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Troubleshooting and Maintenance
MTS FlexTest® Models 40/60/100/200 Controller Hardware Troubleshooting and Maintenance
285
Appendix A
Troubleshooting and Maintenance
Chassis Troubleshooting
J39 Service Test Points
The J39 Power Monitor connector (located on the rear panel of the Model
494.06, 494.10, and 494.20 Chassis) provides service test points. Test points
include all of the power supply voltages and the status of the
overtemperature sensor and the power-fail circuit.
Note Each output signal on the J39 connector includes a 2 K-ohm
current-limiting resistor. These outputs cannot provide enough
current to drive external devices. Do not connect external devices
(other than high-impedance test equipment) to the J39 connector.
494.xx Chassis
J39 Power Monitor
2 + 5 V DC
3 + 12 V DC
4 - 12 V DC
5 + 15 V DC
6 - 15 V DC
7 + 24 V DC
8 AGND
9 2.5 V Ref
10 + 5 V AC Fail
11 AGND
12 + 24 V AC Fail
13 Over Temp (TTL 0 = Overtemp condition)
14 Internal Chassis Temperature*
15 Power Fail (TTL 0 = Power failure)
* Temperature =
(degrees C)
Vout (pin 14)
0.005
- 273.15
1
8
9
15
- MTS FlexTest 1
- Models 40/60/100/200 1
- Controller Hardware 1
- Publication information 2
- Contents 3
- Before You Contact MTS 8
- If You Contact MTS by Phone 9
- Technical Support 10
- Before You Begin 13
- Conventions 14
- Electronic manual 15
- Safety Information 17
- Name: Rich Baker 20
- Date: 01 November 2007 20
- Safety Circuits 21
- Input/Output Verification 22
- E-Stop Circuits 22
- E-Stop Circuit Testing 23
- Hardware Interlocks 24
- Chapter 2 27
- FlexTest Controller Overview 28
- FlexTest 40 FlexTest 60 29
- Transition Bus 30
- Station A 30
- Station B 30
- Installation 31
- Shorting Bar 37
- Required 38
- UPS System Requirements 43
- Battery power 44
- UPS power 45
- DA Output 48
- Model 494.04 Chassis Boards 50
- Slot 3 - 494.40 I/O Carrier 51
- Slot 2 - 494.40 I/O Carrier 51
- Slot 1 - Processor Board 51
- Slot 4-5 51
- 494.41 System I/O 51
- 494.41 System 56
- E-Stop Box 56
- ON = Normal 57
- ON = HPU ON 57
- 494.41 System I/O Board 59
- HPU E-Stop 2 signal 60
- 494.41 System Board 61
- J43 Interlock 61
- J49 Aux Pwr 62
- 100-240 VAC 63
- 50-60 Hz, 1-2 A 63
- 494.04 Chassis 65
- D/A Output 65
- Estop/Run 72
- 494.42 System 73
- 494.42 System Board 76
- J28 (D9S) 76
- Interlock 78
- J54 Digital Input 80
- J54 Dig In 80
- J55 Digital Output 81
- Note: A custom Y Cable 92
- J29A J29B 94
- J55 Dig Out 98
- 494.44 System 100
- I/O Board 100
- Load Frame 100
- Controller capabilities 101
- 7654321A 102
- ARAMETER SPECIFICATION 103
- FlexTest 100 104
- Digital Controller 104
- 9 8 7 6 5 4 3 2 1 B A 105
- FlexTest 200 107
- VME Bus (Front) 108
- Transition Bus (Rear) 109
- VME Bus Boards 113
- VME Bus Board Overview 114
- Board installation 115
- Board removal 116
- Processor Connections 118
- Wago PLC 119
- Board features 120
- Shunt Calibration 122
- Resistors (front panel) 122
- Address Setting 122
- Bridge Completion 122
- Resistors 122
- Model 494.43 Multibox Board 126
- Master/dependent 130
- Mezzanine Cards 133
- About Mezzanine Cards 134
- ODEL MEZZANINE CARD 135
- UNCTION COMPATIBLE 135
