ADC Field Service Manual: Applications Engineering JANUARY 1996

ADC
Field Service Manual
APPLICATIONS ENGINEERING
JANUARY 1996
Revised 02/11/97 by RFK
Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 1

Table Of Contents
TECHNICAL SUPPORT ..........................................................................................................................................................3
INTRODUCTION......................................................................................................................................................................4
ADC SYSTEM COMPONENTS ..............................................................................................................................................6

GMCC......................................................................................................................................................................................6
DIP Switch Settings..............................................................................................................................................................6
Bus Mode .............................................................................................................................................................................................6
Base Address........................................................................................................................................................................................6
I/O Port Address...................................................................................................................................................................................6
Interrupt Port........................................................................................................................................................................................6
GFCC .......................................................................................................................................................................................7
Transducer Inputs ................................................................................................................................................................7
Sensor Inputs........................................................................................................................................................................................7
Connections .....................................................................................................................................................................................7
Buffered Inputs.....................................................................................................................................................................................7
Digital Extension................................................................................................................................................................................12
Connections ...................................................................................................................................................................................12
Handset ..............................................................................................................................................................................13
Connection .........................................................................................................................................................................................13
DIP Switch Settings ...........................................................................................................................................................................13
Ramping.........................................................................................................................................................................................13
PWM..............................................................................................................................................................................................13
Frame Type ....................................................................................................................................................................................13
Typical Settings .............................................................................................................................................................................13
Ramping.........................................................................................................................................................................................14
PWM..............................................................................................................................................................................................14
Typical Settings .............................................................................................................................................................................14
Digital I/O..........................................................................................................................................................................15
Connections........................................................................................................................................................................................15
Specifications .....................................................................................................................................................................................15
Applications .......................................................................................................................................................................................16
Limits..................................................................................................................................................................................17
Clutches..............................................................................................................................................................................19
History................................................................................................................................................................................20
Features description ...........................................................................................................................................................................20
ADC MAIN CABLE .................................................................................................................................................................23
Pin Locations .....................................................................................................................................................................23
Problems ............................................................................................................................................................................24
INTERNAL FRAME CONNECTIONS............................................................................................................................................25
SERVO CONTROLER ................................................................................................................................................................26
Indicator LED Description ................................................................................................................................................26
Adjustments ........................................................................................................................................................................26
CONFIGURATION FILES ....................................................................................................................................................27
ADCFIRM.BIN...................................................................................................................................................................27
Flags...................................................................................................................................................................................................27
SFXXXXXX.CNF................................................................................................................................................................28
Accessing CNF File Parameters .........................................................................................................................................................28
CNF Parameter Description ...............................................................................................................................................................29
How to Tune PIDs...........................................................................................................................................................................31
TWOPT.INF .......................................................................................................................................................................34
DIAGNOSTICS ..........................................................................................................................................................................35
Programs............................................................................................................................................................................35
MT.EXE.............................................................................................................................................................................................35
Diagnost.exe.......................................................................................................................................................................................35
DOS Based Utilities ...........................................................................................................................................................................37
Introduction ...................................................................................................................................................................................37
Address and Port Selection ............................................................................................................................................................37
Programs ........................................................................................................................................................................................38
Diagnostic Procedures Using the ADC Control Panel......................................................................................................40
DIAGNOST.EXE MANUAL ........................................................................................................................................................42

Technical Support
The MTS Technical Support office for electro-mechnical machines may be reached by the
following;
MTS EM Technical Support

1001 Sheldon Drive
Cary, NC 27513
Phone: (919) 677-1610 (Direct)

(800) 328-2255 (Help-Line)
Fax: (919) 677-2480
Email: [email protected]

Introduction
ADC (Advanced Digital Controller) is a third generation electronic system for data aquisition and
control system for MTS SINTECH Material Testing Systems. The system consists of two electronic
boards. The ADC Machine Control Card (GMCC) is located inside of the computer while the ADC
Frame Control Card (GFCC) is inside of the testing frame. A cable connects (CITS Cable) connects
the two together. The GMCC uses a specific portion of computer memory for communicating with the
GFCC. This address is selectable on the GMCC and in the testing software. System components
such as physical limits, encoders, and servo control are connected to the GFCC via a break-out box
inside of the frame. Frame options and parameters are controlled through configuration files.
The ADC electronics have several diagnostic programs which are covered in this manual. The
Diagnost.exe program comes standard with the TestWorks testing software. It has two levels of
diagnostics, a customer level and a Field Service Engineer level. The DOS-based ADC Utilities are
stand alone programs which run from DOS and are available from the MTS EM Technical Support
office.

Below is a block diagram of the ADC Electronics.

ADC System Components
GMCC
GMCC DIP Switch Settings
SW1 - Bus mode

0 = 16-bit transfers (May be req'd if video card uses 16-bit BIOS)
1 = 8-bit transfers (Default)
SW2..SW4 - Memory base address

SW2 SW3 SW4 Addr
0 0 0 EC000 (Default)
0 0 1 E8000
0 1 0 E4000
0 1 1 E0000
1 0 0 DC000
1 0 1 D8000
1 1 0 D4000
1 1 1 D0000
SW5, SW6 - I/O port address

SW5 SW6 Addr
0 0 270 (Default)
0 1 260
1 0 250
1 1 240
SW7, SW8 - Interrupt port

SW7 SW8 IRQ
0 0 12
0 1 11 (Default)
1 0 10
1 1 5
KEY
1 = ON, 0 = OFF

GFCC
Transducer Inputs
The ADC provides three modes of transducer input, Sensored, Buffered, and Digital.
Sensored Inputs
Sensored Inputs provide the signal conditioning for compatible MTS transsducers such as loadcells
and extensometers. The excitation and sensitivity are set in the testing frames software.
Specifications;
Excitation: 2.5, 5.0, and 10 volts. software selectable
Sensitivity variable up to 3.0 millivolt/volt max located
The ADC provides 9-pin DSUB plugs for load cell (internal to frame, on Frame Card) and 2 strain
channels (outside of frame, on Connector Panel Card). These connections are upward-compatible
with DFCC-type sensors. Additionally, the ADC provides shunt cal relays on the strain channels, and
self-id digital bus connections on all three channels.
Connections
An internal cable runs from the GFCC to the Crosshead Junction Box where the external loadcell
connection is made. Strain sensors are connected directly to the GFCC Connector Panel.
Buffered Inputs.
Buffered Inputs are used to input clean 0 - 10 volt DC signals as transducers. The connections are
made via bnc connectors labeled BUFFER INPUTS on the GFCC Connector Panel.
Specifications:
Signal: Conditioned 0 - 10 volt DC

