0189 115585-02 B MTS Systems Corp., 1988 Model 410.81 Function Generator
Table of Contents Section 1 Introduction 1.1 Functional Description 1-1 1.2 Specifications 1-2 Section 2 Operation 2.1 Control Mode Selection 2-2 2.2 Output Mode 2-3 2.3 Selecting and Programming Waveforms 2-4 2.3.1 Programming Cyclic Waveforms 2-8 2.3.2 Programming Ramps 2-10 2.4 Program (Null) Pacing 2-12 2.5 Limit Programming 2-12 Section 3 Service 3.1 Power Supply Voltages 3-1 3.2 Output Calibration 3-2 3.3 Breakpoint Calibration 3-5 3.4 Cosine Calibration (Option A) 3-6 3.5 Voltage Controlled Oscillator Calibration (Option B) 3-8 Section 4 Installation 4.1 Function Generator Installation 4-2 4.2 Equipment Rack Installation 4-2 4.3 Voltage and Grounding 4-3 4.3.1 Line Voltage 4-3 4.3.2 Chassis Common and Grounding 4-4 4.4 Switch and Jumper Descriptions 4-5 4.4.1 S1 Program (Null) Pacing Enable 4-5 4.4.2 S2 Output Scaling Internal/External 4-6 4.4.3 S3 Breakpoint Source 4-6 4.4.4 X1 Cosine Calibration 4-6 4.4.5 X2 VCO Enable 4-7 4.4.6 X3, X4 Cosine Output Enable 4-7 4.4.7 X5, X6 Testing 4-7 4.4.8 X7 Remote Stop/Hold Select 4-8 4.4.9 X8 Remote Start 4-8 4.4.10 X9, X10 Emergency Stop 4-8 4.5 Rear Panel Connectors 4-9 4.5.1 J1 Main Output 4-10 4.5.2 J2 Sync Output 4-10 4.5.3 J3 Gate Input 4-10 4.5.4 J4 VCO External Input 4-10 4.5.5 J5 Remote 4-11 4.6 Cosine Option Installation 4-12 4.7 VCO Option Installation 4-13 iii
Section 5 Theory of Operation 5.1 Front Panel Interface 5-1 5.1.1 Waveform Select 5-1 5.1.2 Thumbwheel Switches 5-1 5.1.3 Breakpoint 5-1 5.1.4 Return to Zero 5-2 5.2 Waveform Generation 5-2 5.2.1 Clock Signals 5-3 5.2.2 Accumulators 5-3 5.2.3 DACs 5-4 5.2.4 Ramp Mode 5-5 5.2.5 Cyclic Mode 5-6 5.3 Cosine Output (Option A) 5-6 5.4 Voltage Controlled Oscillator (Option B) 5-7 5.5 Power Supply 5-7 5.5.1 +5 Vdc Supply 5-7 5.5.2 ±15 Vdc Supply 5-7 List of Figures Figure 1-1 Model 410.81 Function Generator 1-1 Figure 2-1 Function Generator Front Panel Controls and Indicators 2-1 Figure 2-2 Control Mode Switches 2-2 Figure 2-3 Output Mode Switches 2-3 Figure 2-4 Waveform Controls and Indicators 2-4 Figure 2-5 Limit Programming Example 2-13 Figure 3-1 Main Circuit Card Service Locations 3-2 Figure 3-2 Cosine Circuit Card Service Locations 3-6 Figure 3-3 VCO Circuit Card Service Locations 3-8 Figure 4-1 Rack Mounting the Female Slide Assembly (Top View) 4-3 Figure 4-2 Rear Panel Switch Locations 4-5 Figure 4-3 Main Circuit Card Jumper Locations 4-6 Figure 4-4 VCO Enable Jumper 4-7 Figure 4-5 Cosine Enable Jumpers 4-7 Figure 4-6 Remote Stop/Hold Jumper 4-8 Figure 4-7 Gate Input Jumper 4-8 Figure 4-8 Emergency Stop Configurations 4-9 Figure 4-9 Rear Panel Connectors 4-10 Figure 4-10 J5 Remote Signals 4-11 iv
List of Tables Table 1-1 Model 410.81 Function Generator Specifications 1-2 Table 2-1 Control Mode Switch Descriptions 2-2 Table 2-2 Output Mode Switch Descriptions 2-3 Table 2-3 Waveform Controls and Indicators 2-4 Table 2-4 Waveform Descriptions 2-5 Table 2-5 Switch Setting and Frequency Range 2-8 Table 2-6 VCO Frequency Range 2-9 Table 2-7 Switch Setting and Ramp Range 2-10 Table 3-1 Power Supply Voltages 3-1 Table 4-1 Input Voltage and Corresponding PWB Legend 4-4 Table 5-1 PROM Program 5-4 v
Section 1 Introduction The MTS Model 410.81 Function Generator (shown in Figure 1-1) is designed to provide a variety of programming capabilities for use in MTS testing systems. 410.81 Function Generator Output Main Sync Select Waveform Normal Invert Control Mode Local Single Remote Local Cycle Output Mode Finish Local Cycle Start & Stop Ret to Zero Output to 0 Trigger Manual Bkpt Hold Ramp Time 1 (sec) FS 0 t +100% FS 0 +100% FS Ramp Time 2 (sec) FS 0 t Hold Time (sec) FS t 0 Frequency (Hz) Breakpt 5-05% Full Scale Figure 1-1. Model 410.81 Function Generator 1.1 Functional Description The Function Generator can output cyclic waveforms or ramps. The cyclic waveforms include sine, haversine and haversquare programs. Twelve ramp functions provide combinations of dual ramps, hold times and adjustable break points which can produce triangle, saw tooth, trapezoid and custom waveforms. The Function Generator produces cyclic waveform frequencies from 0.00001 Hz to 990 Hz and full-scale ramps can be programmed from 0.001 seconds to 990,000 seconds (11.45 days). All of the waveforms start and stop at zero and may be started positive (normal) or negative (invert). The breakpoint capabilities allow a ramp to change to a second ramp rate or a hold time. The breakpoint can be triggered automatically when the program reaches a preset level (as adjusted by a front panel control), manually (with a front panel switch) or remotely (from an external device). The hold capabilities can be used in conjunction with program null pacing or limit programming. Program null pacing ensures each program level is reached before proceeding to a new level. Limit programming allows transducer feedback limits to trigger breakpoints and/or release hold times of the waveform (Model 448.41 Limit Detector required). 1-1
1.2 Specifications Table 1-1 lists the specifications for the 410.81 Function Generator. Table 1-1. Model 410.81 Function Generator Specifications Parameter Specification Environmental: Temperature 50 F(10 C ) to 104 F (40 C ) Relative Humidity 0 to 85%, noncondensing Program Output: Waveforms Maximum Voltage Maximum Load sine, haversine, haversquare, ramp and hold time ±10 volts 600 Ω Resolution: Ramp 0.05 mv (approximate) at 10 5, 10 4, 10 3, 10 2, 10 1,10 0 rates; 5.0 mv (approximate) at 10-1, 10-2 rates Sine/Haversine 1.2 mv (approximate) at 10-4, 10-3, 10-2, 10-1, 10 0 ranges; 120 mv (approximate) at 10 1, 10 2 ranges Step Accuracy Noise ±2.5 mv less than 63 mv p-p Ramp: Rates (0 to full-scale) Linearity Hold Drift 0.001 to 990,000 seconds ±0.1% from best straight line within ±5 mv for 24 hours Sine wave Harmonic Distortion less than 0.5% Square wave Characteristics flat to within 0.1% of full amplitude, rise time less than 50 µsec Preset Breakpoint: Accuracy Range 0.5% of full-scale between 5% and 95% of full-scale 5 to 95% of full-scale 1-2
