the
HPU to be started (either manually or as “first on”) prior
to being started. False: Indicates the HSM can be
activated without an HPU activation.

Low Percent: 25. HSM low pressure setting as a

percentage of full-scale.
High Percent: 100. HSM high pressure setting as a
percentage of full-scale.
HSM Rate: Slow = 4 seconds. Fast = 2 seconds.
Time to achieve low pressure from zero pressure = (Low
Percent value) x (HSM Rate value).

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HWI Hardware Settings

Item Description

Time to achieve high pressure from low pressure = (High

Percent value x HSM Rate value) - (Time to achieve low
pressure).
Example: If Low Percent value = 25, High Percent value
= 100, and HSM Rate = Slow (4 seconds):
Time to achieve low pressure = 0.25 x 4 = 1 second.
Time to achieve high pressure = (1 x 4) - (1) = 3 seconds.

Interlock Interface icon Connector: J43,J29.

Assign to Interlock: Set to 1.
Gate Interlock: True or False, True = the controller
responds to the gate interlock signal on pins 3 and 4 of
J29. (Default=True.) False=J29 pins 3 and 4 are reserved
for Program Stop interlock.

Caution:
Failure to enable the gate interlock option on
systems that can operate in Slow (low-flow)
mode can result in unexpected actuator
movement when switching the system from
Slow mode to Fast mode.
Unexpected actuator movement can result
in injury to personnel or damage to the
equipment.
Enable the gate interlock option for systems
that include a Slow (low-flow) mode for
specimen installation.

Model 494.44 Two-Station System Board Settings

The Model 494.44 board is used with FlexTest 40 controllers.

Item Description

494.44 System Board circuit board The System Board defines digital and analog inputs and outputs,
icon and hydraulic power unit (HPU) and hydraulic service manifold
(HSM) functionality.

Properties tab Slot: 4.

Slot 4 in the FT-40 chassis is reserved for the system board.

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Item Description

System Rate: 1024, 2048, 4096 and 6144 Hz (binary).

The System Rate must be an integer multiple of the Medium
System Rate.
Medium System Rate: Must be an integer multiple of the Low
System Rate.
The Low System Rate is always set at 25.6. The Medium System
Rate is typically 256.
Low System Rate: 25.6.

Digital Input/Digital Output icons Name: Describes this resource as it will appear in Station Builder
resource lists when opened against an .hwi file. The name includes
the connector number (for example: “Dig In 1-J54”).
Changing this name may invalidate existing station configurations.

Analog Output icons Name: Describes this resource as it will appear in Station Builder
resource lists when opened against an .hwi file.
Connector: Both Analog Outputs are available on the “DA Output”
connector (located on the back of the Model 494.04 chassis).
Changing this name may invalidate existing station configurations.
Each Acumen system requires an Analog Output that provides a
motor command signal for the Elmo motor drive. To designate an
analog output for the motor command signal (Elmo Drive),
right-click on the Analog Output icon and click Elmo Output. An
Elmo Output icon appears. Click on this icon to display a list of
settings required for the Acumen system.

Hydraulic Interface icon (HPU) Connector: J25.

HPU with HSM:
True: Indicates the system’s HPU supplies HSMs.
False: used for HPU only systems (makes HPU selection available
in Station Builder).
Name: Describes this resource as it will appear in Station Builder
resource lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Type:
Off/low/high: three HPU control buttons (Off/Low/High) will appear
on the Station Manager Station Controls panel.
Off/high: two HPU control buttons (Off/High) will appear on the
Station Manager Station Controls panel.
First On:

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HWI Hardware Settings

Item Description

False: Setting First On and Last Off to False allows the HPU to
operate independent of HSM controls.
True: Setting First On and Last Off to True allows HSM Low
selection to activate HPU High without pressing the HPU buttons.
(The first HSM turned on activates the HPU.)
Last Off: True: Causes the last HSM turned off to turn off the HPU.
The First On/Last OFF settings are only available if the HPU with
HSM setting is True.
Visible:
True: Indicates whether or not the HPU button is visible on the
control panel.
False: hides the HPU button display on the Station Manager
window (only if both First On and Last Off are True).
The Visible setting is only available when both the First On and
First Off settings are set to True.

Hydraulic Interface icon (HSM) Connector: J28A or J28B

Name: Describes the hardware resource as it will appear in Station
Builder resource lists.
Changing this name may invalidate existing station configurations.
Interlock: 1 (default for J28A ), 2 (default for J28B).
(Should this be read only?)Type: Solenoid, Proportional, On/Off
Solenoid.

Solenoid: three HSM control buttons (Off/Low/High) will appear on

the Station Manager Station Controls panel.

On/Off Solenoid: only two HSM control buttons (Off/On) will appear
on the Station Manager Station Controls panel.

Proportional: configure the proportional output with the controller

software. The output signal can be ramped from 20 mA (minimum)
to 700 mA (maximum) which corresponds with 50 psi (0.4 MPa)
and 3000 psi (21 MPa). By default, low pressure is factory set at
750 psi (5.25 MPa) and high pressure is set at 3000 psi (21 MPa).

Low Percent: 25. HSM low pressure setting as a percentage of

full-scale.
High Percent: 100. HSM high pressure setting as a percentage of
full-scale.
HSM Rate: Slow = 4 seconds. Fast = 2 seconds.
Time to low pressure from zero pressure = (Low Percent value) x
(HSM Rate value).

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Item Description

Time to achieve high pressure from low pressure = (High Percent

value x HSM Rate value) - (Time to low pressure).
Example: If Low Percent value = 25, High Percent value = 100,
and HSM Rate = Slow (4 seconds):
Time to achieve low pressure = 0.25 x 4 = 1 second.
Time to achieve high pressure = (1 x 4) - (1) = 3 seconds.

Interlock Interface 1 and 2 icon Connector: J43,J29.

Assign to Interlock: Set Interlock Interface 1 to 1or 2, set Interlock
Interface 2 to 1 or 2.
Gate Interlock: True or False, True=the controller responds to the
gate interlock signal on pins 3 and 4 of J29. False=J29 pins 3 and
4 are reserved for Program Stop interlock.

Caution:
Failure to enable the gate interlock option on systems
that can operate in Slow (low-flow) mode can result
in unexpected actuator movement when switching the
system from Slow mode to Fast mode.
Unexpected actuator movement can result in injury to
personnel or damage to the equipment.
Enable the gate interlock option for systems that
include a Slow (low-flow) mode for specimen
installation.

Model 493.42 System Board Settings

The Model 493.42 board is used with FlexTest SE controllers.

Item Description

493.42 System Board circuit The System Board defines digital and analog inputs and outputs, and
board icon hydraulic power unit (HPU) and hydraulic service manifold (HSM)
functionality.

Properties tab Address: Describes the proximity of the circuit board within the chassis.
This value is generated during initialization, and should be changed only
if the value read in from an existing .hwi file is in error.
Slot: 4.
System Rate: 1024, 2048, 4096 and 6144 Hz (binary).

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HWI Hardware Settings

Item Description

The System Rate must be an integer multiple of the Medium System Rate.
Medium System Rate: Must be an integer multiple of the Low System Rate.
The Low System Rate is always set at 25.6. The Medium System Rate is
typically 256.
Low System Rate: 25.6.

Miscellaneous tab # of HPU Interfaces: Allows you to add or remove the HPU interface.
# of HSM Interfaces: Allows you to add or remove the HSM interface.

Digital Input/Digital Output Name: Describes this resource as it will appear in Station Builder resource
icon lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Connector: J54.
Channel: Not applicable.

Hydraulic Interface icon Name: Describes this resource as it will appear in Station Builder resource
(HPU) lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Connector: J25.
HPU with HSM:
True: Indicates the system’s HPU supplies additional HSMs.
False: used for HPU only systems (allows HPU selection to be available
to Station Builder).
First On:
True: Indicates that the first HSM turned on activates the HPU.
False: Setting First On and Last Off to FALSE allows the HPU to turn on
independent of HSM power. Setting First On and Last Off to TRUE allows
HSM Low selection to activate HPU High without pressing the HPU buttons.
Last Off: True: Causes the last HSM turned off to turn off the HPU.
Visible:
True: Indicates whether or not the HPU button is visible on the control
panel. Changing Visible to FALSE turns off the HPU button display on the
Station Manager window, provided both First On an Last Off are True.

Hydraulic Interface icon Name: Describes the hardware resource as it will appear in Station Builder
(HSM) resource lists.
Changing this name may invalidate existing station configurations.
Connector: J28
(Should this be read only?)Type: Solenoid, On/Off Solenoid, Proportional,
Remote.

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Item Description

If you select Proportional, you configure the proportional output with the
controller software. The output signal can be ramped from 20 mA
(minimum) to 700 mA (maximum) which corresponds with 50 psi (0.4 MPa)
and 3000 psi (21 MPa). By default, low pressure is factory set at 750 psi
(5.25 MPa) and high pressure is set at 3000 psi (21 MPa).

If you select On/Off Solenoid, only two HSM control buttons (Off/On) will
appear on the Station Manager Station Controls panel. For the other types,
three HSM control buttons will appear (Off/Low/High).

Remote: select if more than one controller share the same HSM and the
control of the HSM is performed remotely on another controller.

Low Percent: 25. HSM low pressure setting as a percentage of full-scale.

High Percent: 100. HSM high pressure setting as a percentage of full-scale.
HSM Rate: Slow = 4 seconds. Fast = 2 seconds.
Time to achieve low pressure from zero pressure = (Low Percent value)
x (HSM Rate value).
Time to achieve high pressure from low pressure = (High Percent value x
HSM Rate value) - (Time to achieve low pressure).
Example: Suppose Low Percent value = 25, High Percent value = 100,
and HSM Rate = Slow (4 seconds).
Time to achieve low pressure = 0.25 x 4 = 1 second.
Time to achieve high pressure = (1 x 4) - (1) = 3 seconds.

Interlock Interface icon Connector: J43,J29.

Assign to Interlock: Set to 1.

Analog Input/Output icons Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
For FlexTest SE Controllers, the first two analog output resources are
displayed as “Monitor I” and “Monitor 2” by default. These resources
represent BNC connectors on the Controller’s front panel. The third analog
output resource (Anlg Out) is the BNC connector on the system board.
Address: Not applicable.

Model 498.65 ADDA Board Settings

This card is compatible with FlexTest IIm controllers.

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HWI Hardware Settings

Item Description

498.65 ADDA circuit board When the optional Model 498.65 ADDA board is being used, the .hwi file
icon describes this board and the A/D, D/A, and various mezzanine cards that
are installed on it, as follows:
• Model 493.65A-10 8-A/D (8-Channel)
• Model 493.65A-11 8-D/A (8-Channel)
• Model 493.65A-12 Encoder
• Model 493.65A-15 Temposonics
• Model 493.65A-16 Temposonics III
• Model 493.65A-17 Heidenhain 417
• Model 493.65A-18 Heidenhain 425
• Model 493.65A-61 U2 Incremental
• Model 493.65A-62 U2 Temposonics III
• Model 493.65A-66 U2 Absolute

Each mezzanine card can be assigned to one of the four ADDA board
connectors. Each mezzanine card definition is followed by four or eight
signal definitions.

Properties tab Address: Describes the proximity of the circuit board within the chassis.
This value is generated during initialization, and should be changed only
if the value read in from an existing .hwi file is in error.
Slot: Specifies which slot the circuit board occupies in the chassis.

Mezzanines tab Mezzanine n

Model 498.70 Digital I/O Board Settings

This card is compatible with FlexTest IIm controllers.