Diagram of Signal conditioning circuit
Below is a block diagram of the signal conditioning circuit. A low level signal is amplified and sent to
the multiplexer while the high level signal is sent straight to the multiplexer. The signal is then sent
through a 44 Hz filter. A reference signal is then sent to the GMCC which is used to choose the
appropriate gain. The criteria for choosing the gain is to find a gain which will send a 4 to 8 volt signal
to the GMCC. A separate signal is sent through the Programmable Gain Amplifier. The amplified
signal is then sent to the GMCC. The signal is then reduced in order to be sent to a 0-2.5 volt 16 bit
A/D.
GFCC
To GMCC
GMCC
Analog Input channels and Autoranging

The nominal resolution of the A/D converters in the GMCC is 15 bits (plus sign) for full scale 10 volts. This
works out to 0.305 millivolts per count.
Front end gain on the GFCC is 216. Thus at 10V excitation, a load cell with 2mV/V sensitivity will generate
approximately 4.3 volts at full scale. The gain of 216 was selected so that the system would still be able to
measure a 3mV/V load cell at 150% of capacity, which will output approximately 9.7 volts.
Since the A/D converters have the best resolution (relative to the reading) when the input signal is near full
scale, additional gain stages in the GFCC are used to increase the signal going to the A/D converters. These
gain stages can be set for each channel by the firmware for a gain of 1, 2, 4, 8, 10, 20, 40, or 80. The
firmware continually reads the unranged analog voltage off a separate A/D converter (the 12-bit unranged
converter) and uses this to calculate an optimum gain so that the ranged A/D signal for each analog channel is
between 40% and 80% of full scale (autoranging).
The Max Autorange parameter in the ADC configuration limits the highest gain the firmware may select. A
Max Autorange of 1 effectively disables autoranging. The increased resolution at the highest gain ranges may
not improve the measurement any, as most of what is being amplified at that level is noise. (The amount of
noise and fluctuation will not be effected by the range selection, just the resolution to which the noise is being
measured).
Note that the gain at any given time (and thus the resolution in millivolts, lbs, or Kg) depends on the magnitude
of the input signal. A load cell with a 1 volt offset, for example, would not be able to use a gain higher than 8,
as it would saturate at a gain of 10.

Filtering
HIGH-RESPONSE ADC (BAXTER CDR)
Purpose: to provide transient response similar to Instron 4500 console (Filter cutoff frequency =
100 Hz.)
Theory: The Sigma-Delta (16-bit) converter on the GMCC has an inherent 10Hz bandwidth limit.
For faster response we can use the 12-bit A/D converter currently used for auto-ranging as the
primary load data. The digital filtering that is currently in firmware on this channel will be modified so
that its cutoff frequency is variable from 10Hz (the current setting) to 250Hz. This will also give us a
feel for the variable frequency response planned for Mongoose.
Negative issues:
1. Getting the load from the 12-bit A/D converter means a significant loss of resolution, especially
since there is no range (auto or otherwise) amplification.
2. Raising the bandwidth introduces the possibility of picking up 60Hz AC. However, this is not
expected to be significant.
Implementation:
1. Hardware
The GFCC currently has a hardware analog filter with a cutoff frequency of 44 Hz. This can
be raised to 250Hz by changing two capacitors:
C238 to 0.018 F
C241 to 0.039 F
2. Firmware
A new adcfirm.bin has been written to support the option of reading load from the 12-bit
converter.
A baxter bit (800 hex) has been added to the machine attribute word to turn on this
feature.
The software filtering frequency can be set by changing the Clutch2 Initial Goto field in
the cnf file. This field (which is not really used in current software) will be the time constant
of the software filter. Examples:
Time Constant = 40 Cutoff = 10 Hz
Time Constant = 4 Cutoff = 100 Hz
Time Constant = 1 No filtering
If the value entered is not between 1 and 100 a default value of 40 will be used.
Implementation of the variable load channel low-pass filter.
Time Cutoff 400

Constant Frequency
Hz
1 250.0 To make the variable functional, the machine attribute has
2 200.0 to have the bit set (800 hex, 2048 decimal). Once the bit
3 133.3 has been set, the time constant is active and can be
4 100.0 entered. The time constant is entered into the field
5 80.0 "Clutch2 Initial Goto".
6 66.7
7 57.1 If the value is not between 1 and 100, 40 will be used.
8 50.0
9 44.4 Once the high-frequency bit has been set, auto-ranging of
10 40.0 the load channel is no longer active. The "Max
15 26.7 AutoRange" field should be set to 1.
16 25.0
20 20.0 This will only work if the GFCC has been modified with the
21 19.0 two changed capacitor. The part number for the modified
25 16.0 GFCC is 1250118. This structure includes the GFCC
30 13.3 assembly (00.01172 ) and the two capacitors.
35 11.4
40 10.0
50 8.0
60 6.7
70 5.7
80 5.0
90 4.4
100 4.0
Machine Attributes
ADC_HIRATIO 0x0001 / scale turns ratio by 100 instead of 1000 /
ADC_NOBALLS 0x0002 / no ball screw encoder /
ADC_ANAHAND 0x0004 / emulate handset feedback /
ADC_HIBALLS 0x0008 / scale ball screw resolution up by 10 /
ADC_20KHZ 0x0010 / PWM output is Adamel A / B /
ADC_FREQOUT 0x0020 / output is number of counts, not PWM /
ADC_COPLEY 0x0040 / NOT USED -- GFCC to output magnitude and direction /
ADC_NENE 0x0080 / NOT USED -- GFCC to output 0-10V /
ADC_WIDGET 0x0100 / position feedback is up & down pulses /
ADC_EXTRLY 0x0200 / NOT USED -- calibration relay is external to GFCC /
ADC_DFCC 0x0400 / connected to DFCC / QFCC / SIMA /
ADC_BAXTER 0x0800 / use 12-bit converter for load /
ADC_REVERSE 0x1000 / motor direction is inverted /
ADC_UPEND 0x2000 / position feedback is inverted /
ADC_FIXTURE 0x4000 / "Frame" is test fixture /
The easiest way to deal with these, is to switch to HEX, add up your bits and enter the number into the attribute field. Ex.
Baxter bit, w/ no ball screw encoder, w/ anahand. This is 800, 2, and 4. So the attribute is 806 hex. Ex2. Hirratio,
noballs, anahand, and hiballs. This is 1, 2, 4, 8. So F hex is your attribute.