Table 1-1. Model 410.81 Function Generator Specifications (continued) Parameter Specification Frequency: Accuracy Range ±0.1% of range (±1% w/vco option) 0.00001 to 990 Hz Stability 1 hour ±0.05%; 24 hours ±0.1% (±0.5%; ±1% w/vco option) Amplitude Variation (w/freq) Sync Output Gating Input VCO Input Range External Reference Input Range Line Voltage less than 10 mv RMS +5 Vdc 500 µsec pulse (max load 2 kω) jumper selectable, 5 volt logic or relay contacts 0.1 to 10 volts 2 to 10 volts 115/230 Vac (±10%), 50/60 Hz, 40 W Specifications are subject to change without notice. Contact MTS for verification of critical specifications. 1-3
Section 2 Operation This section provides a functional description of the Function Generator front panel controls and indicators. Figure 2-1 shows the Function Generator front panel controls and indicators. Operation of the Function Generator requires the following: Selecting a control mode, Subsection 2.1. Controlling the waveform output, Subsection 2.2. Selecting and programming a waveform, Subsection 2.3. The following are optional operation information: Program pacing information, Subsection 2.4. Limit programming information, Subsection 2.5. 410.81 Function Generator Output Main Sync Select Waveform Normal Invert Control Mode Local Single Remote Local Cycle Output Mode Finish Local Cycle Start & Stop Ret to Zero Output to 0 Trigger Manual Bkpt Hold Ramp Time 1 (sec) FS 0 t +100% FS 0 +100% FS Ramp Time 2 (sec) FS 0 t Hold Time (sec) FS t 0 Frequency (Hz) Breakpt 5-05% Full Scale Figure 2-1. Function Generator Front Panel Controls and Indicators 2-1
2.1 Control Mode Selection The Function Generator provides three modes of operation to start and stop the waveform output. Figure 2-2 shows the controls associated with control mode selection. Table 2-1 describes the control modes. Control Mode Remote Local Local Single Cycle ➊ ➋ ➌ Figure 2-2. Control Mode Switches Table 2-1. Control Mode Switch Descriptions Item Control Description 1 Remote The Remote switch allows an external device (input at the J3 Gate connector) to start and stop the Function Generator output. 2 Local The Local switch allows the front panel controls to start and stop the Function Generator output. 3 Local Single Cycle The Local Single Cycle switch allows one cycle of the Function Generator output after the Local Start switch is pressed. 2-2
2.2 Output Mode The Output Mode section provides controls to start, stop and manually override the waveform output. Output Mode Output to 0 Local Start Finish Cycle & Stop Ret to Zero Trigger Manual Bkpt Hold ➊ ➋ ➌ ➍ ➎ Figure 2-3. Output Mode Switches Table 2-2. Output Mode Switch Descriptions Item Control Description 1 Local Start The Local Start switch begins the waveform output in the Local and Local Single Cycle modes. 2 Finish Cycle & Stop The Finish Cycle & Stop switch allows the waveform to continue until it completes the current cycle, then it stops. 3 Ret to Zero The Ret to Zero switch ramps the waveform from its current value to zero at the Ramp Time 2 setting when in the ramp mode. The sine and haversine modes will stop at the next zero crossing. 4 Trigger Manual Bkpt The Trigger Manual Bkpt switch overrides the programmed breakpoint setting and triggers an immediate breakpoint. One breakpoint can be executed in each waveform quadrant (e.g., 0 to 10V, 10 to 0V, 0 to -10V and -10 to 0V). The breakpoint can be generated by the Trigger Manual Bkpt switch, a preset level or a remote breakpoint signal. 5 Hold The Hold switch stops the waveform at the current level until the Hold switch is pressed again. 6 Main The Main BNC connector provides the waveform output for monitoring. 7 Sync The Sync BNC connector outputs a signal each cycle to trigger an external device (i.e, counting cycles). 8 Output at 0 The Output at 0 indicator lights when the program output is at 0.00 volts. 2-3
2.3 Selecting and Programming Waveforms ➊ Select Waveform Normal Invert ➋ The controls and indicators associated with selecting and programming a waveform are shown in Figure 2-4 and described in Table 2-3. Descriptions of the waveforms are provided in Table 2-4. Operational procedures to program waveforms are provided in Subsections 2.3.1 (cyclic) and 2.3.2 (ramp). ➍ ➎ +100% FS 0 +100% FS ➌ Breakpt 5-05% Full Scale Ramp Time 1 (sec) FS Ramp Time 2 (sec) FS t 0 0 t Hold Time (sec) FS t 0 Frequency (Hz) Figure 2-4. Waveform Controls and Indicators Table 2-3 Waveform Controls and Indicators Item Control Description 1 Select Waveform (16-position switch) 2 Normal/Invert (switch) 3 Breakpt 5-95% Full Scale (10-turn potentiometer) 4 Ramp Time 1 (sec) (thumbwheel switch) Thumbwheel switch The Select Waveform switch selects the desired waveform. Each switch position lights an indicator above the selected waveform along with the appropriate thumbwheel indicator(s). Refer to Table 2-3 for descriptions of the waveforms. The Normal/Invert switch selects the initial polarity of the waveform. The Normal selection starts the waveform positive and the Invert selection starts negative. The Breakpt (breakpoint) control sets a breakpoint level within the range of 5% to 95% of full-scale. The breakpoint level is a point at which the waveform changes to another ramp rate or hold time. The control is scaled from 00 to 100 representing 0% to 100% full-scale (the upper and lower 5% are not used). The Ramp Time 1 (sec) control sets the ramp time (in seconds) for the output to go from zero (0.0 volts) to fullscale (10 volts). The control allows a two-digit number and multiplier to be entered. The function of this control is determined by the waveform selection. The control can set a second ramp time, a hold time or a frequency. The appropriate function indicator lights according to the waveform selection. The control allows a two-digit number and multiplier to be entered. 2-4