Item Description

498.70 DI/O circuit board icon Address: Describes the proximity of the circuit board within the chassis.
This value is generated during initialization, and should be changed only
if the value read in from an existing .hwi file is in error.
Slot: Specifies which slot the circuit board occupies in the chassis.

Digital Input/Output icon Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.

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Item Description

Connector: Not applicable.

Model 498.71 GRES II Board Settings

This card is compatible with FlexTest IIm controllers.

Item Description

498.71 GRES II circuit board The Model 498.71 GRES II board supports both the Remote Station
icon Controller (RSC) and the temperature controller. It must be added to your
system when using either of these components before the components
are installed in the chassis. The GRES II board communicates to the RSC
or temperature controller via a serial transition card located to the rear of
the chassis.
Address: Describes the proximity of the circuit board within the chassis.
This value is generated during initialization, and should be changed only
if the value read in from an existing .hwi file is in error.
Slot: Specifies which slot the circuit board occupies in the chassis.
Clock Type: Master, Dependent.
For Master Clocks
Clock Mode: Decimal, Binary.
System Rate: 1024, 2048, 4096 and 6144 Hz (binary).
The System Rate must be an integer multiple of the Medium System Rate.
Medium System Rate: Must be an integer multiple of the Low System Rate.
The Low System Rate is always set at 25.6. The Medium System Rate is
typically 256.

Digital Input/Output icons Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Channel: Not applicable.

Model 493.40 I/O Carrier Mezzanine Cards

The Model 493.40 board is compatible with FlexTest GT, Aero ST, and TestStar IIm controllers.

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HWI Hardware Settings

Mezzanine Card Compatibility

The following table lists the different mezzanine cards and the type of carrier board where they can be
used.

Mezzanine Card 493.40 494.40 498.65 493.50

I/O I/O ADDA ADDA II
Carrier Carrier Board Board

493.14 2SVD# X

493.15 3SVD# X

493.21 DUC, 493.21B DUC, 493.25 DUC X

493.45 6-A/D X

493.46 6-output D/A X

493.47 Encoder Card X

493.48 Accelerometer Input X

493.55 8-A/D (8-Channel), 493.57 8-A/D (8-Channel) X

493.56 8-D/A (8-Channel) X

493.59-1 U2 Absolute, 493.59-3 U2 Incremental, 493.59-5 U2 X

Temposonics III

494.16 VD/DUC X

494.25 Single DUC, 494.26 Dual DUC X

494.45 8-Input A/D X

494.46 8-Output D/A X

494.47 Dual UART/Encoder X

493.65A-10 8-A/D (8-Channel) X

493.65A-11 8-D/A (8-Channel) X

493.65A-12 Encoder, 493.65A-15 Temposonics,493.65A-16 X

Temposonics III, 493.65A-17 Heidenhain 417,493.65A-18
Heidenhain 425, 493.65A-61 U2 Incremental,493.65A-62 U2
Tempo III, 493.65A-66 U2 Absolute

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Model 493.1x Valve Driver Settings

The following settings apply to the Model 493.14 Two-Stage Valve Driver and the Model 493.15 Three-Stage
Valve Driver.

Item Description

493.14 2SVD mezzanine Describes the valve driver mezzanine card.

card icon 493.15 3SVD
mezzanine card icon

Analog Output icon Connector: the connector that joins the resource to the chassis. This will
likely move up to the daughter level.
Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.

Analog Output icon

continued Caution:
Unexpected actuator movement is possible when the servovalve
is clamped.
Unexpected actuator movement can cause injury and
equipment damage.Your controller’s hardware interface file
(.hwi) includes options to clamp the servovalve when a hydraulic
interlock occurs (these options cause the actuator to stop, fully
extend, or fully retract). However, if the servovalve is
imbalanced, it may move unexpectedly when clamped.
Before enabling the valve clamp feature, ensure that the
servovalve is balanced.

Clamp Mode: Causes the servovalve to clamp as specified to prevent

unwanted actuator movement when a hydraulic interlock occurs.
Disabled—Valve does not clamp. This is the default action if the clamp entry
is omitted.
Hardware will short the servovalve drive signal if a software failure is
detected.
Zero—Clamps the servovalve to zero—if valve balance is used, it will clamp
to this value.
Positive—Clamps the servovalve to positive 50% spool opening on a 2-stage
valve driver, 50% outer-loop command on the 3-stage valve driver.
Negative—Clamps the servovalve to negative 50% spool opening on a
2-stage valve driver, 50% outer-loop command on a 3-stage valve driver.

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HWI Hardware Settings

Item Description

2SVD icon Range: Defines the output (in mA) of the valve driver. The settings are 25
or 50.
Mode: Identifies single or multiple valve driver support. The settings are
Single or Dual.
Dual valve driver support requires a special manifold.

Model 493.2x DUC Card Settings

Settings for the Model 493.21 DUC Card, 493.21B DUC Card, and 493.25 DUC card.

Item Description

493.2x DUC mezzanine card The conditioner definitions describe the characteristics of the Digital
icon Universal Conditioner (DUC) mezzanine card.

Analog Input icon Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Connector: Describes the connector that joins the resource to the chassis.
This will likely move up to the daughter level.
Filter: Settings include: 0 (no filter), 50 (Hz), 100 (Hz), 300 (Hz), 500 (Hz),
or 1000 (Hz).

DUC icon Mode: Specifies the type of conditioning (AC or DC) the DUC will perform.
DUC Icon Right-click Options
Right-click the 493.21B or 493.25 DUC icon to select from the following
options:
• Add Acceleration Compensation
• Add DIO Load Washer
• Add Serial Load Washer

How to Add Accelerometer Compensation to a Model

493.21B/493.25 DUC
This procedure only applies to Model 493.21B and 493.25 DUCs.
1. Add a 493.48 Accelerometer Conditioner board to the .hwi file.
2. Right-click the DUC icon and select Add Accelerometer Compensation.
A 493.48 Accel Input resource appears as an Auxiliary Input on the DUC Properties tab.

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3. If necessary, change the hardware resource name to match the Accel Input where the accelerometer
is physically connected.

How to Add a DI/O Load Washer to a Model 493.21B/493.25 DUC

This procedure only applies to Model 493.21B and 493.25 DUCs.
1. Add a 493.72 DI/O board resource to the .hwi file.
2. Right-click the DUC icon and select Add DIO Load Washer.
A DI/O Load Washer icon appears below the DUC icon.

3. Click the DI/O Load Washer icon and verify that the hardware resource names that appear in the Zero
Bit, One Bit, and Enable boxes are correct.
4. If the hardware resource names are not correct, change the hardware resources names in these boxes
to match the Digital Inputs where these signals are physically connected.
5. If you want to assign custom names to each range, use the Hwi File Editor application to change the
range names to match the range names that you will use in the Station Manager application.
Note:
The range names that appear in the DI/O Load Washer Properties tab must match the range
names assigned in the Sensor tab in the Station Manager application.

How to Add a Serial Load Washer to a Model 493.21B/493.25 DUC

This procedure only applies to Model 493.21B and Model 493.25 DUCs.
1. Add a serial comm resource to the .hwi file (for example, 498.71B GRES III or Ramix serial card).
2. Right-click the DUC icon and select Add Serial Load Washer.
A Serial LoadWasher icon appears below the DUC icon.

3. Configure the Serial LoadWasher.

a) Click the Serial LoadWasher icon.
b) From the Serial Port drop-down list, select the serial port where the loadwasher is connected.
c) Verify the scale settings are correct for the loadwasher that you are using.
d) If you want to assign custom names to each range, use the Hwi FIle Editor application to change
the range names to match the range names that you will use in the Station Manager application.

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Note:
The range names that appear in the Serial LoadWasher Properties tab must match the range
names assigned in the Sensor tab in the Station Manager application.

Model 493.45 Six-Channel A/D Card Settings

Item Description

493.45 6-Input A/D mezzanine card icon Describes the six-channel analog-to-digital converter mezzanine
card.

Channels tab Analog Input n

High Level Specifies an externally conditioned signal in the range of +/-10V.

No Channel Excludes inputs to the selected channel.

Analog Input icon Name: Describes this resource as it will appear in Station Builder
resource lists when opened against an .hwi file.
Changing this name may invalidate existing station
configurations.
Connector: Describes the connector that joins the resource to
the chassis. This will likely move up to the daughter level.

Model 493.46 Six-Output D/A Card Settings

Item Description

493.46 6-Output D/A Describes the six-channel digital-to-analog converter mezzanine card.
mezzanine card icon

Properties tab

Channels tab Analog Output n

High Level Specifies an externally conditioned signal in the range of +/-10V.

No Channel Excludes inputs to the selected channel.

Channels tab 493.79 Multiple For special applications, the Model 493.79 Multiple Universal Driver (MUD)
Universal Valve 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 mezzanine
card on the Model 493.40 I/O Carrier boards.

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Item Description

When you select a MUD board, the Assign Channels dialog appears with
the following fields:
# of Channels: Specifies the number of analog output channels to which
the MUD board applies. By default, this number will include the current
and all descending channels.
Transition Slot #: Specifies the slot in which the MUD board is installed in
the chassis.
Channel #: Specifies the channel number that maps to the selected analog
output.

Analog Output icon Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations. .
Connector: Identifies the I/O Carrier rear panel connector that is available
for MUD board output. This will likely move up to the daughter level.

493.79 MUD icon Slot: Specifies which slot the circuit board occupies in the chassis.
Channel: Not applicable.
Interlock Enable: Indicates the status of cable loss detection:
false=disabled, true=enabled.
Range: Identifies the range of the valve driver’s output (in mA). The settings
are 0, 25, 50, or 75. The 0 setting requires an on-board user-selectable
resistor.

Model 493.47 Encoder Card Settings

Item Description

493.47 Encoder mezzanine The encoder definition describes the optional 493.47 Digital Encoder
card icon mezzanine card. This board must be installed if you want to monitor
encoder or Temposonics sensor feedback.

Analog Input icon Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Connector: Identifies the I/O Carrier rear panel connector that is available
for MUD board output. This will likely move up to the daughter level.

Encoder icon Mode: Specifies what type of device is to be connected. Options are
Incremental, Temposonics 24 Bit, Temposonics 25 Bit, and Teledyne
(absolute encoder, hardware supports 17-bit resolution).

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SSI/Gurley Encoder Application Settings

Application Encoder Settings

Type = Signed Type = Unsigned

Output 4095
Physical Zero Position at Minimum N/A
or Maximum Stroke (device
0 Position
dependent)

Output 4095
Physical Zero Position at Mid N/A
Stroke (device dependent)
0 Position

-2048

Output 4095
Velocity from Device (Temposonics N/A
R option)
0 Velocity

-2048

Note:
The graphs shown above represent a 12-bit linear device.

Application Encoder Signal Range Encoder Settings

Power-up Signal range Type Turns Position

Counting Filter

Operating Signal range

Position-Limited FloatValue Unsigned True Yes

Rotation ~ +360 degrees
SSI Value
Power-up signal 0
4095

range: 0 to 360
degrees

Unlimited Rotation FloatValue

~ +360 degrees Unsigned False See Note
Operating-signal
range: 0 to 360 0 4095 SSI Value

degrees

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Application Encoder Signal Range Encoder Settings

Power-up Signal range Type Turns Position

Counting Filter

Operating Signal range

Position-Limited FloatValue
~ +180 degrees
Signed True Yes
Rotation
SSI Value
Power-up signal -2048
0
2047

range: -180 to +180 ~ -180 degrees

degrees

Unlimited Rotation -2048

FloatValue
+180 degrees
Signed False See Note
Operating-signal 0
SSI Value

range: -180 to +180 -180 degrees

2047

degrees

Note:
Rotary SSI/Gurley devices with Turns Counting = False: filtering may be undesirable because as
the signal is filtered, the angle step that occurs every 360 degrees causes ringing due to the
high-frequency content of the step. Filtering occurs normally if the encoder is operated in a range
that does not include the angle step.