Digital Extension (Quadrature) Input
The ADC provides a 9-pin DSUB receptacle for a user quadrature input channel. This will typically
be used for measuring devices that provides a quadrature output such as the Laser Digital
Extensometer and Digital encoders.
Connections

Handset
Connections
The ADC Handset connector accepts an ADC handset (NOT an original DFCC-type handset).
DIP Switch Settings

There are two assemblies for the ADC Handset. The original design was constructed in order to switch between
ADC and Digital Frames.
For ADC/DFCC Frames (part# 2000164) has original rev a firmware

DIP Switches 1,2: Ramping
SW1 SW2 Ramp Time
OFF OFF 2.0 sec
ON OFF 1.5 sec
OFF ON 1.0 sec
ON ON 0.5 sec
DIP Switch 3: Max. PWM

SW3 Max.
PWM
OFF 100%
ON 50%
DIP Switch 4: Frame Type

SW4 Frame Type
OFF DFCC
ON ADC
Typical DIP Switch Settings

Frame Type Control SW1 SW2 SW3 SW4
Mode
DFCC Frequency OFF ON ON OFF
ADC before 5/1/94 PWM- ON ON ON ON
Current
ADC after 5/1/94 PWM- OFF ON OFF ON
Velocity

1/2/5 ADC with PWM- OFF ON ON ON
PRE-7 Amp Velocity
For ADC only (part# 00.01162)

DIP Switches 1,2: Ramping
SW1 SW2 Ramp Time
OFF OFF 2.0 sec
ON OFF 1.5 sec
OFF ON 1.0 sec
ON ON 0.5 sec
DIP Switch 3, 4: Max. PWM

SW3 SW4 Max. PWM
OFF ON 100%
ON ON 50%
OFF OFF 30%
ON OFF 20%
Typical DIP Switch Settings

Frame Type SW1 SW2 SW3 SW4
1/S ADC (1996 Model Year) OFF ON ON OFF
20/30G (1996 Model Year) OFF OFF ON ON
45/65G (1996 Model Year) OFF OFF ON ON
1/2G ADC (uses Pre-7 Model Amp) OFF OFF ON ON
1All other Sintech ADC Frames OFF ON OFF ON

Digital I/O
The ADC features 4 bits of digital input and 4 bits of digital output, each separately controllable by
TWW. Inputs and outputs are each opto-isolated. All connections are brought out to one 37-pin D-
sub receptacle on the back of the frame.
Connections
In the drawing below, the connections for Digital Input #1 and Digtal Output #1 are shown. The
corresponding pins for channels 2 through 4 are given in the Applications section to follow.
Specifications
Electrical Specification for Digital Input

The digital inputs are differential voltage input circuits.
Input voltage = 5VDC 10%
Electrical Specification for Digital Output

The digital outputs are isolated NPN transistor outputs
Max voltage = 12V
Max current (per output) = 20mA
Example:
Commanding Testworks to send a 0 to Digital output port #1 results in an open circuit between
pins 16 and 35.
Commanding Testworks to send a 1 to Digital output port #1 results in conductivity between

pins 16 and 35 with about 77ohms of resistance due to the opto isolation.

Applications
In the following drawings, the pin numbers for channel 1 are shown, followed by the corresponding
pin numbers for channels 2, 3, and 4 in parentheses.
Example 1: Switch input Example 2: Input fromTTL
Example 3: Phototransistor input
Example 4: Output to TTL Example 5: Output to relay

Limits
The ADC can operate with either optical or mechanical limit switches. In either case, the limit
switches are normally-closed; that is, an open circuit stops motion in the direction of the limit.
Following are wiring examples for both types of limit switches. Pin numbers refer to the 50-terminal
connector module inside the frame.
Connections for Optical Limits
Connections for Mechanical Limits

Application Notes from Matt Perry;
ADC LIMITS
ADC has two different inputs for position limits. Either optical or mechanical. Optical limits are used on Sintech frames
and Instron 45xx and 60xx ReNews. They work on the same basic principal. The only way a frame connected to ADC
can move is for the limits to be grounded. There is a very good reason for this: limits cannot be compromised by faulty
wiring or installation. Most faults will create an open rather than a short. So a broken or missing wire, or an intermittent
connection would generate an open, and the limit would activate, stopping the crosshead
Below is a schematic of the both types of limits and the ADC internals. The wiring for the upper and lower are identical.
VCC (+5V DC)

ADC
FRAME
4.7K Ohm
OUTPUT
VCC (+5V DC) TO CONTROL
LIMIT UPPER
OPTICAL
VCC (+5V DC)
LIMIT +5V IN
0.1 uF
LIMIT UPPER
MECHANICAL
With no input, the 4.7K resistor pulls the output (thats why its called a pull up resistor) to +5V and the a limit is
triggered.
OPTICAL
For optical limits, the input is simple. The optical limits are normally closed to ground. This means their normal state is
grounded. With the limit grounded, all current from VCC on the picture above flows to that ground. The output then
measures a ground, and it allows the frame to move. When an optical limit is triggered, the IR emission is blocked from
the detector. It then becomes an open. When this happens, the pull-up resistor pulls the output to +5V and the frame
stops (in whatever direction the limit was triggered).
MECHANICAL
This is slightly more complicated, but still simple. The LIMIT+5V IN has to be jumped on the 25 pin (or 50 pin internal)
green DIN connector. Jumper pins 20 & 21 to get the +5V required. The photo diode-photo transistor shown in the ADC
portion above acts as a switch. The mechanical limits are also normally closed to ground. So when the limit is not
triggered, current flows through the photo diode, the photo transistor is energized and it shorts to ground. As above this
draws the current and the output sees a ground. When the limit is triggered, the photo diode stops emitting IR, the photo
transistor becomes open; and again the output gets pulled up to +5V stopping the machine.
RENEW OPTICAL LIMITS

On the Instron 45xx and 60xx models they have optical limits with a photo diode and transistor similar to above. In that
case, when the beam is interrupted, the switch opens and gets pulled high. The input still connects to the Optical inputs.

Clutches
The ADC will drive 2 (for a 2-speed machine) or 3 (for a 3-speed machine) 5-volt clutch relays.
In the following wiring examples, pin numbers refer to the 50-terminal connector module inside the
frame.
Clutch Relay Connections for Clutch Relay Connections for

2-Speed Machine 3-Speed Machine

ADC Board History
Board Rev First ship Mfr Description Effect

GMCC 3 QMD original production board
GMCC A Jan 95 MTS Wiring cleanup none
GMCC B Sep 95 MTS change pullup resistor See below
GMCC C Sep 95 MTS Add piggybacked buffer IC See below
GMCC D 2Q96 MTS Blue wires on counter lines See below
GFCC 3 QMD original production board

GFCC A Jan 95 MTS Wiring cleanup See below
GFCC B June 95 MTS change filter resistors none
GFCC C Sep 95 MTS Substantial redesign See below
GFCC D Sep 95 MTS drawing fix none
GCPC * A QMD original production board

GCPC B Note Additional standoffs See below
GCPC C 2Q96 MTS BOM Correction none
* Genghis Connector Panel Card