Table 2-3 Waveform Controls and Indicators (continued) Item Control Description 5 Ramp Time 2 (sec) (indicator) Hold Time (sec) (indicator) Frequency (Hz) (indicator) When the Ramp Time 2 (sec) indicator lights, the thumbwheel switch sets a ramp time (in seconds) for a second ramp rate to go from zero (0.0 volts) to full-scale (10 volts). The ramp is begins at the breakpoint level. When the Hold Time (sec) indicator lights, the thumbwheel switch sets a hold time (in seconds) required for some waveforms. The hold time is applied at the breakpoint level. When the Frequency (Hz) indicator lights, the thumbwheel switch sets a frequency (in hertz) for the cyclic waveforms. 6 Waveforms The waveforms illustrated on the front panel are color coded. The colors indicate which controls set-up the components of the waveform. Refer to Table 2-4 for descriptions of the waveforms. Table 2-4 provides descriptions of the front panel waveform selections. The waveform descriptions assume the Normal/Invert switch is set for Normal operation. Waveform illustrations with black dots indicate the use of the Breakpt control. Table 2-4. Waveform Descriptions Waveform Description Sine The program output is a ±10 volt sine wave. The Frequency (Hz) indicator lights to show which thumbwheel switch sets the frequency of the waveform. Haversine Haversquare The program output is a 0 to 10 volt sine wave (haversine). The Frequency (Hz) indicator lights to show which thumbwheel switch sets the frequency of the waveform. The program output is a 0 to 10 volt square wave (haversquare). The Frequency (Hz) indicator lights to show which thumbwheel switch sets the frequency of the waveform. 2-5
Table 2-4. Waveform Descriptions (continued) Waveform Description Ramp A Ramp B Ramp C Ramp D The program output increases from zero to the breakpoint level at ramp rate 1. Then the program output decreases to zero at ramp rate 1 to complete one cycle of the waveform. The program output increases from zero to 10 volts at ramp rate 1. Then the output decreases to zero at ramp rate 1 to complete one cycle of the waveform. The program output increases at ramp rate 1 from zero to the breakpoint level. The output decreases through zero to the negative breakpoint level and increases to zero to complete one cycle of the waveform. The program output increases at ramp rate 1 from zero to 10 volts. Then the output decreases through zero to -10 volts. The output increases to zero to complete one cycle of the waveform. Ramp E Ramp F Ramp G Ramp H The program output increases at ramp rate 1 from zero to the breakpoint level. Then the output increases at ramp rate 2 to 10 volts and holds the output at 10 volts until the Ret to Zero switch pushed. The program output increases at ramp rate 1 from zero to the breakpoint level. Then the output decreases at ramp rate 2 to zero to complete one cycle of the waveform. The program output increases at ramp rate 1 from zero to the breakpoint level. The output increases at ramp rate 2 to 10 volts. Then the output decreases at ramp rate 2 from 10 volts to the breakpoint level and changes to ramp rate 1 through zero to the negative breakpoint level. The output decreases at ramp rate 2 to -10 volts. Then the output increases at ramp rate 2 to the negative breakpoint level and changes to ramp rate 1 to zero to complete one cycle of the waveform. The program output increases at ramp rate 1 from zero to the breakpoint level. The output decreases at ramp rate 2 from the breakpoint level through zero to the negative breakpoint level. Then the output increases at ramp rate 1 to zero to complete one cycle of the waveform. 2-6
Table 2-4. Waveform Descriptions (continued) Waveform Description Ramp I Ramp J Ramp K Ramp L The program output increases at ramp rate 1 from zero to the the breakpoint level and holds the output. When the hold time is over, the output decreases at ramp rate 1 to zero to complete one cycle of the waveform. The program output increases at ramp rate 1 from zero to the breakpoint level and holds the output. When the hold time is over, the output increases at ramp rate 1 to 10 volts. Then the output decreases to the breakpoint level and applies the hold time again. When the hold time is over, the output decreases at ramp rate 1 to zero to complete one cycle. The program output increases at ramp rate 1 from zero to the breakpoint level and holds the output. When the hold time is over, the output decreases at ramp rate 1 through zero to the negative breakpoint level and holds the output again. When the hold time is over, the output increases at ramp rate 1 to zero to complete one cycle of the waveform. The program output increases at ramp rate 1 from zero to the breakpoint level and holds the output. When the hold time is over, the output increases at ramp rate 1 to 10 volts and decreases to the breakpoint level at ramp rate 1 and applies the hold time. When the hold time is over, the output decreases at ramp rate 1 through zero to the negative breakpoint level and applies the hold time. When the hold time is over, the output decreases at ramp rate 1 to -10 volts then increases to the negative breakpoint level and applies the hold time. When the hold time is over the output increases at ramp rate 1 to zero to complete one cycle of the waveform. 2-7
2.3.1 Programming Cyclic Waveforms The Function Generator includes the cyclic waveforms: sine, haversine and haversquare. The cyclic waveform selections are color coded green and lights the Frequency (Hz) indicator of the thumbwheel switches. The VCO (voltage controlled oscillator) option allows an external device to control the frequency. The waveform frequency (within a selected range) is controlled by an external device connected to the rear panel VCO EXT input. The input voltage determines the waveform frequency. When using the VCO input, the front panel thumbwheel switches are normally set to 0.0 (only the multiplier is set). This scales the VCO input so that a 0.1 volt input causes the minimum frequency in a given range and a 10 volt input causes the maximum frequency of the range. If desired, the thumbwheel switches may be set to a value other than zero. For example; a thumbwheel setting of 4.0 X 10 2 (400 Hz) and a VCO input of 2.5 volts (250 Hz) will result with a 650 Hz output. Perform the following to program a cyclic waveform: 1. Select the desired waveform with the Select Waveform switch to light the appropriate green indicator. The Frequency (Hz )control indicator will also light. NOTE: The maximum frequency for a cyclic waveform is 990 Hz. The maximum frequency using the VCO option is 1000 Hz. Tables 2-5 and 2-6 do not include the ranges 10 3, 10 4 and 10 5 ; these ranges provide the same frequencies as the 10 2 range. 2. Set the Frequency Hz switches to the desired program frequency (a two- digit number and multiplier). Table 2-5 shows the frequency range of the corresponding thumbwheel switch settings. Table 2-6 shows the frequency range and corresponding thumbwheel switch settings for the VCO option, only the multiplier is normally set for VCO operation. Table 2-5. Switch Setting and Frequency Range Switch Setting Frequency Range 0.1-9.9 x 10 2 10-990 Hz 0.1-9.9 x 10 1 1-99 Hz 0.1-9.9 x 10 0 0.1-9.9 Hz 0.1-9.9 x 10-1 0.01-0.99 Hz 0.1-9.9 x 10-2 0.001-0.099 Hz 0.1-9.9 x 10-3 0.0001-0.0099 Hz 0.1-9.9 x 10-4 0.00001-0.00099 Hz 2-8