Model 493.48 Accelerometer Input Card Settings

Item Description

493.48 Accel. Input On systems affected by acceleration induced errors, an optional

mezzanine card icon acceleration conditioner board can be linked to a conditioner (DUCB only)
to perform acceleration compensation.
The acceleration conditioner definition specifies a list of auxiliary inputs
that the DUC conditioners can use on the acceleration mezzanine card.
(Each DUC mezzanine card definition is enhanced to allow an auxiliary
input to be defined.)

Accel. Input icons Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Connector: Not applicable.

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Model 493.50 ADDA II Mezzanine Cards

The mezzanine cards listed in this section can be used in the Model 493.50 ADDA II board. The Model
493.50 board is compatible with FlexTest IIm, FlexTest GT, Aero ST, and TestStar IIm controllers.

Model 493.55/493.57 8-Channel A/D Card Settings

Item Description

493.55 and 493.57 8-A/D The Model 493.55 8-A/D mezzanine card, available for installation on
mezzanine card icon ADDA II boards, provides 8 channels of A/D with digital filtering. Filter
settings can be applied to controller feedback, scope, meter, and limit
detector signals. Each D/A mezzanine card definition is followed by eight
signal definitions.

Properties tab Filter: On/Off.

The 493.57 A/D Card includes an elliptical filter with the following settings
(available through the Analog Input icon): off, 500, 1000, 1500, 2000 Hz.

Channels tab Analog Input n

High Level Specifies an externally conditioned signal in the range of +/-10V.

No Channel Excludes inputs to the selected channel.

497.13 AC/497.14 AC/497.22 Chassis: Not applicable.

Dual DC Conditioner icon
Slot: Specifies which slot the circuit board occupies in the chassis.
Channel: Not applicable.
Filter: On/Off.
Connector: Not applicable.

Model 493.56 8-Channel D/A Card Settings

Item Description

493.56 8-D/A mezzanine card The analog output definition describes the D/A Analog Output mezzanine
icon card.
The connector specification identifies the rear panel connector that is
available for analog outputs.

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Item Description

Properties tab Filter: On/Off.

Channels tab Analog Output n

High Level Specifies an externally conditioned signal in the range of +/-10V.

No Channel Excludes inputs to the selected channel.

497.15 3-Stage/497.26 Dual Chassis: Not applicable.

2-Stage Valve Driver icon
Slot: Specifies which slot the circuit board occupies in the chassis.
Channel: Not applicable.
Filter: Not applicable.
Connector: Not applicable.

Model 493.59x Encoder Card Settings

Encoder mezzanine cards use the following designators for each type of encoder: 1 for absolute encoders,
3 for incremental encoders, and 5 for Temposonics III encoders

Item Description

493.59-1 U2 Absolute/ Encoders require a special mezzanine card be plugged into the ADDA II
493.59-3 U2 Incremental/ board. The encoder mezzanine card can occupy any of the four ADDA II
493.59-5 U2 Temposonics III address locations.
mezzanine card icons
• The encoder mezzanine card supports four encoder signals.
• The encoder mezzanine card processes the pulse stream from an
encoder.

Temposonics III sensors require a special mezzanine card on the ADDA

board. The Temposonics III mezzanine card can occupy any of the four
ADDA address locations.
• The Temposonics III mezzanine card supports two “double-wide”
Temposonics sensor signals.
• The Temposonics III mezzanine card processes pulses from the digital
output of a Temposonics III sensor.

Filter: On/Off.
Baud Rate: (493.59-1 U2 Absolute and 493.59-5 U2 Temposonics III only)
Select a baud rate. Allows you to change the baud rate if the cable length
requires a slower baud rate

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Item Description

Analog Input icon Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Connector: Describes the connector that joins the resource to the chassis.
This will likely move up to the daughter level.

Model 494.40 I/O Carrier Mezzanine Cards

The mezzanine cards listed in this section can be used in the Model 494.40 I/O Carrier board. The Model
494.40 board is compatible with FlexTest 40/60/100/200 controllers.

High Speed Data Acquisition Settings

Each Series 494 DUC has a High Speed Data hwi setting that is used to enable high-speed data acquisition.
Note:
High-speed data acquisition is required for some applications (for example, the MPT High Speed
Timed Acquisition process).

High-speed data limitations

The Model 494.40 I/O Carrier board allows up to six high-speed data inputs per carrier board. This could
be an issue if four Model 494.26 Dual DUCs are installed on a 494.40 I/O carrier.

Setting Description

True Enables high-speed data acquisition. The high-speed rate is determined

by the system rate and a number of other factors.
See your test application documentation for details.

False (default) High-speed data acquisition is not available.

Model 494.16 VD/DUC HWI Settings

Item Description

494.16 VD/DUC mezzanine Describes the valve driver/DUC mezzanine card.

card icon
Application Attribute: Not applicable

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Item Description

Type: defines how the card is used and what resources are available.
• DUC and 2SVD: when configured as a two-stage valve driver, the DUC
portion of this card is available as a system resource.
• 3SVD: when configured as a three-stage valve driver, the DUC portion
of this card is reserved for the valve LVDT.

494.16 Analog Input icon Note:

The Analog Input icon only appears if the 494.16 VD/DUC is
configured as a two-stage valve driver.

Name: Describes this resource as it will appear in Station Builder resource

lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Connector: Describes the front-panel I/O Carrier connector assigned to
this input.
Application Attribute: Not applicable.
Filter Type: Used to select the type of filter used to filter the digital output
of the DUC. Selections include: Disabled, Bessel, Butterworth, and Elliptical.
(Default=Bessel, 300 Hz.)
Filter: This is the frequency where the filter, selected in the Filter Type box,
attenuates the signal by 3 dB. A setting of zero disables the filter.
High Speed Data:
True=enables high-speed data acquisition. The high-speed rate is
determined by the system rate and a number of other factors.
False (default) = high-speed data acquisition is not available.
The Model 494.40 I/O carrier limits the number of high-speed data inputs
on a carrier to a maximum of six.

494.16 Analog Output icon Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Application Attribute: Not applicable.
Connector: Describes the front-panel I/O Carrier connector that joins the
resource to the chassis.
Clamp Mode: Causes the servovalve to clamp as specified to help prevent
unwanted actuator movement when a hydraulic interlock or various
processor errors occur.
• Disabled—Valve does not clamp. This is the default action if the clamp
entry is omitted.
• Zero—Clamps the servovalve to zero—if valve balance is used, it will
clamp to this value.

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Item Description

• Positive—Clamps the servovalve to positive 50% spool opening on a

2-stage valve driver, 50% outer-loop command on the 3-stage valve
driver.
• Negative—Clamps the servovalve to negative 50% spool opening on
a 2-stage valve driver, 50% outer-loop command on a 3-stage valve
driver.

Caution:
Your controller’s hardware interface file (.hwi) includes options
to clamp the servovalve when a hydraulic interlock occurs
(these options cause the actuator to stop, fully extend, or fully
retract). However, if the servovalve is imbalanced, it may move
unexpectedly when clamped.
Unexpected actuator movement can cause injury and
equipment damage.
Before enabling the valve clamp feature, ensure that the
servovalve is balanced.

2SVD Analog Output icon Mode: Select Single to configure this card to drive a single servovalve;
select Dual to configure this card to drive dual servovalves.
Range: Enter the full-scale current value for the servovalve driven by this
card (100 mA maximum per output).

Model 494.21 Multi-Range DUC with Acceleration Compensation

Card HWI Settings
This card combines a DUC and an accelerometer compensation input on a single card. The summing of
the two signals is done on the card based on settings in your test application.

Item Description

494.21 DUC mezzanine card icon Describes the valve driver/DUC mezzanine card.

494.xx Analog Input icon Connector: Describes the front-panel I/O Carrier connector assigned
to this input.
Name: Describes this resource as it will appear in Station Builder
resource lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.

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Item Description

Filter Type: Used to select the type of filter used to filter the digital
output of the DUC. Selections include: Disabled, Bessel, Butterworth,
and Elliptical.
Filter: This is the frequency where the filter, selected in the Filter Type
box, attenuates the signal by 3 dB. A setting of zero disables the filter.
(Default=Bessel, 300 Hz.)
High Speed Data:
True=enables high-speed data acquisition. The high-speed rate is
determined by the system rate and a number of other factors.
False (default) = high-speed data acquisition is not available.
The Model 494.40 I/O carrier limits the number of high-speed data
inputs on a carrier to a maximum of six.

494.xx DUC icon Mode: Specifies the transducer type (AC/DC) connected to the DUC.
Bridge Type (DC only): specifies the type of bridge (full, half, quarter)
and the number of wires. The High Level option is used for high-level
voltage inputs (typically ± 10 V DC).
Shunt Excitation/Shunt Feedback (DC only): the shunt excitation and
shunt feedback settings determine where the shunt calibration resistor
is applied.

494.xx Accel Input icon The Accel Input icon only appears if you right-click the DUC icon and
and select Add Accelerometer Compensation.
Name: Describes this resource as it will appear in Station Builder
resource lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Connector: Describes the front-panel I/O Carrier connector assigned
to this input.
Input Selection: specifies the type of accelerometer that you will
connect to the acceleration input.
Bridge Device: this selection provides an input for the output from a
bridge-type accelerometer.
Current Source: this selection provides a 3.5 mA current source
excitation and a differential amplifier for direct accelerometer
connections.
Acceleration compensation settings appear in your control software.
Select None to disable acceleration compensation in your control
software.

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How to Enable Acceleration Compensation on the Model 494.21

Card
You must enable acceleration compensation on the Model 494.21 Elastomer DUC card before you can
connect an accelerometer.
1. Add the 494.21 DUC to an I/O carrier.
2. Right-click the DUC icon and select Add Accelerometer Compensation.

How to Add a DI/O Load Washer to a Model 494.21 Card

1. Add a 494.21 card resource to the .hwi file.
2. Right-click the DUC icon and select Add DIO Load Washer.
A DI/O Load Washer icon appears below the DUC icon.

3. Click the DI/O Load Washer icon and verify that the hardware resource names that appear in the Zero
Bit, One Bit, and Enable boxes are correct.
4. If the hardware resource names are not correct, change the hardware resources names in these boxes
to match the Digital Inputs where these signals are physically connected.
5. If you want to assign custom names to each range, use the Hwi File Editor application to change the
range names to match the range names that you will use in the Station Manager application.
Note:
The range names that appear in the DI/O Load Washer Properties tab must match the range
names assigned in the Sensor tab in the Station Manager application.

How to Add a Serial Load Washer to a Model 494.21 Card

1. Add a serial comm resource to the .hwi file .
2. Right-click the DUC icon and select Add Serial Load Washer.
A Serial LoadWasher icon appears below the DUC icon.

3. Configure the Serial LoadWasher.

a) Click the Serial LoadWasher icon.
b) From the Serial Port drop-down list, select the serial port where the loadwasher is connected.
c) Verify the scale settings are correct for the loadwasher that you are using.
d) If you want to assign custom names to each range, use the Hwi FIle Editor application to change
the range names to match the range names that you will use in the Station Manager application.

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Note:
The range names that appear in the Serial LoadWasher Properties tab must match the range
names assigned in the Sensor tab in the Station Manager application.