Bumped to rev C for BOM correction so there is no Rev B Card Assy
Features Description
Note: The Board rev field below indicates when the change was first implemented; thus
GMCC Rev A indicates that GMCC rev A or later supports the feature. When more than one board
is listed, all the boards listed are required for the feature to operate.
Feature: Limit detection level cleanup

Board rev: GFCC Rev A
Details: On earlier GFCCs, the limits would be detected by the servo amp before they were
noted by the software; thus the crosshead would be inhibited from moving with no indication of the
reason in Testworks.
Feature: Diagnostic LED

Board rev: GFCC Rev C
Details: The diagnostic LED gives the following indications:
Red: GFCC powered up but not talking to the GMCC
Blinking green: GFCC in communication with GMCC
Feature: Support for Synergie & Renew systems

Details: Previous GFCCs used with Copley servo amps required a jumper soldered to the
GFCC. This jumper grounded an input to the PWM control PLD to select Copley-style PWM output.
This would require a specially modified GFCC be sent if the customer required a replacement.
With the revised GFCC, the selection pin is brought out through the ribbon cable to the 50-pin
connector block, so that modification of the GFCC is no longer required. Jumper the pins as follows:
Adamel amp: Pin 27 to Pin 29
Copley amp: Pin 27 to Pin 31
Feature: Analog Handset Feedback

Details: Unlike the DFCC, the GFCC has no CPU which would allow a speed control loop for
handset operation. With CSM servo amps we were able to provide a workaround by switching the
servo amp to operate in velocity mode for handset operation (using the speed control loop built into
the amplifier), and in torque mode for computer-controlled operation (using the ADC speed control
loop). However, Copley and Adamel servo amps do not support this mode switching, so there is no
speed control loop available without the computer.
Using the analog handset feedback feature, handset operation is routed through the computer
speed control loop when the computer is on and the adcfirm.bin is loaded and running (with the
computer off, the handset provides only crude control as before). Note that to turn this feature on,
the cnf file for the frame must have the anahand bit set (the anahand.exe utility will do this).
Feature: Excitation current limiting

Details: On previous GFCCs the excitation buffer amp would be destroyed if the load cell cable
were miswired.
Feature: Excitation current monitoring

Details: Allows test programs to determine whether load cell is shorted, open, or operating
correctly.
Feature: Limits voltage monitoring

Details: Allows test programs to read the voltage at the limits, thus permitting adjusting the limits
with the machine closed up.
Feature: Changes to PGA control bits (side-effect of other GFCC mods)

Details: Starting with this revision, PGA gain is limited to 80. Selecting a higher value for max
PGA in the frames environment will default to 80.
Feature: Self-ID lines on DIN connector block

Details: For possible future use. Eliminates connections for second clutch relay on 3-speed
frames (3-speed ADC frames were never implemented). Removal of jumpers and plugging relay into
GFCC restores 3-speed function, if anyone ever needs it.
Feature: Handset & Computer boot problems fixed

Board rev: GMCC Rev B, GFCC Rev C
Details: In the past, there have been widespread problems of the handset not initializing
correctly when the frame is powered up. Also, some computers would not boot if the frame were
turned on first. The solution to this required that the termination of certain signals be relocated from

the GFCC to the GMCC. To allow compatibility with earlier GMCCs, the termination is still provided
on the GFCC.
Therefore, to fix the problem requires the following procedure:
1. Make sure both GMCC and GFCC are at least the revs noted above.
2. Remove the socketed termination SIP RP6 from the GFCC.
GMCC Rev B GMCC Rev < B
GFCC Rev C with RP6 removed Problem fixed Boards will not function
GFCC Rev C with RP6 installed (default) Problem happens Problem happens
GFCC Rev < C Problem happens Problem happens
Feature: Improve serial bus line drive

Board rev: GMCC Rev C
Details: Certain earlier GMCCs tended to fail to initialize the GFCC correctly or to lose
communication with the GFCC. This is indicated by Testworks or ADC Diagnostics errors indicating
that the frame is not powered up or that the software thinks a loopback connector is detected. The
fix for this involves a second buffer IC piggybacked onto U25 on the GMCC.
Feature: Improved GFCC mounting

Board rev: GFCC Rev C, GCPC Rev B
Details: Provision for 4 additional (total of 6) plastic mounting standoffs between GFCC and
GCPC, to fix problem of boards coming disconnected during assembly and shipping.
Feature: GMCC compatible with DFCC, QFCC

Board rev: GMCC Rev D
Details: Added wires to connect quadrature input signals to up/down counter and digital inputs.
This allows these lines to read DFCC/QFCC decoded quadrature pulses and limit signals.

ADC Main Cable
Pin Locations
Pin# Signal
1 Relay -
2 Digital Ground
3 Digital Ground
4 Digital Ground
5 Digital Ground
6 Digital Ground
7 Digital Ground
8 Digital Ground
9 Digital Ground
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24 Sclk
25 Step 1
26 PWM
27 Sdatr
28 Ldx A
29 Screw A
30 Motor A
31
32
33
34
35 Dach4
36 Dac3+
37 Dac2-
37 Dac1+
39 Fgen+
40 Strain2 +
41 Strain1 +
42 Load+
43 Relay+
44
45 Step 2
46 Dir
47 IRQ
48 LDX B
49 Screw B
50 Motor B
51
52 Un. Strain 2
53 Un Strain 1
54 Un Load
55 Dac4-
56 Dac3-
57 Dac2-
58 Dac1-
59 Fgen-
60 Str2-
61 Str1-
62 Load-
ADC Main Cable Problem History;

Following is a history of problems associated with this cable.
1. Pins have dislodged causing sporadic problems.

2. Outside sheathing has come loose.

Internal Frame Digital Signals
The internal frame signals are connected to the ADC electronics via a green break-out box which is
connected to the GFCC by a 50 pin ribbon cable.
Pin #
Motor Encoder VCC 50
49 VCC Ballscrew Encoder
Motor Enc A+ 48
47 Screw Enc A+
Motor Enc A- 46
45 Screw Enc A-
VTHR 1.6V 44
43 VTHR 1.6V
Motor Enc B+ 42
41 Screw Enc B+
Motor Enc B- 40
39 Screw Enc B-
GND 38
37 GND
Clutch Relay Clutch1 Com 36
35
Clutch1 NC 34
33
Clutch1 NO 32
31 AC Mon Hi AC Monitor
Clutch2 Com 30
29 AC Mon Lo
Clutch2 NC 28
27 GND
Clutch2 NO 26
25 VCC Limits
AC Relay AC Relay NO 24
23 Limit +5V in
AC Relay Com 22
21 Limit Uppper Opto
20
19 Limit Lower Opto
18
17 Limit Upper Mechanical
Amp I/O Amp PWM/UP 16
15 Limit Lower Mechanical
Amp Dir/Down 14
13 GND
Amp Inhib 12
11 Step Out Stepper Out
Amp /Reset 10
9 Step Enable
Amp up limit 8
7 Step Direction
Amp Down Limit 6
5 Step Current
Amp /Fault 4
3 Step return
GND 2
1 GND