Table 2-6. VCO Frequency Range Switch Setting Frequency Range 0.0 x 10 2 10-1000 Hz 0.0 x 10 1 1-100 Hz 0.0 x 10 0 0.1-10 Hz 0.0 x 10-1 0.01-1 Hz 0.0 x 10-2 0.001-0.1 Hz 0.0 x 10-3 0.0001-0.01 Hz 0.0 x 10-4 0.00001-0.001 Hz 3. Select the initial waveform polarity with the Normal/Invert switch. Normal selects a positive waveform. Invert selects a negative waveform. 4. Press the desired Control Mode switch. The control mode determines how the Function Generator program is started; perform one of the following: A. If Local or Local Single Cycle is selected, press the Local Start switch to begin the cyclic waveform program. B. If Remote is selected, refer to the product manual of the remote device for operation procedures to start/stop the program (ensure the remote device is properly connected to the Function Generator). 5. To stop the waveform, press the Finish Cycle & Stop or Ret to Zero switch, or the appropriate stop control on the remote device. 2-9
2.3.2 Programming Ramps The Function Generator includes twelve ramp waveforms (A through L) as described in Table 2-4. Waveforms A through D are programmed with one thumbwheel switch. Waveforms E through L require are programmed with both thumbwheel switches. The ramp rate setting defines the slope of the ramp. A ramp is programmed in seconds to cause the Function Generator output to go from zero (0.0 volts) to full-scale (10.0 volts) even though the ramp may change at a breakpoint. Perform the following to program a ramp. 1. Select the desired ramp with the Select Waveform switch to light the desired indicator (A through L). If waveform A through D is selected, the Ramp Time 1 (sec) indicator will light. If waveform E through L is selected, the Ramp Time 1 (sec) indicator will light along with the Ramp Time 2 (sec) or Hold Time (sec) indicator. NOTE: The minimum ramp period is 0.001 seconds. Table 2-7 does not include the ranges 10-3 and 10-4 ; these ranges provide the same frequencies as the 10-2 range. 2. Set the thumbwheel switches of Ramp Time 1 (sec) to the desired ramp time. A two digit number and a multiplier can be set. Table 2-7 shows the ramp range and corresponding switch settings. Table 2-7. Switch Setting and Ramp Range Switch Setting Ramp Range (in seconds) 0.1-9.9 x 10 5 10,000-990,000 0.1-9.9 x 10 4 1,000-99,000 0.1-9.9 x 10 3 100-9,900 0.1-9.9 x 10 2 10-990 0.1-9.9 x 10 1 1-99 0.1-9.9 x 10 0 0.1-9.9 0.1-9.9 x 10-1 0.01-0.99 0.1-9.9 x 10-2 0.001-0.099 2-10
3. For waveforms E through L, set the thumbwheel switches of Ramp Time 2 (sec)/hold Time (sec) to the desired time. A two digit number and multiplier can be set. 4. Adjust the Breakpt control to the desired percent of full-scale (within 5 to 95% full-scale) where the second ramp or hold time is to be applied. 5. Select the initial waveform polarity with the Normal/Invert switch. Normal starts the waveform positive and Invert starts the waveform negative. 6. Press the desired Control Mode switch. The control mode determines how the Function Generator program is started; perform one of the following: A. If Local or Local Single Cycle is selected, press the Local Start switch to begin the cyclic waveform program. B. If Remote is selected, refer to the product manual of the remote device for operation procedures to start the program (ensure the remote device is properly connected to the Function Generator). 7. To stop the waveform, press the Finish Cycle & Stop or Ret to Zero switch, or the appropriate stop control on the remote device. 2-11
2.4 Program (Null) Pacing Program (null) pacing holds the Function Generator output at the breakpoint level to allow the servohydraulic system to reduce any error before continuing the waveform program. This is accomplished by sending a dwell signal from the Function Generator to the servohydraulic controller to check the difference (dc error) between the program command and the transducer feedback. The dwell signal is sent when the output reaches the breakpoint level. If the level of dc error exceeds the limit adjusted on the system controller, the Function Generator holds the program level to allow the system to reduce the dc error. When the dc error reaches an acceptable level, the system controller outputs a null signal to the Function Generator and the program continues. Program pacing can only be used with waveforms containing hold times (waveforms I through L). To enable the program pacing function ensure the system controller is properly connected to the Function Generator (Subsection 4.5.5) and set the rear panel Null Pacing switch to the In position (Subsection 4.4.1). NOTE: For program pacing, the setting of the Hold Time switch should exceed the anticipated dwell time. The Function Generator resumes the program when the null signal is received or the end of the hold time is reached. 2.5 Limit Programming Limit programming is similar to program pacing except it is used in systems containing a Model 448.41 Limit Detector. The Limit Detector monitors the output of three transducers. An upper and lower limit is adjusted for each transducer output. If a transducer output exceeds the adjusted limit, the Function Generator will change the program output according to the waveform selected. Each of the transducer feedback signals of the Model 448.41 Limit Detector can be configured to initiate a breakpoint or release a hold time. Observe the following considerations when operating in the limit programming mode: Adjust the Breakpt control to 1000 (100% full-scale). The breakpoint function will be performed by the Limit Detector module. If the breakpoint level is below full-scale, the program output may change prematurely causing the remaining program changes to occur out of sequence. 2-12