Model 494.25/494.26 DUC HWI Settings

The settings for both the Model 494.25 Single DUC and Model 494.26 Dual DUC mezzanine cards are
the same - with the exception of Acceleration Compensation.
Accelerometer Compensation - The Model 494.26 Dual DUC can be configured for accelerometer
compensation. When configured for accelerometer compensation, the A input is used for the load cell and
the B input is used for the accelerometer.
To configure a dual DUC for accelerometer compensation, right-click on the top DUC icon and click Add
Accelerometer Compensation. Once configured, an Auxiliary Input property that lists the connector
number for the accelerometer input appears at the bottom of the list.

Item Description

494.xx DUC mezzanine card icon Describes the valve driver/DUC mezzanine card.

494.xx Analog Input icon Name: Describes this resource as it will appear in Station Builder
resource lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Filter Type: Used to select the type of filter used to filter the digital
output of the DUC. Selections include: Disabled, Bessel,
Butterworth, and Elliptical.
Filter: This is the frequency where the filter, selected in the Filter
Type box, attenuates the signal by 3 dB. A setting of zero disables
the filter. (Default=Bessel, 300 Hz.)
High Speed Data:
True = enables high-speed data acquisition. The high-speed rate
is determined by the system rate and a number of other factors.
False (default) = high-speed data acquisition is not available.
The Model 494.40 I/O carrier limits the number of high-speed data
inputs on a carrier to a maximum of six.
Connector: Describes the front-panel I/O Carrier connector
assigned to this input.

494.xx DUC icon Mode: Specifies the transducer type (AC/DC) connected to the
DUC.
Bridge Type (DC only): specifies the type of bridge (full, half,
quarter) and the number of wires. The High Level option is used
for high-level voltage inputs (typically ± 10 V DC).

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Item Description

Shunt Excitation/Shunt Feedback (DC only): the shunt excitation

and shunt feedback settings determine where the shunt calibration
resistor is applied. See the following table and figure.

Model 494.45 8-Input A/D Converter HWI Settings

Item Description

494.45 8-Input A/D Describes the eight-channel analog-to-digital converter mezzanine card.
mezzanine card icon

Properties tab Application Attribute: Not applicable

Channels tab Each analog input has a drop-down menu where you can select one of
the following input options:

High Level Specifies an externally conditioned signal in the range of +/-10V.

No Channel Excludes inputs to the selected channel.

Analog Input icon Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Application Attribute: Not applicable
Filter: This is the frequency where the filter, selected in the Filter Type box,
attenuates the signal by 3 dB. A setting of zero disables the filter.
Connector: Describes the I/O Carrier board connector that joins the
resource to the chassis. This will likely move up to the daughter level.
Filter Type: Used to select the type of filter used to filter the digital output
of the A/D Converter. Selections include: Disabled, Bessel, Butterworth,
and Elliptical. (Default=Bessel, 300 Hz.)

Model 494.46 8-Output D/A Converter Card HWI Settings

Item Description

494.46 8-Input D/A mezzanine card Describes the eight-channel digital-to-analog converter mezzanine
icon card.

Properties tab Application Attribute: Not applicable

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Item Description

Channels tab Each analog output has a drop-down menu where you can select
one of the following output options:

High Level Specifies an analog output in the range of +/-10V.

No Channel Excludes outputs to the selected channel.

49x.79 Multiple Universal Valve Specifies that this output is used to drive one of the valve drivers
Driver on the Model 49x.79 8-Channel Valve Driver transition board.
When you select the 49x.79 Valve Driver, the Assign Channels
window appears.
# of Channels: Specifies the number of analog output channels
to which the MUD board applies. By default, this number will include
the current and all descending channels.
Transition Slot #: Specifies the slot in which the Valve Driver
board is installed in the chassis.
Channel #: Not applicable

Analog Output icon Name: Describes this resource as it will appear in Station Builder
resource lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Application Attribute: Not applicable
Connector: Describes the I/O Carrier board connector that joins
the resource to the chassis. This will likely move up to the daughter
level.
Each Acumen system that runs on a FlexTest 60 Controller requires
an Analog Output that provides a motor command signal for the
Elmo motor drive. The analog output is provided by a Model 494.46
mezzanine card. To designate an analog output for the motor
command signal (Elmo Drive), right-click on the Analog Output
icon and click Elmo Output. An Elmo Output icon appears. Click
on this icon to display a list of settings required for the Acumen
system.

494.79 MUD icon Slot: Specifies which slot the circuit board occupies in the chassis.
Channel: Not applicable.
Interlock Enable: Indicates the status of cable loss detection:
false=disabled, true=enabled.
Range: Sets the range of the valve driver’s outputs (in milliamps).
There are two different ways to set the valve driver’s output range:
• For most standard servo valves - Enter one of the following
valve-driver range values: 25, 50, or 75. Range values are in
milliamps, for example: 25=25 mA, 50=50 mA, and 75=75 mA.

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Item Description

• For non-standard servo valves - MTS installs resistors on

the board that set the valve-driver range. When resistors are
installed, you must set the Range value to zero.
Important:
If factory-installed resistors are used to set a
non-standard valve-driver range, this range is added to
each of the allowable Hwi range settings (0, 25, 50, 75).
For example, if the resistor provides a 15 mA range: a
range setting of 0 becomes 15 mA, a setting of 25
becomes 40 mA, a setting of 50 becomes 65 mA, and a
setting of 75 becomes 90 mA.

Model 494.47 Dual UART/Encoder/External Clock HWI Settings

You can configure this card to condition two UART devices, or two encoders, or to provide an external
clock output.

Item Description

494.47 Dual Type: specifies the type of device used with this card: Encoder, UART, or
UART/Encoder/External external clock output.
Clock mezzanine card icon
The external clock selection provides an external clock output (RS-485
differential output) on the front-panel JXA connector located on the Model
494.40 I/O Carrier. The external clock output can be used to synchronize
subsystems (such as data acquisition) to the controller clocks.

Encoder Properties Note:

The following settings only appear if Encoder was selected from the
Type menu.

Application Attribute: Not applicable

Mode : specifies the type of encoder used with this card: Gurley (Teledyne),
Incremental/Velocity, SSI (Temposonics R), PWM (Temposonics G).
Debounce Filter: specifies the filtering applied to the input signal. Debounce
filtering is typically used clean up the shape of the pulse in situations where
there are long cable runs or signals with long rise and fall times (for example,
a proximity switch counting gear teeth) with noise riding on the signal.
The default setting (40 ns) works for most applications. Incremental/velocity
encoder signals (especially single-ended counter types) are somewhat more
susceptible to noise. If the noise results in extra counts, you may need a
longer debounce time setting. If the debounce setting is too long, the
debounce filter will filter out the encoder signal.

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Item Description

SSI (Temposonics R) /Gurley (Teledyne) encoders only:

Resolution (bits): this setting must match the number of bits in the encoder’s
data stream. Gurley=16 or 17 bits; SSI=1-32 bits.
Baud Rate: specifies the communications clock rate between the processor
and the encoder.
Type: specifies the type of encoding (Binary or Gray Scale) used by the
encoder.

Encoder icon Application Attribute: Not applicable

Type
For Incremental/Velocity and PWM (Temposonics G) encoders, selections
include Quadrature or Counter (single ended).
For SSI (Temposonics R) and Gurley (Teledyne) encoders, selections
include Signed or Unsigned.
For rotary devices, this setting is user preference. When “Turns Counting”
(see below) is enabled, the “Signed/Unsigned” setting only affects the range
of the initial reading at power up.
For linear devices, the “Signed/Unsigned” selection is based on the behavior
described below.
• Signed–the reading from the device represents both positive and negative
values. For example, -180 to +180 degrees for a rotary device, -100mm
to +100mm for a linear device.
• Unsigned–the reading from the device represents only positive values.
For example, 0 to 360 degrees for a rotary device, 0mm to +200mm for
a linear device.

Encoder icon Mode

Selections include Rotary or Linear.
Turns Counting (rotary encoders only): (only available for SSI (Temposonics
R) and Gurley (Teledyne) settings)
True: the firmware adds an offset to the signal that reflects the number of
turns (for each turn, the firmware adds 360 degrees to the encoder output
signal.) For example, if the device powers up at 0 degrees and rotates 1.5
positive revolutions, the encoder channel will read 540 degrees.
False: the encoder channel represents the actual reading from the device.
Each time the encoder signal reaches 360 degrees, the encoder output
resets to zero. For example, if the device powers up at 0 degrees and is
rotated 1.5 positive rotations, the encoder channel will read 180 degrees.

Encoder icon AutoZero on Index Pulse

(only available for the Incremental/Velocity setting):

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Item Description

True: the encoder position signal is zeroed each time an index pulse is read.

False (default): after a maximum count of 231, the encoder position signal
resets to -231 and continuously counts up to 231 and resets.

Analog Input icons Each encoder input includes two analog-input icons:
Analog Inputs (position) with encoder icons–allow you to set input filtering
for the encoder position signals.
Analog Input (velocity) icons–allow you to set input filtering for the velocity
signal derived (by firmware) from the encoder’s position signal.
Connector: the connector number for that input.
Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Note:
Changing this name may invalidate existing station configurations.

Application Attribute: Not applicable

Input Filter Settings:
Filter Type: Used to select the type of digital filter used to filter the input
signal. Filter selections include: Disabled, Bessel, Butterworth, and Elliptical.
(Default=Bessel, 300 Hz.)
Filter: This is the frequency where the filter, selected in the Filter Type box,
attenuates the signal by 3 dB.
Low frequency limit = >0 Hz (A setting of 0 disables the filter.) High frequency
limit = 1/2 the system rate.
Important:
Rotary SSI/Gurley devices with Turns Counting = False: filtering may
be undesirable because as the signal is filtered, the angle step that
occurs every 360 degrees causes ringing due to the high-frequency

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Item Description

content of the step. Filtering occurs normally if the encoder is operated

in a range that does not include the angle step.

UART Serial Comm icon Note:

Only appears when UART is selected as the device type.

Connector: the connector that joins the resource to the chassis.

Name: describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Note:
Changing this name may invalidate existing station configurations.

Baud Rate: select the baud rate for the serial device.
Type: select the type of device (2-wire or 4-wire). This setting defines which
pins are used and how the system communicates with the UART device.
Note:
Model 409 Temperature Controllers are 2-wire devices; Model 494.05
Handsets are 4-wire devices.

Application Attribute: Not applicable

External Clock icon Note:

Only appears when external clock is selected as the device type.

Name: Describes this resource.

Note:
Changing this name may invalidate existing station configurations.

Output Clock Rate: enter the frequency (Hz) for the clock output.
Application Attribute: Not applicable

SSI/Gurley Encoder Application Settings

Application Encoder Settings

Type = Signed Type = Unsigned

Physical Zero Position at Minimum N/A

or Maximum Stroke (device
dependent)

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Application Encoder Settings

Type = Signed Type = Unsigned

Output 4095
Physical Zero Position at Mid N/A
Stroke (device dependent)
0 Position

-2048

Output 4095
Velocity from Device (Temposonics N/A
R option)
0 Velocity

-2048

Note:
The graphs shown above represent a 12-bit linear device.

Application Encoder Signal Range Encoder Settings

Power-up Signal range Type Turns Position

Counting Filter
Operating Signal range

Position-Limited FloatValue Unsigned True Yes

Rotation ~ +360 degrees
SSI Value
Power-up signal 0
4095

range: 0 to 360
degrees

Unlimited Rotation FloatValue

~ +360 degrees Unsigned False See Note
Operating-signal
range: 0 to 360 0 4095 SSI Value

degrees

Position-Limited FloatValue
~ +180 degrees
Signed True Yes
Rotation
SSI Value
Power-up signal -2048
0
2047

range: -180 to +180 ~ -180 degrees

degrees

Unlimited Rotation -2048

FloatValue
+180 degrees
Signed False See Note
Operating-signal 0
SSI Value

range: -180 to +180 -180 degrees

2047

degrees

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Note:
Rotary SSI/Gurley devices with Turns Counting = False: filtering may be undesirable because as
the signal is filtered, the angle step that occurs every 360 degrees causes ringing due to the
high-frequency content of the step. Filtering occurs normally if the encoder is operated in a range
that does not include the angle step.