Motor/Servo Controllers
MTS SINTECH Frames use servo controlers made by Custom Servo Motors (CSM). A few ReNew
systems use Copley controlers.
Below is a list of motors and amplifiers used on MTS Sintech systems.
Amp Motor
Stock # Model Stock # Model
15.00105 Pre-07 15.10028
15.00108 Pre-15 15.10030
15.00112 Pre-25 15.10029
15.10026
15.10028
15.10031
15.10027
Servo Amp LED Description

Power ( Green) - The Power LED is on when the Servo Amp is getting its 110 or 220 volts.
Mark (Red) - This is not used with SINTECH systems.
Current (BI-Color) - This is a BI-colored LED that produced either red or green as a function of load. The
intensity increases with load. Red indicates positive torque and green indicates negative
torque.
There are eight faults that will reduce amplifier current to zero. All are red when on.
Continuous - If a load condition exists that causes the amplifier to produce more than its continuous
rating, this fault occurs.
Stator Shorts - If stator shorts or most major wiring errors of the stator occur, This fault occurs.
Amplifier Thermal - An 85 C thermostat is mounted to the amplifiers IGBT heat sink. If an excess
temperature is sensed, this fault occurs.
Feedback Wiring - For most resolver wiring errors, defective resolvers or lost wires to the resolver, this fault
occurs.
Motor Thermal - If an excess thermal condition exists in the motor, this fault occurs.
Hi-Bus - If excess AC Voltage or a failure of the shunt circuit occurs, this fault occurs.
Reset - During the first second of power up or if the reset input is active, this LED will be on.
Limit - If either of the limit inputs are on, this LED will be on. This lamp is on any time the
SINTECH machine is not moving.
Adjustments
Contrary to initial popular opinion, CSM amplifiers do have adjustments. The only critical one is the BALANCE. If
this is improperly tuned, the machine will drift slightly after coming to a stop.
Potentiometer Settings:
BAL (Balance): tune as required to keep the crosshead from drifting in the time between physical handset
use and the servo amp is disabled (approximately 3 seconds)
CUR (Current Limit): fully clockwise (CW)
RESP (Response): fully counterclockwise (CCW)
SIG (Signal): fully clockwise (CW)
LEAD (Lead): fully counterclockwise (CCW)

Configuration Files
Overview
The ADC software configuration files contain important information for machine control. The machine
driver is broken down into two separate files named ADCFIRM.BIN and xxxxxxxx.CNF where
XXXXXX refers to the specific frame. An options file, TWOPT.INF, controls the access to
purchasable software and hardware options, and contains customer infomation. A xxxxxxxx.DEF file
acts as a backup for the xxxxxxxx.CNF and must be created at the time of installation by the MTS
Field Service Engineer. Below is an explanation of these files.
ADCFIRM.BIN Basic machine parmeters for all frame types. This file changes to
improve machine performance and add capabilities.
xxxxxxxx.CNF Contains specific machine parameters such as encoder
resolutions, gear ratios, and PID parameters for motor control.
xxxxxxxx.DEF An exact copy of xxxxxxxx.CNF that has been copied by an MTS
Field Service Engineer.
TWOPT.INF Controls access to purchasable software and hardware options.
ADCFIRM.BIN Description
This file is created by the MTS SINTECH Systems Engineer and cannot be modified in the field. The
latest revision is included on the frames testing software distribution diskettes. This firmware file is
down loaded to the GFCC then the electronics are initialized. Basically, the firmware tells the
hardware how to perform. It sets bit registers in the hardware which will control hardware functions.
One example is a bit which controls weather the ballscrew encoder or motor encoder is used for
position control. One register may be user modified in the field. Below is a list of each modifiable bit
followed by several procedures for modifying these bits.
FLAGS
Bit # Name Function Hex Decimal
0 hiratio Scales turns ratio by 100 inst 0x0001 1

1 noballs Routes motor encoder pulses to the ballscrew 0x0002 2
encoder
2 anahand Emulate handset feedback 0x0004 4
3 hiballs Scale ballscrew resolution upward X 10 0x0008 8
4 a20khz PWM output is Adamel A/B*/ 0x0010 16
5 freqout Output is number of counts 0x0020 32
6 copley Not used 0x0040 64
7 nene Not used 0x0080 128
8 widget Position feedback is up & down 0x0100 256
9 extrelay Not used 0x0200 512
10 dfcc Connected to DFCC/QFCC/ 0x0400 1024
11 extload Use 12 bit converter for load 0x0800 2048
12 reverse Motor direction is inverted 0x1000 4096
13 upend Position feedback is inverted 0x2000 8192
14 fixture Frame is test fixture 0x4000 16384
15 not used not used 0x8000 32768
TO edit this register;

To change any of the cnf flags, use one of the three following procedure;
Procedure 1
1. Start the testing software.
2. Choose ENVIRONMENT
3. Choose ADC
4. Type BECAREFUL and then press ENTER.
5. Find the Flag field
6. Type in new value.
7. Press OK.
Procedure 2
1. Exit Windows to the DOS environment. Do not use a DOS shell.
2. Use the Machtype.exe ADC DOS-base utility program (See ADC DOS-Based
Utilitties for more information).
Procedure 3
1. Exit Windows to the DOS environment. Do not use a DOS Shell.
2. Change to the Testing softwares sub-directory.
3. Type DEBUG xxxxxxxx.CNF, where xxxxxxxx.CNF is the specific file name for the
frame, and then press ENTER.
4. Type E 15C and then press ENTER.
5. The current value will be displayed in hex.
6. Type in new value in hex and then press ENTER.
7. Type W and then press ENTER.
8. Type Q and then press ENTER.
CNF File Description

This file is loaded into the GMCCs memory to control vital machine functions. It is created at the time
of system fabrication and maybe modified in the field. For example, it contains items to calculate the
encoder resolution such as ballscrew pitch and the turns ratio between the motor and ballscrew. The
name of this file depends on the frame type chosen in the testing softwares Environment.
How to find out which CNF file is being used;

To find out which CNF File is being used, follow the procedure below;
1. Remove all *.CNF files from the testing softwares subdirectory.
2. Start the tesing software.
3. Select ENVIRONMENT.
4. Choose the correct frame type next to the field labled Machine Type.
5. The file name will be contained in the error message, Error loading xxxxxxxx.CNF.
How to access the CNF file parameters.