- RANSITION BOARDS 135
- Mezzanine 139
- Connector 139
- I/O Carrier 139
- 4. Insert the mezzanine card 140
- ≤1% typical 146
- SPECIFICATION 147
- Full-bridge 148
- Half-bridge 149
- I/O Carrier Board 150
- Transducer 150
- Model 494.25 Single DUC Card 154
- Hardware 155
- Cable Grounding 156
- Model 494.26 Dual DUC Card 157
- PARAMETER SPECIFICATION 161
- RJ-50 Pin Assignments 165
- (front view) 165
- Front-Panel 166
- RJ-50 Connector 166
- Compensation Card 168
- Pin Assignments 174
- Elastomer Adapter Box 175
- Load Cell 175
- Accelerometer 175
- Model 494.40 I/O 177
- Carrier Board 177
- Transition 178
- Card Cage 178
- VME Card CageAnalog 178
- 494.46 8-Output D/A 180
- Mezzanine Card 180
- VME Card Cage 181
- VME Card Cage Servovalves 182
- Digital transducer 183
- RJ-50 Connectors 191
- JXA and JXB 191
- RJ-50 Pin 192
- Assignments 192
- Temposonics G 193
- Model 493.80 195
- Encoder Interface Board 195
- Quad Encoder 200
- Transition Board 200
- Counters I/O Carrier Board 200
- G transducers) 203
- TEDS Transducer ID Module 206
- Chapter 5 207
- Digital I/O Hardware Devices 208
- Digital I/O Channels 209
- Inputs Outputs 209
- Model 493.31 213
- DI/O Breakout Box 213
- Breakout box 214
- Model 493.72 board 214
- 493.31 DI/O Breakout Box 215
- 493.72 Digital I/O 215
- Model 493.72 216
- Digital I/O 216
- Model 494.31 218
- Model 493.72 Digital I/O 219
- 494.44 System Board 221
- Output circuits 222
- Input circuits 222
- Inputs 1-4 use PWR 1 225
- Inputs 5-8 use PWR 2 225
- External 226
- Power Supply 227
- Electrical 228
- Environmental 229
- Dimensions 229
- Output Pwr cable 233
- Input Pwr cable 233
- Model 494.31 DI/O 233
- Breakout Box 233
- Power Connections 234
- Model 494.32 DI/O 235
- Transition Boards 237
- Model 493.73 Specifications 239
- E-STOP IN 241
- 493.73 HPU Board 243
- HPU Board 244
- To calculate ramp rates 250
- 493.74 HSM Board 251
- External Device 252
- Run/Stop status 254
- (all SSI or all non-SSI) 259
- Mode Settings 260
- Mode Settings for use with 260
- J49 AUX PWR 261
- J3A STA 261
- J3B STA 261
- J28A HSM 261
- J28B HSM 261
- Single two-stage valve 274
- Dual two-stage valves 274
- To 493.42 276
- System I/O 276
- Module (J25) 276
- COMPATIBLE WITH JUMPERS 277
- 039-713-7XX 278
- Converter box 279
- Controller 280
- Series 494 Cable Part Numbers 281
- Series 494 Cable Connections 282
- Chassis Troubleshooting 285
- Service Connections 288
- Chassis Maintenance 289
- Six-Station Configurations 291
- Eight-Station Configurations 292
- Aero Multibox Systems 293
- Aero Multibox Overview 294
- Multibox Hardware 295
- J8 Intlk In 296
- J9 Intlk Out 296
- J51 Box In 296
- J52 Box Out 296
- Chassis (box) 296
- Multibox Processor Settings 301
- (Master) 304
- (Dependent) 304
- Box 1 (Master) 305
- Box 2 (Dependent) 305
- Model 49x.43 307
- Multibox Board 307
- Processor 307
- Gigabit Ethernet 308
- Reboot the Controllers 315
- OXES 1-6 BOXES 7-12 319
- Define the VME Slot Locations 320
- Configure Servo Valve Outputs 324
- “Disabled.” 327
- Model 793 Multibox Systems 331
- Optional–Delete the 334
- Multibox Configuration 338
- Numerics 339
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