Model 494.49 Quad Encoder Interface HWI Settings

You can configure this card to condition four encoders, or to provide an external clock output. When
configured for encoders, each encoder includes two signals:
• The position signal from the encoder
• A velocity signal derived from the encoder’s position signal

With the exception of no support for UART devices, the Model 494.49 .HWI settings are identical to the
Model 494.47 .HWI settings.

Model 498.65A-10 Eight-Channel Card Settings

Item Description

498.65A-10 8-A/D mezzanine The Model 498.65A-10 8-A/D mezzanine card, available for installation on
card icon ADDA boards, provides 8 channels of A/D with digital filtering. Filter settings
can be applied to controller feedback, scope, meter, and limit detector
signals. Each D/A mezzanine card definition is followed by eight signal
definitions.

Properties tab Address: Describes the proximity of the mezzanine card within the circuit
board. This value is generated during initialization, and should be changed
only if the value read in from an existing .hwi file is in error.
Filter: Off/On.

Channels tab Analog Input n

High Level Specifies an externally conditioned signal in the range of +/-10V.

No Channel Excludes inputs to the selected channel.

497.13 AC/497.14 AC/497.22 Chassis: Not applicable.

Dual DC Conditioner icon
Slot: Specifies which slot the circuit board occupies in the chassis.
Channel: Not applicable.
Filter: Off/On.
Connector: Not applicable.

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Model 498.65A-11 D/A Card Settings

Item Description

498.65A-11 8-D/A mezzanine The analog output definition describes the D/A Analog Output mezzanine
card icon card.
The connector specification identifies the rear panel connector that is
available for analog outputs.

Properties tab Address: Describes the proximity of the mezzanine card within the circuit
board. This value is generated during initialization, and should be changed
only if the value read in from an existing .hwi file is in error.
Filter: Off/On.

Channels tab Analog Output n

High Level Specifies an externally conditioned signal in the range of +/-10V.

No Channel Excludes inputs to the selected channel.

497.15 3-Stage/497.26 Dual Chassis: Not applicable.

2-Stage Valve Driver icon
Slot: Specifies which slot the circuit board occupies in the chassis.
Channel: Not applicable.
Filter: Not applicable.
Connector: Not applicable.

Model 498.65A-12 Encoder Card Settings

Item Description

498.65A-12 Encoder/ -15 The analog input definition describes the encoder mezzanine card.
Temposonics/ -16
The connector specification identifies the rear panel connector that is
Temposonics III/ -17
available for analog inputs.
Heidenhain 417/ -18
Heidenhain 425/ -61 U2 Address: Describes the proximity of the mezzanine card within the circuit
Incremental/ -66 U2 Absolute board. This value is generated during initialization, and should be changed
mezzanine card icon only if the value read in from an existing .hwi file is in error.
Filter: Off/On.

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Item Description

Analog Input icon Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Address: Not applicable.
Connector: Describes the connector that joins the resource to the chassis.
This will likely move up to the daughter level.

Transition Board Settings

Transition boards are used in FlexTest GT, TestStar IIm, Aero ST, and FlexTest 60/100/200 controllers.

Model 493.72 Digital I/O Transition Board Settings

Item Description

493.72 DI/O transition board The DI/O Transition Board definition describes the Model 493.72 Digital
icon I/O Transition Panel digital input and outputs. The information shown
defines 16 digital inputs and 16 digital outputs.
Transition Slot: Specifies the transition slot where this board is installed.

Digital Input/Digital Output Name: Describes this resource as it will appear in Station Builder resource
icon lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Connector: Describes the connector that joins the resource to the chassis.
This will likely move up to the daughter level.

Model 493.73 HPU Transition Board Settings

Item Description

493.73 HPU transition board Transition Slot: Specifies the transition slot where this board is installed.
icon

Hydraulic Interface icon Name: Describes the hardware resource as it will appear in Station Builder
resource lists.
Changing this name may invalidate existing station configurations.

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Item Description

Connector: J25. (Should this be read only?)

HPU with HSM: True: Indicates the system’s HPU supplies additional
HSMs. False: used for HPU only systems (makes HPU selection available
in Station Builder).
Type:
Off-high–only two HPU control buttons (Off/High) will appear on the Station
Manager Station Controls panel.
Off-low-high–three HPU control buttons (Off/Low/High) will appear on the
Station Manager Station Controls panel.
Power Type: Select Electric or Hydraulic depending upon system power.
First On: True: Indicates that the first HSM turned on activates the HPU.
False: Setting First On and Last Off to False allows the HPU to turn on
independent of HSM power. Setting First On and Last Off to True allows
HSM Low selection to activate HPU high without pressing the HPU buttons.
Last Off: True: Causes the last HSM turned off to turn off the HPU.
Visible: True: Indicates whether or not the HPU button is visible on the
control panel. Changing Visible to False turns off the HPU button display
on the Station Manager window, provided both First On and Last Off are
True.

Model 493.74 HSM Transition Board

Item Description

493.74 HSM transition board icon The hydraulic control definition assigns the Hydraulic Power Unit
(HPU) transition board and each Hydraulic Service Manifold (HSM)
transition board to their appropriate rear panel connectors. Each of
the two HSM transition boards allowed in your system can support
up to two HSM stations.
Transition Slot: Specifies the transition slot where this board is
installed.

Hydraulic Interface icon Changing this name may invalidate existing station configurations.
Name: Describes this resource as it will appear in Station Builder
resource lists when opened against an .hwi file.
Connector: J28A or J28B.
Type: Solenoid, On/Off Solenoid, Proportional.

If you select On/Off Solenoid, only 2 HSM control buttons (Off/On)

will appear on the Station Manager Station Controls panel. For the
other types, 3 HSM control buttons will appear (Off/Low/High).

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Item Description

If you select Proportional, you configure the proportional output with

the controller software. The output signal can be ramped from 20
mA (minimum) to 700 mA (maximum) which corresponds with 50
psi (0.4 MPa) and 3000 psi (21 MPa). By default, low pressure is
factory set at 750 psi (5.25 MPa) and high pressure is set at 3000
psi (21 MPa).

Hydraulic Interface icon (continued) Low Percent: 25. HSM low pressure setting as a percentage of
full-scale.
High Percent: 100. HSM high pressure setting as a percentage of
full-scale.
HSM Rate: Slow = 4 seconds. Fast = 2 seconds.
Ramp time from zero to low pressure = Low Percent value x HSM
Rate value
Ramp time from low to high pressure = High Percent value x HSM
Rate value / Ramp time from zero to low pressure
Time to achieve low pressure from zero = (Low Percent value) x
(HSM Rate value).
Time to achieve high pressure from low pressure = (High Percent
value x HSM Rate value) - (Time to achieve low pressure).
Example: Suppose Low Percent value = 25, High Percent value =
100, and HSM Rate = Slow (4 seconds).
Time to achieve low pressure = 0.25 x 4 = 1 second
Time to achieve high pressure = (1 x 4) - (1) = 3 seconds
Connect to HPU:
True: Indicates the HSM requires the HPU to be started (either
manually or as “first on”) prior to be started.
False: Indicates the HSM can be activated without an HPU activation.

Interlock Interface icon Connector: J29A or J29B.

Assign to Interlock: Select a interlock chain (1–8) for the J29
interlocks. You can assign more than one J29 interlock to the same
interlock chain to provide redundancy.
Note:
Typically, the interlock chain assignment that you make in the
.hwi file should match the interlock chain that you assign to
the station when you load it in Station Manager.

Gate Interlock: True or False, True=the controller responds to the

gate interlock signal on pins 3 and 4 of J29. False=J29 pins 3 and
4 are reserved for Program Stop interlock.

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Caution:
Failure to enable the gate interlock option on systems that can operate in Slow (low-flow)
mode can result in unexpected actuator movement when switching the system from Slow
mode to Fast mode.
Unexpected actuator movement can result in injury to personnel or damage to the equipment.
Enable the gate interlock option for systems that include a Slow (low-flow) mode for specimen
installation.

Model 494.74 HSM Transition Board

Item Description

494.74 HSM transition board The hydraulic control definition assigns the Hydraulic Power Unit (HPU)
icon transition board and each Hydraulic Service Manifold (HSM) transition
board to their appropriate rear panel connectors. Each of the two HSM
transition boards allowed in your system can support up to two HSM
stations.
Transition Slot: Not applicable.

Hydraulic Interface icon Changing this name may invalidate existing station configurations.
Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Connector: J28A or J28B.
Type: Solenoid or On/Off Solenoid.

On/Off Solenoid: only two HSM control buttons (Off/On) will appear on the
Station Manager Station Controls panel.
Solenoid: three HSM control buttons will appear (Off/Low/High).
Power Type: Select Electric or Hydraulic depending upon system power.

Connect to HPU:
True: Indicates the HSM requires the HPU to be started (either manually
or as “first on”) prior to be started.
False: Indicates the HSM can be activated without an HPU activation.

Hydraulic Interface icon Changing this name may invalidate existing station configurations.
Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Connector: J28A or J28B.
Interlock: Select a interlock chain (1–8) for the HSM interlocks.

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Item Description

Typically, the interlock chain assignment that you make in the .hwi file
should match the interlock chain that you assign to the station when you
load it in Station Manager.
Type: Solenoid or On/Off Solenoid.

Interlock Interface icon Connector: J3.

Assign to Interlock: Select a interlock chain (1–8) for the HSM interlocks.
Typically, the interlock chain assignment that you make in the .hwi file
should match the interlock chain that you assign to the station when you
load it in Station Manager.
Low Flow Interlock: True or False, True=controller responds to a low-flow
interlock signal on J3.

FlexTest IIm Chassis Settings

The following hardware settings are only available on the Chassis tab that appears for FlexTest IIm
controllers.

Item Description

497.01 Analog Chassis There can be up to two Model 497.01 Analog Chassis. This block defines
chassis icon a chassis number. See the ADDA definition for more information.
Chassis: Not applicable.
Host Port: Not applicable.

497.05 Hydraulic Control The hydraulic station definition describes the Model 497.05 Hydraulic
Panel chassis icon Control Panel chassis. At least one HSM must be defined. The FlexTest
IIm software and the Model 497.05 Chassis supports up to 4 stations.
Chassis: Not applicable.
Host Port: Not applicable.

Hydraulic Interface icons Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Connector: The connector number represents a rear panel connector on
the chassis.

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Miscellaneous Device Settings

Use the drop-down lists in the Miscellaneous tab to add various external devices to the .hwi file. The
devices listed here are not automatically added by the Hardware Detect option.

Temperature Controller Settings

Item Description

Temperature Control icon This indicates a Eurotherm Series 2200 or Series 2400 temperature
controller is connected to the controller. A Model 409 Temperature controller
may contain multiple Eurotherm controller channels.
A GRESIII board or Model 494.47 Dual UART/Encoder card is required to
support a temperature controller.
Type: Enter the name of the temperature controller as desired.
Interlock Temperature (deg C) Define the default temperature. This
temperature will be sent to the temperature controller whenever the station
is interlocked or not loaded.
Use Interlock Temperature: Select True to use the interlock temperature
feature.
Com Timeout Delay (sec): Enter the amount of time to wait for
communication time-out with a temperature controller before reporting an
error.
Serial Port: Select the serial port where you will connect the temperature
controller.