Use the ADC System Parameters Window to view or change CNF parameters.
1. Start the testing software.
2. Select ENVIRONMENT.
3. Select the ADC button.
4. Type BECAREFUL and then press ENTER

CNF Parameter Description;
Below are explanation of each CNF parameter.
I. GoTo
A. Braking Distance - Determines when crosshead ramps down for GoTo and Return
commands. The larger the number, the sooner the crosshead ramps down. A high
value will cause the crosshead to stop too soon. A low value will cause overshoot.
Typical value will be between 100 to 2000.
B. Initial GoTo - Controls the speed during a GoTo. 65535 equals the maximum speed
set in the Environment. Lower this value to prevent overshoot on GoTo commands.
C. Minimum GoTo - Used to fine tune overshoot. Value range is 0 to the encoder
resolution. 200 is a typical value.
D. Ramp Step - This controls the time it takes for the crosshead to get to speed. The lower
the number the slower the crosshead ramps to speed. The maximum value is 500. The
range is generally 50 to 500. Note: A smaller ramp is the only parameter that will soften
stops after a test. All other parameters in this section affect GoTos and Returns.
II. Resolutions/Ratios
A. Motor Encoder - Number of pulses for one revolution of the motor encoder.
B. BallScrew Encoder - Number of pulses for one revolution of the ballscrew encoder.
C. Turns - Ratio of the number of turns of the motor to the ballscrew. It may be calculated
by the following;
(Motor encoder pulses) * (Ballscrew encoder resolution)

(Ballscrew pulses) * (Motor encoder resolution)
The ballscrew and motor pulses are determined by moving the crosshead at least one
revolution and reading the encoder pulses in the ADC Control Panel which is located in
the Advanced Diagnostics section of the Diagnost.exe program.
D. Clutch 1 - The ratio of the first clutch. TestWorks will use a different set of PIDs when
the chosen speed is in this range. If a clutch does not exist, then this will act as a
virtual clutch.
E. Clutch 2 - The ratio of the second clutch. TestWorks will use a different set of PIDs
when the chosen speed is in this range. Since TestWorks with ADC does not support 3-
speed machines, this will always act as a virtual clutch.
III. PID
Command to Servo Amp = Kp * (E) + Ki * (E) + K d * (E) + Kf * previous command/100
where (E) is the Error.
A. KP - Proportional factor in PID control. (Range = 0 to )

B. KI - Integral factor in PID control. (Range = 0 to )
C. KD - Derivative factor in PID control. (Range = 0 to )
D. KF - Feed Forward. (Range = 0 to )
E. Counts - Defines the window for the size of KI error. (The units are unknown.)
F. Interval - Update rate for KD in milliseconds.

II. Miscellaneous
A. Max Speed (mm/Min) - Maximum speed of the machine. This is a function of the
maximum motor speed and gearing.
B. Ballscrew Pitch - The distance (in millimeters) that the crosshead will move during one
turn of the ballscrew. It may be calculated by measuring the distance between the
adjacent threads of the ballscrew.
C. Max AutoRange - Used to limit the number of load ranges used. This is mainly used in
trouble shooting noise problems in the load channel.
D. # of Clutches - This tells TestWorks which clutch is the first virtual clutch. (e.g. # of
clutches equals 2 means that clutch 1 is a physical clutch and clutch 2 is a virtual
clutch.)
III. Calibration Information - Contains serial number and calibration of GMCC.
IV. Get Defaults - This button will bring up the ADC parameters from a file called, xxxxxxxx.DEF,
where xxxxxxxx is the name of the CNF file. After setting the PIDs, make a copy of the
xxxxxxxx.CNF file called xxxxxxxx.DEF.

How To Tune PID Parameters
Done by ADC Motor with

ServoAmp encoder/resolver
Speed Command
+ Error Command to Servo
Amp is an equation
based on error
-
Actual Speed
What gets calculated?

Error (E) = Speed Command - Actual Speed
Command to Servo Amp = Kp * (E) + Ki * (E) + K d * (E) + Kf * previous command/100

where (E) is the Error.
Kp, Ki, Kd, & Kf are all factors that can be adjusted to tune the speed control of the system.
There are 2 other variables that are used in SINTECH products: Counts & Interval. These will be discussed at the end.
How to tune each factor in the command equation?

Tuning the factors for speed control of SINTECH frames takes practice. This is because each factor contributes to the entire command
generated. Just like everything else in life, too much or too little of a good thing can cause you problems. If your factors are set too
high or too low, your machine will not function properly. So, practice by setting each factor to 0 except for one factor and varying this
factor from 0 up until the machine starts vibrating. Use the maximum speed at first, and then try the minimum speed. Make sure that
both speeds do not vibrate. This means the system is out of control or unstable. Typically, it is best to adjust the parameters in order:
Kp, Ki, Kd, & Kf. Heres what it looks like on paper.
If all factors are 0 except Kp,

Command to Servo Amp = Kp * (E)
As you increase Kp , the error becomes smaller and thus decreases the effect of the Kp increase. You will come to a point that
Kp is so large that it causes the machine to vibrate (unstable). This is because at one instance, Kp * (E) is so large that the
motor overshoots the correct speed significantly. At the next instance, the error is so large in the negative direction (thus, the
Kp * (E) is large in the negative direction) that the motor stomps on the brakes, and the original problem starts all over again.
I.E. the command is stomping on the gas and then stomping on the brake. At high speeds, this is what really gets the machine
moving initially.
If all factors are 0 except Ki,

Command to Servo Amp = Ki * (E)
If your Ki is any number > 0, then you will eventually attain the speed that you are looking for, it just may take a while. (You
may run out of ballscrew travel.) This is because the integration will eventually add up to be a significant command to get the
system moving. (NOTE: There is a way to limit this: See the section on Counts) As you increase Ki , the amount of initial
error becomes smaller. You will come to a point that Ki is also too large that it causes the machine to vibrate (unstable). This
is because of the same thing that happened with Kp.

If all factors are 0 except Kd,
Command to Servo Amp = Kd * (E)
This factor is usually associated with dampening. It doesnt play a big role in getting the machine moving; its main purpose is in
controlling the rate of acceleration. No matter what Kd is, the system will not move if all the other factors are set to 0. This is because
without any of the other factors involved, there is never any change in error. The initial speed is 0 and all subsequent speeds are 0 and
so the machine doesnt move.
If all factors are 0 except Kf,

Command to Servo Amp = 0
With this, the speed is 0 always.
What to keep in mind while tuning speeds?

It always helps me to think of what happens at the 2 extreme speeds (minimum & maximum) at 2 different times: Initially and Steady
State. Here again is what it looks like on paper:
Maximum Speed.
Initially (within 1 or 2 sec of starting)
(E) Error is typically large

(E) is small but growing.
(E) is small but also growing.
previous command/100 is also small but growing
Therefore, Kp & Kf are the main factors that get the system moving.
Lesson: If Kp & Kf are increased, the machine will get to speed faster.
Caution: If Kp is set too high the machine will vibrate. If Kf is too high, the machine will never settle in on the right
speed.
Steady State
(E) Error is around 0.