If a waveform with a hold time is selected, ensure to program a hold time of sufficient duration to allow a limit to be detected. If the hold time is completed before a limit is detected, the program output will resume prematurely causing the remaining program changes to occur out of sequence. Figure 2-5 illustrates an example of limit programming. In the example shown, waveform J and normal are selected. The 448.41 Limit Detector is set-up with the load limit detector set for a breakpoint and the strain limit detector set for release (refer to the Limit Detector product manual). Function Generator Output (Waveform L) Upper Limit Load Feedback Lower Limit Upper Limit Strain Feedback Lower Limit Figure 2-5. Limit Programming Example 2-13
The program output increases at ramp rate 1 until the upper load limit is detected. The upper load limit causes the output to hold until the upper strain limit is detected. When the upper strain limit is detected, the output increases at ramp rate 1 until full-scale (+10 volts) is reached and the output decreases (at ramp rate 1) until the lower load limit is detected. The lower load limit causes the output to hold until the lower strain limit is detected. When the lower strain limit is detected, the output decreases at ramp rate 1 until zero (0.00 volts) is reached and another cycle begins. 2-14
Section 3 Service This section provides calibration information for the Model 410.81 Function Generator. In cases where the Function Generator unit is supplied as part of an MTS Systems Corporation testing system, the Function Generator unit will have been calibrated at the factory. Field calibration may be necessary when a new Function Generator is installed, a replacement unit is required, or calibration is deemed necessary after checking calibration accuracy. The procedures in the following subsections assume the person performing calibration is familiar with the use of electronic test equipment and the operation of system components. NOTES: The adjustment values specified in the following procedures provide for optimum calibration accuracy. The adjustment tolerances of these procedures during field calibration are dependent on system requirements and available test equipment. All calibration procedures are performed with hydraulic pressure turned off and the Function Generator set for Local Start control. 3.1 Power Supply Voltages Table 3-1 lists the monitoring point to check the power supply voltages. Figure 3-1 shows the locations of the monitoring points. Remove the top cover to access the test points. The +5 volt power supply is adjusted with R1 on the power supply circuit card assembly. The ±15 volt power supplies, -12 volt supply and the +10 volt reference are not adjustable. Common is TP10. Table 3-1. Power Supply Voltages Voltage Test Point + 5 Vdc; ±10 mv TP7 +15 Vdc; ±0.6 V TP8-15 Vdc; ±0.6 V TP9 +10 Vdc; ±0.1 V TP5-12 Vdc; ±0.6 V TP11 3-1
TP7 +5V TP9-15V TP10 COM TP8 +15V R45 TP12 BRKPT REF 1 R83 2 R46 R82 3 4 5 R48 R42 TP5 10V REF R110 6 7 8 9 10 A B R41 R21 X2 TP11 E J K -12 V C D L M N TP6 MAIN OUTPUT TP4 BRKPT REF TP13 10V BRKPT REF Figure 3-1. Main Circuit Card Service Locations 3.2 Output Calibration The Function Generator includes three digital-to-analog converters (DAC). The accuracy of the Function Generator output depends on the calibration of the DACs. The main 12-bit DAC is calibrated for a fullscale output of +10 volts using the internal reference voltage. The two 8-bit fill-in DACs are calibrated to smooth out the steps of the main DAC. The fill-in circuit is active for cyclic frequencies below 9.9 Hz (frequency multipliers 10 0 through 10-4 ) and ramps above 10 seconds (ramp multipliers 10 0 through 10 5 ). Perform the following procedure to calibrate the output of the Function Generator. Refer to Figure 3-1 for the adjustment locations. NOTE: Ensure the 10 volt reference voltage is within the specifications defined in Subsection 3.1. 3-2
1. If mounted in an equipment rack, pull the Function Generator out and remove the top cover. 2. Set the rear panel Output Scaling switch to Int to establish a fullscale output of +10 volts. Set the rear panel Output Scaling switch to Ext to establish a fullscale output representing the external reference voltage. If external scaling is selected, change the voltage levels in the following steps to reflect the reference voltage input through the Remote connector J5. 3. Apply power to the Function Generator. 4. Connect a digital voltmeter (DVM) to TP6 (MAIN OUTPUT) and TP10 (COM). 5. Select the square waveform. Set the Frequency Hz switch to 1.0 x 10 0 (1 Hz). 6. Press the Hold switch, this allows the DACs to increment only one step when the Local Start switch is pressed. 7. Set the Normal/Invert switch to the Invert position. 8. Press the Local Start switch. The output will go negative fullscale (-10 volts) and hold. 9. Adjust R42 (ZERO) for a DVM reading of -10.000 Vdc. 10. Set the Normal/Invert switch to the Normal position. 11. Press the Local Start switch. The output will go positive fullscale (+10 volts) and hold. 12. Adjust R41 (GAIN) for a DVM reading of +10.000 Vdc. 13. Press the Ret to Zero switch. The DVM reading should be 0.000 volts (±2.5 mv). Note the actual reading. 14. Connect the DVM to the front panel Main output. 15. Adjust R110 for the same reading noted in step 13. 16. Connect a DVM to TP6 (MAIN OUTPUT) and TP10 (COM). 17. Select the sine waveform. 18. Set the Normal/Invert switch to the Invert position. 19. Press the Local Start switch; this causes the DAC to decrease 1 step. Note the DVM reading, the voltage should be a few millivolts. 3-3