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Item Description

If a GRESIII board is used, you must set the baud rate for the serial port
to 9600.
Channels: Specifies the number of temperature controllers on that will
share the serial port. For example, a Model 409 Temperature controller
may contain multiple Eurotherm temperature controllers that all share the
same serial port.
For FTIIm Systems–The maximum number of temperature controllers that
can be supported is 16, four on each of the four GRES ports. Since RSCs
must be on an interlock chain numerically equal to their port number (Intlk
1 = Port 1, etc.), a station on interlock X will not be able to use an RSC if
there is a temperature controller on port X.

Analog Output icon Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Address: Not applicable.

How to Add Temperature Controllers

Before you can add temperature controllers, you must add a GRES III board or 494.47 Dual UART/Encoder
mezzanine card.
1. Select Controller in the tree view pane.
2. Click the Miscellaneous tab.
3. Specify the number of temperature controllers.
Each temperature controller is associated with a specific Serial Port. Up to four temperature control
channels may be specified per temperature controller (Serial Port).

4. Select the correct Serial Port on the Temperature Control Properties tab.
Important:
If a GRESIII board is used, you must set the baud rate for the serial port to 9600.

5. Optional—define default temperature.

Set the Use Interlock Temperature field to True.
Enter the Interlock Temperature. This temperature will be sent to the temperature controller whenever
the station is interlocked or not loaded.

6. In the Com Timeout Delay field, enter the amount of time in seconds to wait for a communication time-out
with a temperature controller before reporting an error.
7. Select the number of temperature control Channels on the Temperature Control tab. Up to four channels
may be specified per temperature controller.

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Temperature Controller Settings

Item Description

Temperature Control icon This indicates a Eurotherm Series 2200 or Series 2400 temperature
controller is connected to the controller. A Model 409 Temperature controller
may contain multiple Eurotherm controller channels.
A GRESIII board or Model 494.47 Dual UART/Encoder card is required to
support a temperature controller.
Type: Enter the name of the temperature controller as desired.
Interlock Temperature (deg C) Define the default temperature. This
temperature will be sent to the temperature controller whenever the station
is interlocked or not loaded.
Use Interlock Temperature: Select True to use the interlock temperature
feature.
Com Timeout Delay (sec): Enter the amount of time to wait for
communication time-out with a temperature controller before reporting an
error.
Serial Port: Select the serial port where you will connect the temperature
controller.
If a GRESIII board is used, you must set the baud rate for the serial port
to 9600.
Channels: Specifies the number of temperature controllers on that will
share the serial port. For example, a Model 409 Temperature controller
may contain multiple Eurotherm temperature controllers that all share the
same serial port.
For FTIIm Systems–The maximum number of temperature controllers that
can be supported is 16, four on each of the four GRES ports. Since RSCs
must be on an interlock chain numerically equal to their port number (Intlk
1 = Port 1, etc.), a station on interlock X will not be able to use an RSC if
there is a temperature controller on port X.

Analog Output icon Name: Describes this resource as it will appear in Station Builder resource
lists when opened against an .hwi file.
Changing this name may invalidate existing station configurations.
Address: Not applicable.

Remote Station Control (RSC) Settings

The RSC can not be used with Series 494 hardware.

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Note:
The FlexTest SE and FlexTest 40/60/100/200 Controllers do not support RSCs.

Item Description

Remote Station Control icon The Remote Station Controller (RSC) is a table-top, stand-mounted, or
hand-held device that is primarily used for specimen installation and the
starting and stopping of tests. A GRES III board is needed to support an
RSC in your system.
Remote Station Controllers are not available with the optional 6 or 8-station
system configurations
The FlexTest IIm/CTC controller can support an RSC for each station (for
a total of four RSCs) on the 498 RS-485 Transition Board.
Name: Specifies the desired resource name. Changing this name will not
cause file conflicts.
Host Port: The host port entry specifies which Com port on the GRES III
plug-in board the Model 493.71 Serial Interface transition board port is
mapped to. (This determines which port the RSC must be plugged into.)
Interlock: Specifies the interlock chain number. By default, the interlock
chain number and the RSC number are equal. If you want to map an RSC
with a different interlock chain (if available), change this value.

How to Add Remote Station Controls (RSC)

Before you can add RSC or Handsets, you must add a GRES III board or 494.47 Dual UART/Encoder
mezzanine card.
Note:
FlexTest SE Controllers do not support Remote Station Controls (RSCs).

1. Select Controller in the tree view pane.

2. Click the Miscellaneous tab.
3. Specify the number of remote station controls. Each RSC is associated with a specific Host Port.
4. On the Remote Station Control Properties tab, select the correct HOST PORT.

Model 494.05 Handset Settings

Item Description

Handset icon The Model 494.05 Handset is primarily used for specimen installation and
the starting and stopping of tests. The handset requires a hardware
resource with serial ports (such as the Model 494.47 UART card, Ramix
Serial Card, or GRES III card).

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Item Description

Name: Specifies the desired resource name. Changing this name will not
cause file conflicts.
Serial Port: Select the serial port where the Handset is connected. Once
you select a a serial port, you must configure that port for a baud rate of
19200.

Model 494.05 Handset Hwi File Editor Settings

To initially install the handset:
1. Physically install the serial boards required for the number of handsets used by the system:
The Model 494.05 Handset requires one of the following serial boards:
• FlexTest 40, 60, 100, 200 systems—a Model 494.47 Dual UART/Digital Transducer Conditioner
mezzanine card that is installed on a Model 494.40 I/O Carrier board can support up to two handsets.
• FlexTest IIM, GT, and TestStar IIM systems—a Model 498.71 GRES III board can support up to
four handsets.

2. Use the Hwi File Editor application to add the required serial board resources to the .hwi file.
a) Click the Controller icon.
b) Click the Board tab and add the GRES III board. GRES III boards are typically placed in VME Bus
slot 10.
or
For Series 494 systems, right-click an empty 494.40 I/O carrier slot and select the Model 494.47
UART mezzanine card.

3. Define the number of handsets used with the system.

a) Click the Controller icon.
b) Click the Miscellaneous tab and select the # of Handset Controls from the drop-down list.
4. Click each handset icon to select the card and the serial port used by the handset.
5. Click the serial board icon and set a 19200 baud rate for each Serial Comm port assigned to a handset.
6. Set the comm port Type for Model 494.47 UART cards to 4 Wire.

CAN Bus Interface

Note:
CAN Bus interface support is not available for MTS FlexTest SE Controllers.

CAN Bus Interface Requirements

A controller area network (CAN) bus interface requires a CAN bus controller mezzanine card that is installed
on a processor board.

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The CAN bus card can include multiple CAN controllers that are configured and assigned independently.
The mezzanine card provides a network connector for each CAN bus port.

CAN Bus Interface Setup

1. Open the .hwi file.
2. Click the Controller icon, and then click the Miscellaneous tab.
3. From the # of CAN Bus Interfaces list, select 1.
A series of CAN bus icons appear under the processor icon.

4. Configure the CAN bus interface as shown in the following table.

Item Description

CAN Bus Icon Type: Select the model number of the CAN bus controller mezzanine
card that is installed on the processor board.

Port Icon(s) Each port icon represents a separate CAN bus controller port that you
can configure independently.
Baud Rate: Enter baud rate for the CAN bus port’s RS-485 interface.
Frame Format: select the frame (message) format required by the CAN.
Selections include Basic or Extended.

Modbus Interface Settings

A Modbus Interface consists of a networked Modbus node that connects to the controller processor through
an Ethernet network switch. A Modbus node includes a Modbus chassis (DIN rail) populated with various
modules including an Ethernet TCP/IP Fieldbus Coupler.

Item Description

Miscellaneous Tab (Controller icon) # of Modbus Interfaces: Enter the number of Modbus interfaces. Each
Modbus interface (Modbus node) consists of a DIN rail, modules,
and an Ethernet TCP/IP Fieldbus Coupler.

Modbus icon(s) This icon represents a Modbus device connected to the controller
through an Ethernet switch.
Type: This field is set to Generic by default. Select Wago if the
Modbus node is Wago. If the Type is Wago and both input and output
process image offsets are 0 (zero), 793 Sysload will perform a
Modbus node module verification.
IP Address: Enter the IP address that was previously assigned to the
Modbus node (using the manufacturer’s configuration hardware).
Protocol: Select TCP or UDP

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Item Description

Clock rate: Enter the clock rate (Hz) of the Modbus node. The default
clock rate is 64 Hz. The clock rate can be adjusted based on the
number of modules and the type of application.
Process Image Input Offset and Process Image Output Offset: Specify
a value for the input and output process image offsets. The values
for the input and output process image offset are passed to the node
as part of the Modbus protocol.
# of Modules: Enter the number of modules mounted on the DIN rail.
Only count modules that provide data to the process image For
example, do not include the Fieldbus Coupler module or the End
module.
Right-clicking a module provides a list of supported modules.

Module icons Module Assignments: Right-click each module and select the module
type from the pop-up lists. Modules must be assigned in the order
that they appear on the DIN rail.

About EtherCAT
Series 793 software includes a keyed option that provides support for EtherCAT devices. EtherCAT is an
Ethernet-based real-time network that uses a master-slave approach. In the 793 environment, the FlexTest
controller is the master device.
There are two unique file types associated with EtherCAT functionality:
• ENI (EtherCAT network information) files
• ESI (EtherCAT slave information) files
A third-party configuration tool is used to define the network and create ESI files for all slaves in the system.
The final output from the configuration tool is an ENI file that gets loaded into a sub-directory of your 793
controller folder.

EtherCAT Settings
To add EtherCAT to your station, right-click on the Controller icon in the Hwi Editor application tree view,
and select EtherCAT.

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Digital I/O and Analog I/O signals are available to EtherCAT.

The signals associated with the EtherCAT network listed in the Hwi Editor tree view will appear in the
Station Builder and Station Manager applications.

EtherCAT Settings
To add EtherCAT to your station, right-click on the Controller icon in the Hwi Editor application tree view,
and select EtherCAT.

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Digital I/O and Analog I/O signals are available to EtherCAT.

Item Description

Name Signal names are generated by the configurator tool, and users may
choose to edit the names in the configurator tools prior to adding
EtherCAT to the 793 .hwi file. Signal names can also be modified
later in the Station Builder application.

Version

Interlock Action

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About Read-Only HSMs

A read-only HSM refers to a hydraulic pressure source that is controlled by an external system (or manually)
and monitored by the MTS controller. The read-only HSM state (pressure) is monitored using one or two
dedicated digital inputs. The Hwi Editor application assigns these inputs to the read-only HSM.

How to Configure a Read-Only HSM

Read-only HSMs require digital input resources that monitor digital HSM pressure signals. The HWI Editor
application assigns two digital inputs to each read-only HSM.
1. Make sure that the controller has the digital input resources required by the read-only HSM.
2. Click the Controller icon and then click the Miscellaneous tab.
3. Select the # of Read-only HSMs from the drop-down list.
A Read-only HSM icon appears in the navigation pane.

4. (Optional) Click the Read-only HSM icon and change the digital input resource names that were
automatically assigned to the read-only HSM.

Item Description

Read-only HSM icon Name: Specifies the desired resource name. Changing this name will
cause file conflicts.
Connector: use this field to annotate the hwi editor file.
On Bit: this is the digital input signal that indicates “low HSM pressure.”
This name must match the resource name of the digital input.
High Bit: this is the digital input signal that indicates “High HSM pressure.”
This name must match the resource name of the digital input.
Make sure that the digital input resource name in the On Bit and High
Bit fields matches the physical input used for these signals.
For HSMs that are either on or off (no low pressure setting), make both
the On Bit and High Bit digital input resource name assignments the
same.