(E) is steady at a given value.
(E) is around 0.
previous command/100 is small almost nothing.
Therefore, Ki is the main factor that keeps the system moving.

Lesson: There must be Ki in order to achieve steady state. If it or the other factors are set too high, the system may
not achieve steady state because the system is out of control. But, if the parameters are set too low, the system will
eventually get to speed if you have anything for Ki (Assuming that there is enough ballscrew travel & there is no cap
on the summation of error-see last section.)
Minimum Speed.
Initially (within 1 or 2 sec of starting)
(E) Error is typically small (because the speed itself is small)

(E) is small but growing.
(E) is small and will remain small. (because the speed itself is small and any change in speed will therefore be
small)
previous command/100 is small but growing.
Therefore, Ki & Kf are the main factors that get the system moving.
Lesson: Kf is the main factor that gets the system moving initially because all of the other factors are so small. An
increase in Ki & Kf will cause the machine to get to speed faster.
Caution: Same caution should be taken for this as is in Maximum Speed.
Steady State
(E) Error is around 0.

(E) is steady at a given value.
(E) is around 0.
previous command/100 is small almost nothing.
Therefore, Ki is the main factor that keeps the system moving and therefore the same holds true for minimum speed as does
maximum speed.
NOTE: Notice that Kd is not necessarily mentioned as far as moving the system. You should use Kd to control the acceleration. The
way I do this is by listening to the acceleration at maximum speed and adjusting Kd to make it as smooth as possible.
What are the two other factors that are used with ADC?
Counts and Interval are the other 2 factors that affect the control equation. They affect the command equation as follows:
Counts
This value essentially restricts the summation of error. It caps the summation to a value.
Mathematically, it looks like this:
(E) <= Counts
Lesson: Counts can be used so that in the unlikely event that something goes wrong and the system does not respond, the
command equation will not build up error in the integral and produce the volcano effect on the system.
Caution: If set too low, the system may never sum up enough error to move at low speeds especially if the system
experiences loading. This may cause the system not to pull to load. If the system doesnt pull to load, try increasing this
slightly.
Interval
This value is used to limit the change in the derivative (E) . FYI, the derivative is really used to stabilize the other factors.
Because there is a significant amount of change when you initialize the command equation, the derivative can contribute to
the system being out of control instead of acting as a stabilizer. To combat this, the controller will only change the derivative
value periodically based on the interval value that is given. Instead of determining the derivative every time that the
command equation is calculated, the controller will determine it on a predefined interval and use that same value until the next
interval.
For example, if the interval = 5, then the command calculation will be performed 5 times with the same derivative
value (E) and then a new derivative value is determined and the process is repeated for the next 5 times, and so on.
Caution: If set too low, the system may go out of control because Kd * (E) is too erratic. If set too high, the system may not
be affected by the dampening effect of Kd * (E) .

TWOPT.INF File Description;
This file controls access to purchasable software and hardware options. The hardware options are
controled only on ADC systems. It is created using an options file maker called OPT.EXE. This
program is to be used only by MTS SINTECH Applications Engineers. DO NOT LEAVE OPT.EXE
ON A CUSTOMERS COMPUTER. The available options are listed below;
Software Options Hardware Options Information
ReportWorks ADC Hardware Company Information

Material Reference Strain 1 Job#
SQC/SPC Strain 2
Batch Plotting Buffered Output
LIMS 3 Channel MCC
Master Generator 3rd Channel GMCC
MultiChannel Software Multichannel Hardware (Select board type)
ADC High Data aquisition Rate Buffered Outputs
Enable Stress/Strain Limits
Maximum number of data points
Sample ID Length
Rules;
1. Always make a copy on the network S:\applic\Admin\inf\JOB#
2. Enter the Site and System numbers under JOB#.
3. Make the INF File before leaving for a system installation.
4. If any changes are made on site, replace the copy on the network
5. DO NOT LEAVE OPT.EXE ON A CUSTOMERS COMPUTER.
6. Only give the customer the options that they purchased.
7. Get confirmation of any option changes BEFORE giving it to the customer.
8. AVOID RUNNING OPT.EXE IN FRONT OF THE CUSTOMER. If you must, then DO NOT
EXPLAIN WHAT YOU ARE DOING TO THE CUSTOMER.

Diagnostics
Programs
There are two windows based diagnostic programs, MT.EXE, and DIAGNOST.EXE.
MT.EXE
This program may be run from the file manager. It is useful for checking analog signals such as loadcells
and extensometers. DANGER: DO NOT USE THIS PROGRAM FOR CHECKING LOAD CELLS
ON RENEW SYSTEMS!!!!!!!
Procedure
1. Start Windows
2. Select File in the program Manager.
3. Type C:\TW300\MT.EXE in the command line where C:\TW300 is the path for the testing
software.
4. The password is BECAREFUL
5. Select Options
6. Select Analog Test
DIAGNOST.EXE
Introduction
Diagnostics are performed from a separate software program called DIAGNOST.EXE. This program
is divided into three main sections, Basic Diagnostics, Advanced Diagnostics, and QC Tests.
Advanced Diagnostics and QC Tests are password protected and are only to be used by MTS
SINTECH Field Service Engineers. Basic Diagnostics contain customer level tests for checking the
system electronics. Below is a brief description of each section. See the ADC Diagnostics Manual for
more details.
Basic Diagnostics
This menu item contains three customer level diagnostic tests for checking the electronics.
Full Diagnostics Loopback test for checking the GMCC, GFCC, and CITS cable. If a
problem is found, then the program will prompt the user to place an ADC Loopback Connector
to various points along the system and then determine the malfunctioning component. The
program will indicate that all tests passed if a problem does not exist.
System Electronics This will perfrom the exact same tests as Full Diagnostics but will
report results on a pass/fail basis.
ADC Loopback The will perform diagnostics only on the GMCC. An ADC Loopback
is required to run this test. DO NOT RUN THIS TEST WITHOUT THE ADC LOOPBACK
CONNECTOR.
Advanced Diagnostics
This contains more detailed diagnostic programs for the MTS SINTECH Field Service Engineer. This
section is password protected. The password is BECAREFUL. DO NOT LEAD THE CUSTOMER
HERE UNLESS ABSOLUTELY NECESSARY.
ADC Loopback This performs the same tests as the ADC Loopback test but with
more details. The number of times the tests are performed may be controlled.
ADC Control Panel A panel that shows the status of all ADC signals. See Diagnostic
Procedures for details on these signals.
Speed Accuracy This should be used for checking the accuracy of specific speeds.
Make sure that the limits are properly set and that all grips and fixtures are removed before
running this test.
Procedure
1. Select Speed Accuracy
2. Enter the job# (or any other number)
3. Enter 999999 in the field labeld Ballscrew Counts
4. Enter the speed in mm/min.
5. Start the test.
6. Read the %error on the bottom of the screen.
QC Tests
This section contains programs for performing quality control testing of load frames. These are
performed when the frame is fabricated. Some of these maybe used on ReNew systems.
This program should be run from Windows. This program is divided into three main sections;
Baisc Diagnostics For customer use.