20. Set the Normal/Invert switch to the Normal position. 21. Press the Local Start switch; this causes the DAC to increase 1 step. Note the DVM reading. 22. The voltage noted in steps 19 and 21 should be the same. If not, adjust R46 (SINE FILL IN) for a DVM readout to reflect the same voltage noted in step 19. 23. Return to step 18 and recheck the symmetry between a positive step and a negative step. Repeat this step until both DVM readings are within 1 mv. 24. Press the Return to Zero switch. Adjust R48 (MIN OFFSET) for a DVM readout of 0.000 volts (±1 mv). 25. Repeat steps 18 through 24 as necessary to balance the voltages to less than 1 mv. 26. Select the Ramp A waveform. Set the Ramp Time 1 (sec) switch to 1.0 x 10 1 (10 second ramp rate). 27. Set the Normal/Invert switch to the Invert position. 28. Press the Local Start switch; this causes the DAC to decrease 1 step. Note the DVM reading, the voltage should be a few millivolts. 29. Set the Normal/Invert switch to the Normal position. 30. Press the Local Start switch; this causes the DAC to increase 1 step. Note the DVM reading. 31. The voltage noted in steps 28 and 30 should be the same. If not, adjust R45 (RAMP FILL IN) for a DVM readout to reflect the same voltage noted in step 28. 32. Repeat steps 27 through 31 as necessary until the symmetry between a positive step and a negative step is within 1 mv. 33. Install the top cover removed in step 1 then push the Function Generator back into the equipment rack. 3-4
3.3 Breakpoint Calibration The breakpoint calibration procedure establishes the accuracy of the front panel Breakpt 5-95% Full Scale control. Perform the following procedure to calibrate the Breakpt control. NOTE: The adjustment range of the front panel Breakpt control is 5 to 95% full-scale. The first and last 50 increments of the control dial do not function. 1. If mounted in an equipment rack, pull the Function Generator out and remove the top cover. 1. Adjust the front panel Breakpt control to exactly 1000 (100% fullscale). 2. Connect a DVM to the wiper of the Breakpt control and TP10 (COM). 3. Adjust R82 (BRKPT 10V REF ADJUST) for 10.000 Vdc. 4. Connect the DVM to TP4 (BRKPT REF). 5. Adjust R19 (BRKPT REF UPPER CLAMP) for 9.500 Vdc. 6. Set the Breakpt control for 900 (90% full-scale) note the DVM reading. 7. Connect the DVM to TP12 (INV BRKPT REF). 8. Adjust R83 (BRKPT BAL) for a DVM reading of the negative voltage noted in step 6. 9. Connect the DVM to TP4 (BRKPT REF) 10. Set the Breakpt contro to l 000 (0% full-scale). 11. Adjust R21 (BRKPT REF LOWER CLAMP) for a DVM reading of 0.500 Vdc. 3-5
3.4 Cosine Calibration (Option A) This subsection provides the procedure to calibrate the cosine DACs for a full-scale output of ±10 volts. Unless otherwise noted, all test points, jumpers and adjustments are located on the cosine circuit card assembly shown in Figure 3-2. R9 R11 R8 R7 1 X1 TP3 TP2 TP1 J3 Figure 3-2. Cosine Circuit Card Service Locations 1. Set the rear panel Output Scaling switch to Int to establish a fullscale output of +10 volts or, set the rear panel Output Scaling switch to Ext to establish a full-scale output representing the external reference voltage. If external scaling is selected, change the voltage levels in the following steps to reflect the reference voltage input through the Remote connector J5. 2. Connect a DVM to TP1. Ensure the reference voltage selected in step 1 is within 0.1 volt of the selected level. 3. Position jumper X1 across pins 2 and 3 to select the calibration mode. 4. Connect a DVM to the rear panel J1A Cosine connector. 5. Select the haversquare waveform. Set the Frequency (Hz) switch to 9.9 x10-2. 6. Set the Normal/Invert switch to the Invert position. 7. Select the Local mode of operation. 3-6
8. Press the Local Start switch. When the output reaches -10 volts, press the Hold switch. 9. Adjust R8 (-FULL SCALE) for a DVM reading of -10.000 Vdc. 10. Set the Normal/Invert switch to the Normal position. 11. Press the Hold switch to release the hold function. Press the Local Start switch. When the output reaches 10 volts, press the Hold switch. 12. Adjust R7 (+FULL SCALE) for a DVM reading of +10.000 Vdc. 13. Press the Hold switch to release the hold function. Press the Ret to Zero switch and verify a DVM reading of 0.000 (±2.5 mv). 14. Select the sine waveform. Set the Frequency (Hz) switch to 9.9 x10 0. 15. Remove the DVM and connect an oscilloscope to the rear panel J1A Cosine connector. 16. Press the Local Start switch. 17. Adjust R9 (FILL IN) for the smoothest waveform (i.e., to fill in the steps of the DAC). 18. Set-up the oscilloscope to trigger when TP3 goes high. 19. Adjust R11 (MIN OFFSET) for 0.0 volts at the start of a trace on the oscilloscope. 20. Position jumper X1 across pins 1 and 2 for normal operation. 3-7
3.5 Voltage Controlled Oscillator Calibration (Option B) The voltage controlled oscillator (VCO) option is calibrated so the output frequency tracks the internal or external frequency setting to within 1% of any range. Unless otherwise noted, all test points, jumpers and adjustments are located on the VCO circuit card assembly. R16 R13 R5 J8 Figure 3-3. VCO Circuit Card Service Locations 1. Select the haversquare waveform. 2. Ground the J4 VCO Ext connector on the rear panel. 3. Set the Frequency (Hz) switch to 0.1 X 10 2. 4. Connect a frequency counter to the rear panel J1 Main connector. 5. Adjust R13 (VCO ZERO) for a frequency counter reading of 100 ms (±0.1 ms). 6. Set the Frequency (Hz) switch to 9.9 x 10 2. 7. Adjust R5 (VCO GAIN) for a frequency counter reading of 1.01 ms (±0.001 ms). 8. Repeat steps 3 through 7 until no further adjustment is needed. 9. Connect a voltage source to the rear panel J4 VCO Ext connector. 10. Set the Frequency (Hz) switch to 0.0 X 10 2. 11. Set the voltage source to 9.900 Vdc. 12. Adjust R16 (EXT VCO INPUT GAIN) for a frequency counter readout of 1.01 ms (±0.001 ms). 3-8
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Section 4 Installation This section provides information for installing the Model 410.81 Function Generator. The Function Generator installation involves mounting the chassis, configuring the power supply to the local line voltage, configuring the operational characteristics with jumpers and connecting the Function Generator to other system components. Read and observe the following note before installing the Function Generator. NOTES: The Model 410.81 Function Generator contains components which are sensitive to static. Care should be exercised when handling these components to prevent circuit card and/or component damage. The following precautions are suggested: Do not install or remove a jumper while power is applied. Touch the console or other ground point before removing or installing a circuit card. When handling printed circuit cards, avoid making physical contact with any components or circuitry on the card. Hold the card by its sides. Maintain the same potential between the printed circuit card and the equipment or surfaces it will contact by touching the surfaces first. Handle the integrated circuits by the edges. Avoid touching the pins themselves. Any circuit card repairs should be made at a static-free work station by personnel familiar with repairing such devices. 4-1