Read-Only HSM Control Logic

Dual input
The following table shows the control logic for systems where different digital inputs are used for the On
Bit and High Bit digital input resources..

“On Bit” Digital Input “High Bit” Digital Input HSM State

Low Low HSM Off

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“On Bit” Digital Input “High Bit” Digital Input HSM State

Low High High HSM Pressure

High Low Low HSM Pressure

High High High HSM Pressure

Single input
The following table shows the control logic for systems where both the On Bit and High Bit digital input
resource name assignments are the same.

Digital Input HSM State

Low HSM Off

High High HSM Pressure

Note:
Refer to the controller hardware manual to determine digital input wiring and specifications.

Uninterruptible Power Supplies (UPS)

The Model 493.73 HPU board, Model 494.42 system board, and Model 494.44 system board have dedicated
digital inputs that can monitor a UPS. These inputs monitor normally open UPS Line Fault and UPS Low
Battery contacts on the UPS.
Note:
FlexTest SE, FlexTest 40 (Model 494.41), TestStar IIs, and FlexTest IIm Controllers do not have
dedicated UPS monitoring inputs. With these controllers, you can configure the digital inputs that
are part of general-use DI/O for UPS support.

How to Add an Uninterruptible Power Supply (UPS)

1. Add the UPS interface.
a) Select Controller in the tree view pane.
b) Add the appropriate hardware resource (for example, a Model 493.73 HPU board).
c) Click the Miscellaneous tab.
d) Select 1 for the # of UPS Interfaces.
2. Configure the UPS interface.
a) Double-click the UPS icon to display UPS inputs and outputs:

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UPS Input/Output Description

UPS Line Fault (Digital Input This input changes state when the UPS normally open Line Fault
1) contacts open to indicate that AC power is lost and that the UPS is
supplying battery power to the system.

UPS Low Battery (Digital This input changes state when the UPS normally open Low Battery
Input 2) contacts open to indicate that UPS battery power is low (regardless
of whether the UPS is supplying power to the system or not).

UPS External Event (Digital Only supported in systems that use a Model 493.73 HPU board.
Input 3)

UPS Off (Digital Output 1) Not Used.

b) Define the State, Persistence, and Polarity settings for each UPS input.

UPS Setting Description

State The State setting is locked in the Enabled state.

Future - Determines whether or not the line fault detector changes state if
power is supplied by the UPS. The default setting is Enabled.

Persistence Time value in milliseconds. This is the number of milliseconds in which the
state must persist before the software recognizes the change. The default
setting is 0, which means the change in state is recognized immediately.

Polarity Normal or Inverted. The default value depends on the type of hardware
resource used to monitor the UPS:
For Model 494.44 and Model 494.42 system boards: Default = Normal
For Model 493.73 HPU boards: Default = Inverted
These default polarity settings are based on normally open contacts.

3. Define Station UPS Options with the Station Manager application.

When you open a station configuration created with an .hwi file that includes a UPS, you can select
UPS options in the Station Setup window.
For more information on , see the Series 793 Control Software manual (PN 100-147-130).

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How to Set Model 493.40 I/O Carrier Address

(FlexTest GT/SE, TestStar IIm)

Use the DIP switch (S1) and rotary DIP switch (S2) on each I/O Carrier board to set its address in accord
with its chassis slot as follows:

Slot 1 2 3 4 5 6 7 8 9 10
Number

Address PPC C20 C22 C24 C26 C28 C2A C2C C2E

The DIP switch settings for address C20 is shown below. Set the rotary DIP switch to complete I/O Carrier
board addressing

How to Set ADDA II Board Address (FlexTest

GT, TestStar IIm, FlexTest IIm)

Set the board’s rotary DIP switches (S3, S2) and the front-panel rotary DIP switch on each ADDA II board
to the address that matches the chassis slot number where the board is installed (see below).

Slot Number 1 2 3 4 5 6 7 8 9 10

Address PPC PPC C40 C41 C42 C43 C44 C4A C4C

The DIP switch settings for address C40 are shown below. Set the front-panel DIP switch to complete
ADDA II board addressing.

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How to set the Model 494.40 I/O Carrier Board

Address

The address setting for the I/O Carrier board must match the settings used by the system control software.
1. Determine the I/O Carrier address.
2. Locate address switches SW1 and SW2 on the I/O Carrier circuit board and set the board address
using the settings shown below.

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Topics:

• Controller Options Description.........................................................................................................106

• Using the Controller Management Tool...........................................................................................112

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Controller Options Description

Selecting Controller Options on the Controller Management Tool window opens the Controller Options
window, which allows you to configure local settings on the Controller.
The activities you can perform with the Controller Options window varies with the type of Controller you
have.

For FlexTest SE controllers

The Controller Options window includes Controller Attributes, Passwords, User Files, Regional Settings,
and License Keys tabs.
You can use this window to perform the tasks you normally perform in Config > Local Settings on the
FlexTest SE Controller’s front panel. This includes changing controller attributes, passwords, adding license
keys, selecting hardware configuration files, station configuration files, and unit assignment sets.

For Aero ST controllers

The Controller Options window displays only the Controller Attributes tab.

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Note:
The Controller Type for FlexTest SE Controllers is always set to Independent. Aero ST Controllers
may be set to either Master, Dependent, or Independent.

Controller Attributes tab

Multi controller considerations

Important:
Ensure that the ID of each Controller you plan to use in a network is unique before changing it.

You can use Controller ID to examine and change the Controller’s ID.

Item Description

Controller Name Specifies the controller’s name. By default, the name will be the serial
number of the Model 493.42 System I/O Board (for FlexTest SE

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Item Description

Controllers) or Model 493.43 System I/O Board (for Aero ST Controllers)

in the Controller chassis. You can change this name as desired.
When operating in the automation mode, the controller name may
appear in the title bar of the Station Builder and Station Manager
applications.
• In a multicontroller FlexTest SE network (in which each controller
operates independently) each unique instance of Station Manager
displays the name of its associated controller in its title bar. The
controller name appears on the title bar of the Station Builder
application in the same way.
• Independent Aero ST controllers work as described above.
• In an Aero ST controller network (which consists of master and
dependent controllers), Station Builder and Station Manager
applications display only the name of the master controller in their
title bars.
Note:
If you change the Controller Name you must re-register the
Controller. When changing the original Controller name, use
the Unregister Controller control.

Controller ID (FlexTest SE Specifies the controller’s network identification number (0 - 15), which
Controllers only) determines the TCPIP address of the controller on the network.
You can enter the Controller ID as desired. Each controller in the
network must have a unique address.
Important:
This number must be an integer in the range of 0 - 15.

Note:
If you change the Controller ID you must re-register the controller.

Controller ID (Aero ST Specifies the controller’s network identification number (0 - 15), which
Controllers only) determines the TCPIP address of the Controller on the network.
This value is read by the CMT application from the switch setting on
the Model 493.43 System I/O Board. The displayed value is read-only.
Important:
During system setup, the Model 493.43 System I/O Board in one
of the controllers must be set to 0 to provide a Master Controller.

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Item Description

If no controller or more than one controller is designated as a

Master, the controller network will not operate.

IP Address Displays the address of the processor in four-part numerical format,

giving the processor a unique identification in its TCP/IP network.

Controller Type (FlexTest SE All FlexTest SE Controllers are configured as Independent Controller
Controllers only) types. This selection is read-only.

Controller Type (Aero ST Specifies Master, Dependent, and Independent Controller assignments.
Controllers only) The CMT application automatically assigns Master and Dependent
roles according to Controller ID settings. Any controller that has a board
ID of 0 is designated as a Master. To change an assignment you must
change the Controller ID number on the Model 493.43 board.
Master: Specifies the network’s Master Controller. The Master Controller
synchronizes the distribution of command and data acquisition to and
from the Dependent Controllers, as well as interfacing directly with
system hydraulics.
Note:
CMT automatically assigns any controller that has a board ID of
0 as a Master. A controller network must include one Master (so
if a controller network contains only one controller, it must be a
Master). However, a controller network cannot have more than
one Master.

Dependent: Specifies controllers that are subordinate to the Master

Controller.
Independent: Specifies controllers which are not subordinate to the
Master Controller.
Note:
If you change the Controller Type you must re-register the
controller using the Register Multiple Controllers control.

Note:
Aero ST hwi files are automatically labeled “aero.hwi” for new systems (existing .hwi names are
preserved).

User Files tab (FlexTest SE only)

Use the User Files tab to select the name of both the hardware configuration file (.hwi) and station
configuration file (.cfg) for the controller selected on the Controller Management Tool window.
The Configuration File selection box is typically not used for Aero ST applications. (Aero ST applications
typically do not use Station Builder and Station Manager applications, which require a cfg file.)

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License Keys tab (FlexTest SE only)

Use the License Keys tab to install purchased software options for your controller. Check the appropriate
option box, and then enter the corresponding option key provided by MTS.

Regional Settings tab (FlexTest SE only)

Use the Regional Settings tab to change elements of the controller that pertain to localization. For instance,
you can select how the controller displays the date, and the units with which the controller displays data
values.

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Item Description

Language English is the standard language installed on the Controller and displayed on
the interface. If available, select other languages as desired.

Decimal Separator Specifies the decimal symbol used in numbers. Select Period (.) or Comma
(,).
Appearance using Period (.): 34678288.00
Appearance using Comma (,): 34678288,00

Date Format Selects the format in which the date stamp is displayed on the message log.
Select M/D/Y, D/M/Y, or D.M.Y.
Appearance examples: M/D/Y, 4/24/2002; D/M/Y, 24/4/2002; D.M.Y., 24.4.2002.

Time Format Selects the format in which the time stamp is displayed on the message log.
Select 12-hour or 24-hour.
Appearance examples: 12-hour, 6:31:23 PM; 24-hour, 18:31:23.

Unit Assignment Set Specifies the unit assignment set used by the Controller to display
measurements of all types. For instance, SISET - SI defines a set of units that
contains customary international (metric) units. It provides force, and
force-related units, in kN.
The following unit assignment sets are available:
CGSSET - Centimeters, Grams, Seconds: Defines a set of units that is based
upon centimeters, grams, and seconds.
ENGSET - U.S. Engineering Units: Defines a set of units that contains
customary U.S. engineering units. It provides force, and force-related units, in
kip.

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Item Description

ENGSETSM - U.S. Engineering Units (small)—Defines a set of units that

contains customary U.S. engineering units. It provides force, and force-related
units, in lbf.
SISET - SI (Systeme International d’Unites)—Defines a set of units that contains
customary international (metric) units. It provides force, and force-related units,
in kN.
SISETSM - SI (Systeme International d’Unites) - small—Defines a set of units
that contains customary international (metric) units. It provides force, and
force-related units, in N.
SYSDEF - System Units Definition—Contains a copy of the units that are used
in the hardware and software to represent test values of interest.

Passwords tab (FlexTest SE only)

Use the Passwords tab to enter passwords for tuning, calibration, and configuration level access for the
selected controller.
Important:
Passwords should only contain characters found on the controller’s front panel’s numeric keypad.
These are the only keys available when entering passwords in stand-alone mode.

Using the Controller Management Tool

The CMT tasks are modular; you may perform them separately or in combination, depending on your
circumstances. For instance, if you want to register a standalone FlexTest SE Controller for automated
operation, you will not have to perform all of the tasks listed.

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CMT is not intended to be run concurrently with other testing applications (for instance, CMT is not intended
to be used as a status checking application that you keep open on the desktop). Use CMT to perform the
tasks listed in this manual as required, then exit the application before continuing normal use of your
Controller. Running CMT continuously may interfere with Controller performance and result in unpredictable
operation.

FlexTest SE multi Controller Considerations

Important:
If you intend to operate the controller in a network, ensure the ID and name of each controller in the
network is unique. Do this before cabling the controllers to the hub of the supervising PC and
launching the Controller Management Tool.

It is good practice to examine the ID of every controller you wish to operate in a controller network before
you cable the network. You can do this by operating each controller in the Stand-Alone boot mode and
examining the ID as follows:
Path: Config > Local Settings > Networking > Controller ID

FlexTest SE Version Checking

Before performing most tasks, the Controller Management Tool (CMT) checks software version differences
between the Series 793 software in the servicing PC and the Series 793 software in the flash disk of the
controller currently being serviced.
If a version difference is detected, CMT displays a warning message while the requested task proceeds.
Because of the software mismatch, however, unexpected results may occur.
To correct the version mismatch, a software upgrade is recommended for either the controller being
serviced or the PC servicing the controller.
Note:
The detection of a version mismatch is typical while updating system files during a normal software
upgrade.

How to put a FlexTest SE Controller in the Service boot mode

1. Ensure the controller is cabled to a PC equipped with MTS Series 793 software.
You can select Standalone w/Network boot mode in the next step (in place of Automation). If you do,
ensure the controller is cabled to your PC. If it is not cabled to your PC you will experience long boot
times (three minutes or more).

2. Switch to the Automation boot mode.

From the controller’s menu, select the Automation boot mode as follows:
Path: Config > Local Settings > Networking > Boot Mode > Automation

3. Reboot the controller.

Press one of the reboot buttons on the controller’s menu (e.g. Path: Status > <<Reboot>>), or use the
power button located to the rear of the chassis. The controller will boot up in the Automated mode.

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4. Launch the Controller Management Tool (CMT) on the PC.

Once MTS software is installed, you can launch the Controller Management Tool from the Start menu
as follows:
Path: Start > Programs > MTS 793 System Software > Tools
You can also launch the application by typing ctrmgmttool from the command line.

5. In the CMT Controllers list, select the controller you just rebooted.
6. In the Next Controller Boot Mode selection list, select Service.
7. Reboot the controller again.
Press the CMT Reboot Controller button. The controller will boot up in the Service mode, displaying
the MTS logo.

8. Perform the desired service operation.

How to Install or Update System Files on FlexTest SE Controllers

This procedure copies system files from the servicing PC to the selected FlexTest SE Controller. System
files include the executable code for the Controller and unit assignment sets(.uas).
1. If required, perform the procedure to put the controller in the Service boot mode.
2. Select the controller you wish to service from the displayed list of controllers.
3. Copy necessary system files to the selected controller.
Select either Install System Files or Update System Files.
Selecting Install System Files will delete all existing files before copying system files to the controller.
Be sure to back up files to the PC before making this selection.

4. Perform other operations as desired.

5. In the Next Controller Boot Mode selection list, select Standalone, Standalone w/Network, or Automated,
as appropriate.
6. Reboot the controller. Press CMT’s Reboot Controller button, or press the <<Reboot>> key on the
controller’s front panel. The controller will boot in the selected boot mode.

How to Update or Backup User Files on FlexTest SE Controllers

The update procedure copies user files from the servicing PC to the selected controller. The backup
procedure copies files from the controller to the servicing PC. User files include the hardware interface
files (.hwi) and station configuration files (.cfg).
1. If required, perform the procedure to put the controller in the Service boot mode.
If you do not have a station loaded, you can also update or backup user files in the Automation, Remote,
or Local boot modes.

2. Select the controller you wish to service from the displayed list of controllers.
3. If desired, select Update User Files to copy user files in the servicing PC to the selected controller. If
the same files already exist on the controller, you will be prompted to verify overwriting the existing
files.
To avoid running out of flash memory, make sure that the backup directory does not contain an excessive
number of files.

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4. If desired, select Backup User Files to copy the user files in the controller to the servicing PC. The files
are copied to a designated root directory destination or to a new folder.
5. Perform other operations as desired.
6. In the Next Controller Boot Mode selection list, select Standalone, Standalone/Net, or Automated, as
appropriate.
7. Reboot the controller. Press CMT’s Reboot Controller button, or press the <<Reboot>> key on the
controller’s front panel. The controller will boot in the selected boot mode.

How to Register a FlexTest SE Controller for Automation

1. Launch CMT and verify that all controllers appear in the main window as connected.
2. Select the controller that you want to register.
3. Register the selected controller.
a) Select Register Controller to create a controller-specific folder in the “Controllers” directory on the
servicing PC.
b) The hwi file and config folder are then copied to this new folder from the controller being registered.
4. In the Next Controller Boot Mode selection list, select the desired boot mode.
5. Perform other operations as desired.
6. Reboot the controller. Press CMT’s Reboot Controller button, or press the <<Reboot>> key on the
controller’s front panel. The controller will boot in the selected boot mode.

How to Unregister a FlexTest SE Controller

1. Launch CMT and verify that all controllers appear in the main window as connected.
2. Select the controller that you want to unregister.
3. Unregister the selected controller.
a) Select Unregister Controller.
b) The controller-specific directory is optionally removed from the servicing PC.
You may want to set the controller to boot in the Stand-alone boot mode rather than the Automation
boot mode after you unregister it.

How to Set Controller Options on FlexTest SE Controllers

From the controller’s front panel, press Config > Local Settings to change Controller options.
Note:
You typically use the controller’s front panel to change the controller options. CMT offers the Controller
Options window as a convenience. If you are using CMT to accomplish another task, you may find
it efficient to use CMT to change controller options as well. Otherwise, use the front panel of the
FlexTest SE Controller.

1. Press the Controller Options button to display the Controller Options window. Change system options,
passwords, initial hardware interface file (.hwi), station configuration file (.cfg), unit assignment set
(.uas) and other controller attributes as desired. The changes you make are recorded in the FlexTest
SE registry.ini file.

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2. In the Next Controller Boot Mode selection list, select Stand-alone or Automation as desired.
3. Perform other operations as desired.
4. Reboot the controller. Press CMT’s Reboot Controller button, or press the <<Reboot>> key on the
controller’s front panel. The controller will boot in the selected boot mode.

How to Configure a FlexTest SE Controller to Boot in a Different

Boot Mode
If the controller is not currently in the Service boot mode running the Controller Management Tool, the
quickest way to change boot modes is from the controller’s front panel, as follows:
Path: Config > Local Settings > Networking > Standalone, or Standalone/Net
Note:
You cannot select the Service or Automation boot mode from the controller’s front panel. To put the
controller in the Service or Automation boot mode, select the Standalone/Net boot mode (if
necessary), reboot, and run the Controller Management Tool application.

Note:
This procedure applies only to FlexTest SE Controllers.

1. In the Next Controller Boot Mode selection list, select the boot mode as desired.
2. Reboot the controller.

How to Configure a New Aero ST Multi Controller System

This procedure assumes that all controller hardware has been configured and successfully booted, and
that .hwi files have been created for each box and stored in separate directories on the PC.
1. Launch CMT and verify that all controllers appear in the main window as connected.
2. Starting with the first box in main window list, select Install System Files.
3. Select Controller Options.
4. Under the Controller Attributes tab, give the controller a unique name and verify proper controller type
(Master, Dependent).
5. Repeat steps 2 through 4 for all controllers in the list.
6. Select Register Multiple Controllers.

About Rebooting Aero ST Controllers with CMT

When the system and a station is loaded

When a station is loaded, you cannot reboot any controller (Master or Dependent) from CMT.

When only the system is loaded

When the system is loaded (after the System Loader application has been run), you cannot reboot individual
Dependent Controllers with CMT. In this case, you can only reboot the Master Controller, which will reboot
all Dependent Controllers.

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When the system is not loaded

When the system is not loaded, you may independently reboot the Master or any Dependent Controller
with CMT.
Note:
Rebooting from CMT (using the Reboot Controller button) may not work if communication problems
exist in the controller network. If you cannot reboot a controller from CMT, use the reboot button on
the affected controller’s processor card, or remove and reapply power to affected controller.

User File Access for Registered Controllers

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

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Acumen System Setup
Topics:

• Acumen Hwi Setup..........................................................................................................................120

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Acumen System Setup

Acumen Hwi Setup

Acumen Hwi Settings

This section lists the Hwi settings for each piece of MTS FlexTest Controller hardware required by the
Acumen system. The slot location of individual mezzanine cards my vary depending on the type of controller
used.

Model 494.26 Dual DUC - Load Cell with Acceleration Compensation

When configured for acceleration compensation, the A input is used for the load cell and the B input is
used for the accelerometer.
To configure a dual DUC for acceleration compensation (see the following figure), right-click on the top
DUC icon [1] and click Add Accelerometer Compensation. Once configured, an Auxiliary Input property
[2] that lists the connector number for the accelerometer input appears at the bottom of the list.

Acceleration Compensation Setup

Model 494.47 Incremental Displacement Encoder

The displacement encoder used in the Acumen system connects to a Model 494.47 Dual UART/Encoder
card. The settings for this card are shown below.

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Important:
The name for the encoder input (for example: 494.47 Encoder S2-J2A) must be entered in the
Encoder box in the Elmo Output window.

Temposonics R 494.26 DUC

The Temposonics R transducer used in the Acumen system provides an absolute position reference for
the actuator. The transducer’s analog output is conditioned by a Model 494.26 Dual DUC card. The settings
for this card are shown below.
Important:
The name for the Temposonics input (for example: 494.26 DUC S2-J3A) must be entered in the
Absolute Temposonics R box in the Elmo Output window.

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Handset/Frame Status Model 494.47 Dual UART card

A Model 494.47 Dual UART/Encoder card configured for UART (serial) communications is required for
the following devices:
• Communications between the controller and the frame control panel (handset).
• Communications between the controller and the frame electronics (for status information).

Note:
If necessary, each of the two serial communications can reside on different Model 494.47 cards.

The settings for the Model 494.47 card are shown in the following figures.
Note:
The settings for the frame control panel are identical to a Model 494.05 Handset.

Important:
The name for the “Frame Status” input (for example: 494.47 UART S2-J4B) must be entered in the
Serial Port box in the Elmo Output window.

Elmo Output Settings

Each Acumen system requires an Analog Output that provides a motor command signal for the Elmo motor
drive. For a Flextest 40 Controller, the system uses the analog output on the Model 494.44 or 494.42
system board. For a FlexTest 60 Controller, the analog output is provided by a Model 494.46 mezzanine
card.

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To designate an analog output for the motor command signal (Elmo Drive), right-click on the Analog
Output icon and click Elmo Output. An Elmo Output icon appears. Click on this icon to display a list of
settings required for the Acumen system. These settings are listed in the table below.

Elmo Output Settings

Setting Description
Parameter File
Used to update the motor drive software.

Program File
Used to update the motor drive software.

Checksum File
Used to update the motor drive software.

Firmware File
Used to update the Acumen frame firmware.

Bootload File
Used to update the Acumen frame firmware.

Download File
Used to update the Acumen frame firmware.

Encoder
Enter the name for the displacement encoder input (for example: 494.47 Encoder
S2-J2A) in the Encoder box.

Absolute
Enter the name for the Temposonics input (for example: 494.26 DUC S2-J3A) in
Temposonics R
the Absolute Temposonics R box.

Serial Port
Select the “Frame Status” input (for example: 494.47 UART S2-J4B) from the
Serial Port drop-down list.

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MTS Systems Corporation
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Toll Free Phone: 800-328-2255
(within U.S. or Canada)
Phone:952-937-4000
(outside the U.S. or Canada)
Fax 952-937-4515
E-mail: [email protected]
Internet: www.mts.com

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