4.1 Function Generator Installation The installation of the Function Generator is subject to specific system requirements. Perform the following to install the Function Generator. 1. Ensure the Function Generator has arrived with no shipping damage. If damaged, contact the Customer Service Division of MTS Corporation. 2. Refer to Subsection 4.2 to install the Function Generator in an equipment rack. 3. Perform the line voltage and grounding procedures in Subsection 4.3. 4. Circuit card switches and jumpers establish the operational characteristics of the Function Generator. To determine if any configuration changes are needed, refer to Subsection 4.4 for descriptions of the switches and jumpers. 5. Subsection 4.5 provides information for the rear panel connections. Each subsection includes signal identification, signal levels, I/O indication and pin numbers. Review the possible connections to determine which connections are required. 6. If the Cosine option is to be installed, refer to Subsection 4.6. 7. If the VCO option is to be installed, refer to Subsection 4.7. 4.2 Equipment Rack Installation The Function Generator chassis is installed in an equipment rack with slide rails. Perform the following procedure to rack-mount the Function Generator: 1. Determine a mounting position in the equipment rack for the Function Generator. Note which two holes on each of the equipment rack front hole strips will be used to mount the slide rails (refer to Figure 4-1). Ensure the slide rails are positioned at the same level. 2. Separate the female slide assembly (outer slide) from the male slide assembly (attached to the chassis) by pulling the female slide to the rear of the chassis and unlocking the spring latch. 3. Install the female slide assembly to the console as shown in Figure 4-1 using the hex head screws and bar nuts from the slide rail mounting hardware. 4. Repeat steps 2 and 3 to mount the other female slide assembly on the opposite side of the console. 4-2
5. Fully extend the female slides from the console. Insert the male slides mounted on the chassis into the female slides until the spring latch locks. 6. Press the spring latch releases and slide the chassis into the console. Rear Equipment Rack Hole Strap Hex Head Screw Chassis Slide Mounting Bracket Female Slides Male Slide attached to Chassis Front Panel Hex Head Screw Equipment Rack Front Equipment Rack Hole Strap Bar Nut Figure 4-1. Rack Mounting the Female Slide Assembly (Top View) 4.3 Voltage and Grounding The following subsections provide information to match the Function Generator to local line voltages and to properly ground the chassis. 4.3.1 Line Voltage The Function Generator receives power from a detachable, three-wire power cord. The power cord plugs into an input power connector block located on the Function Generator rear panel. Located in the input power connector block are the input power fuse and a PWB to adapt the Function Generator to various input line voltages. The power switch is located on the rear panel, on is labeled and off is labeled O. Perform the following procedure to change the setting to the available line voltage: 1. Disconnect the input power cord from the input power connector. 2. Slide the plastic cover over the input power connector to access the fuse and PWB. 3. Lift the FUSE PULL lever outward and toward the input power connector and remove the fuse. 4. Remove the PWB by inserting a hook in the hole through the PWB to pull it out. 4-3
5. Refer to Table 4-1. Position the PWB such that the appropriate input voltage selection legend will be visible and push the PWB back into the input power connector block. Table 4-1. Input Voltage and Corresponding PWB Legend Input Voltage PWB Legend 104-126 Vac 120 207-253 Vac 240 NOTE: The Function Generator specifications are maintained providing the line frequency is within 48 to 63 Hz. Table 4-1 shows the recommended PWB selections for optimum operation. 6. Install a 1 amp, slo-blo fuse for 120 Vac operation. Install a 0.5 amp, slo-blo fuse for 240 Vac operation. 7. If necessary, replace the main power cord with one having the appropriate wall receptacle connector. 4.3.2 Chassis Common and Grounding The external connections for circuit common (black terminal) and chassis common (metallic terminal) are located on the rear panel of the Function Generator. The Function Generator is manufactured with both terminals connected together (for stand alone applications). For equipment rack installations remove the commoning wire from the ground terminals. The circuit common terminal is connected to a single power ground or earth ground with a braided wire (typically connected to a single point with the circuit common of other equipment). The chassis common terminal is connected to the equipment rack frame with a braided wire. Both wires should be long enough to allow the chassis to be pulled out of the console for testing and calibration. 4-4
4.4 Switch and Jumper Descriptions The following subsections provide information on the effect of the rear panel switches and circuit card jumpers on the operation of the Function Generator. The rear panel switches are shown in Figure 4-2 and the location of the circuit card jumpers are shown in Figure 4-3. To access the circuit card jumpers, remove the top cover of the chassis (secured with four screws). Configure the Function Generator rear panel switches and circuit card jumpers per system requirements. NOTE: The jumper illustrations show a jumper block as a shaded rectangle. Figure 4-2. Rear Panel Switch Locations 4.4.1 S1 Program (Null) Pacing Enable Switch S1 enables or disables the Function Generator for program null pacing. Setting the Null Pacing switch to Out disables program (null) pacing; setting the Null Pacing switch to In enables program (null) pacing. Program (null) pacing ensures programed levels are reached by the feedback signal of the servocontroller before continuing the program. This is accomplished by sending a dwell signal to the servohydraulic controller; the controller returns a null signal when the transducer feedback is within an acceptable limit of the program command. Refer to Subsection 2.4 for additional information. 4-5
4.4.2 S2 Output Scaling Internal/External Switch S2 selects the source of the reference voltage to scale the Function Generator output. The internal selection (Int) provides a fullscale output of ±10 volts. The external selection (Ext) allows an external reference voltage to be input through the Remote connector J5 to establish a full-scale output equal to the external reference voltage. The external reference voltage can be from 2 to 10 volts. 4.4.3 S3 Breakpoint Source Switch S3 selects the source of the breakpoint reference voltage. The internal selection (Int) enables the front panel Breakpt control. The external selection (Ext) provides an external level input through the Remote connector J5. The external breakpoint reference voltage can be from 0.5 to 9.5 volts. E F G H J K 1 X4 2 3 4 5 X9 X6 X10 6 7 8 X2 9 10 X8 X3 X7 X5 11 A B C D L M N MP-E003B Figure 4-3. Main Circuit Card Jumper Locations 4.4.4 X1 Cosine Calibration Jumper X1 (not shown) is located on the cosine option circuit card assembly. The jumper is provided to calibrate the cosine circuit. The jumper is positioned across pins 1 and 2 for normal operation. 4-6
4.4.5 X2 VCO Enable Jumper X2 enables the voltage controlled oscillator (VCO) option. The jumper determines if the operating frequency is established with the front panel thumbwheel switches or the VCO option. The VCO option is used with the sine, haversine and haversquare waveforms only. Refer to Figure 4-4 and configure jumper X2 per system requirements. VCO Enable X2 VCO Disable X2 Figure 4-4. VCO Enable Jumper 4.4.6 X3, X4 Cosine Output Enable Jumpers X3 and X4 configures the Function Generator to operate with the cosine option. Jumper X3 allows the cosine output to finish its cycle when the program is stopped (after the sine wave program stops). Jumper X4 enables the cosine output to be routed to the rear panel connector J1A. Refer to Figure 4-5 and configure jumpers X3 and X4 per system requirements. Cosine Enable X4 Cosine Disable X4 1 1 1 X3 1 X3 Figure 4-5. Cosine Enable Jumpers 4.4.7 X5, X6 Testing Jumpers X5 and X6 are provided for factory testing purposes. Both jumpers should be positioned across pins 1 and 2 for normal operation. 4-7
4.4.8 X7 Remote Stop/Hold Select Jumper X7 determines if the Function Generator output returns to zero or is held at the current level when the remote stop signal is detected. Refer to Figure 4-6 and configure jumper X7 per system requirements. Remote Stop Remote Hold/Resume X7 X7 1 3 1 3 Figure 4-6. Remote Stop/Hold Jumper 4.4.9 X8 Remote Start Jumper X8 configures the input electronics to accept a 5 volt logic signal or switch contacts from an external gate signal. The gate signal is input through the rear panel Gate connector J3 (refer to Subsection 4.5.3). Refer to Figure 4-7 and configure jumper X8 per system requirements. 5 Volt Logic Switch Contacts 1 X8 1 X8 Figure 4-7. Gate Input Jumper 4.4.10 X9, X10 Emergency Stop Jumpers X9 and X10 configure the Function Generator operation for an emergency stop signal. Jumper X9 enables an emergency stop signal to control the Function Generator output (return to zero or hold). Jumper X10 determines how the Function Generator output returns to zero (if necessary) when the emergency stop signal is reset. When an emergency stop signal is detected, jumper X9 can be configured to execute a return to zero, hold the output at the current level then return the output to zero according to jumper X10 or the emergency stop function can be disabled. When the emergency stop signal is reset (interlock reset), jumper X10 can be configured to execute a return to zero (according to the setting of the Ramp Time 2 switch) or step the output directly to zero. 4-8
NOTE: When the Function Generator executes a return to zero for a sine, haversine or haversquare waveform; the output will continue until it reaches the next zero crossing. Refer to Figure 4-8 and configure jumpers X9 and X10 per system requirements. Return to Zero Hold Output and X10 No E-Stop X9 4 X9 X9 Ramp to Zero Intlk Reset X10 1 3 Step to Zero Intlk Reset X10 1 3 ' Figure 4-8. Emergency Stop Configurations 4.5 Rear Panel Connectors All input and output signals that interface the Function Generator with other system components are connected to, or available at the rear panel connectors shown in Figure 4-9. This section provides information on all input/output signals at the rear panel. The sequence of the following subsections is in the numerical order of the rear panel connectors. Figure 4-9. Rear Panel Connectors 4-9
4.5.1 J1 Main Output Two J1 Main connectors are on the rear panel and one Main connector is on the front panel. These BNC connectors provide the Function Generator program output (within ±10 volts). When the cosine option is installed, rear panel connector J1A provides the 90 (phase lag) program output. The front panel Main Output connector is buffered and provided for monitoring purposes. 4.5.2 J2 Sync Output The Sync connector outputs a sync pulse at the beginning of each cycle. The sync pulse is a 5 volt, 500 µs signal which can be used for cycle counting. Connector J2 is a BNC connector. 4.5.3 J3 Gate Input The Gate BNC connector allows an external device to start and stop the Function Generator. The input signal can be from switch contacts or a 5 volt logic signal (refer to Subsection 4.4.9 to configure the input). The Function Generator program starts when closed contacts or a high logic signal is detected; the output stops when open contacts or a low logic signal is detected. The gate function operates in conjunction with the front panel Remote switch. NOTE: A 25 Vdc signal through a 22k resistor can also be used when jumper X8 is configured for switch contacts. 4.5.4 J4 VCO External Input The VCO Ext (Voltage Controlled Oscillator) connector provides an input to control the frequency of a cyclic waveform when option B is installed. The input signal can be within 0.1 volts to 10.0 volts. Refer to Subsection 4.7 for installation information and Subsection 2.2.1 for operational information. 4-10