Advanced Diagnostics MTS SINTECH Field Service Engineers use only.
QC Tests MTS SINTECH Field Service Engineers use only.

ADC DOS Based Utilities
Introduction
I. To guarantee operation of the programs it is highly recommended not to run in a DOS shell
from Windows. Exit all the way out of Windows to the DOS prompt.
II. Before running any utilities the adcfirm.bin file must have been loaded into the ADC and the
ADC operation initiated. This can be done in one of three ways:
A. Run loader.exe, described below.
B. Go into TestWorks and exit.
C. Go into the ADC Diagnostics, start some test (for example, System Electronics), abort,
and exit.
III. Most any program that runs in a continuous loop can be exited by hitting the Escape key.
IV. Command line arguments and options will be displayed for any program by typing
programname -? (for example, spdtest -?) at the DOS prompt.
V. For programs that take a clutch parameter, -h selects high clutch, -l selects low clutch (on 2-
speed frames), and -ll selects virtual low clutch.
VI. Where analog channels are identified by number, 0 is Load, 1 is Strain 1, 2 is Strain 2, and 3
is Function Generator or Handset Feedback.
VII. Parameters and most displayed values are in raw integer counts. For programs that take a
speed parameter, a value of 65535 represents the maximum speed for the clutch selected.
ADC Address and Port Selection

The default address for the ADC in all programs is EC000. The default I/O port is 270.
For all programs that access the ADC hardware, the -a and -p options override the default address
and port. For example, to run loader.exe on an ADC at address D0000 and I/O port 240, type loader
-aD000 -p240. The default address can be also be changed by setting the environment variable
ADCADDR. For example, if the GMCC is at address D0000, type the line set ADCADDR=D000 at
the DOS prompt before running the utilities. (Note only the first 4 characters of the address are
entered in both cases.)

Programs
loader.exe
Loads the adcfirm.bin file and (optionally) a selected cnf file and boots the ADC. The default is to
load adcfirm.bin from the current directory, with no cnf file. To load the adcfirm.bin from the
TestWorks directory with the 10g cnf file, for example, type
loader c:\tw300\adcfirm.bin c:\tw300\sf10g.cnf at the DOS prompt. To reboot the ADC without
reloading the files, type loader -nofile. A Verify Error means the computer did not find the ADC at
the expected address; check the DIP switches on the PC and/or try another address. (No
connection detected means that the GMCC initialized fine but did not detect a GFCC.)
addrtest.exe
Halts the ADC and tests access to the ADC RAM, one address line at a time. If errors are listed in
the last 3 address lines only, it means the computer is unable to control the ADC through the I/O port;
check the DIP switches on the PC and/or try another port address.
readloop.exe
Another ADC memory test, this one tests access to memory while the firmware is up and running.
jog.exe
Useful for several functions:
Provides a software handset with the Up and Down arrow keys working like the rocker switch on
the physical handset. Page Up and Page Down work similarly except that the frame continues to
move until another key is pressed.
The program also allows you to tune PID parameters on the fly. Type the first letter of the
parameter displayed and you will be allowed to enter a new value. Note that the parameters
are in raw integer form. Important: changes to the parameters are only reflected in the GMCCs
RAM and will be overwritten whenever the ADC is reloaded. To save changes to the PIDs to the
cnf file, type w and the cnf file name to update the cnf file (or create a new cnf file).
Typing a ? while the display is up will calculate the turns ratio for the frame based on the motor
and ballscrew encoder counts and encoder resolutions from the cnf file. Note that both counters
are reset when jog.exe starts up.
Load is continuously displayed (as raw counts, where 3276800 counts corresponds to 10 volts).
spdtest.exe
Measures speed accuracy at any speed at any clutch. Useful in combination with jog.exe for tuning
PID parameters. Hit Enter to end and save the results.
cmdtest.exe
Most anything can be done from here, the details of which are beyond this document. Hit Shift-F7 to
get a continual update of all the real-time analog and status inputs.
runlback.exe
Runs the internal diagnostic routines (same as called by System Diagnostics or PC Loopback Test in
the ADC Diagnostics).
Example: to run continuously until an error is encountered, type runlback -v -l -s
ddump.exe
Displays all the debug output messages the ADC has queued since it was last rebooted.
lcwiring.exe

For rev C and above GFCC. Tests load cell wiring to automatically determine if it is operating
properly.
limvolts.exe
For rev C and above GFCC. Displays voltages at both limit inputs. Just like using a voltmeter to
measure the limit voltages at the 50-pin connector block, but without having to open up the machine
to adjust the limits.
The following utilities do not access the ADC hardware; rather, they are utilities for working with cnf
files. Note that the ADC must be reloaded for any changes to the cnf file to take effect.
cnfdump.exe
Displays the contents of the cnf file to the screen. Note that these are raw integer values and will not
appear the same as in the TWW/Diagnostics Environment dialog.
Example: cnfdump sf10d.cnf
editcnf.exe
Allows you to quickly change any value in the cnf file, as displayed by cnfdump. Example: editcnf
sf10d.cnf ramp_step[0]=300
anahand.exe
Sets the anahand bit in the cnf file to use (or not use) the analog handset feature found on recent
GFCCs.
machtype.exe
Displays the attribute flags in the machine_type field of the cnf file and allows changing any of these
flags. This field is the integer sum of various binary flags for arcane features of particular machines
(and includes the anahand bit mentioned above.)
Examples:
To display the attributes from a file: machtype ren1123.cnf
To extract the attributes for a machine type integer: machtype 76
To change an attribute in a cnf file: machtype ren1123.cnf copley=1

Diagnostic Procedures Using the ADC Control Panel;
To check a load cell.
1. Select Sensor for the load channel under the section labeled Input Multiplexer.
2. Select the appropriate excitation for the load channel under the section labeled Excitation. (10
volts for MTS SINTECH load cells, 2.5 volts for Instron cells.)
3. Read the voltage from the load cell under the section marked Unranged Inputs.
4. Select Cal 1 under the section labeled Cal Relay. This toggles the calibration relay into one leg
of the Wheatstone Bridge in the load cell circuitry.
5. Read the calibration voltage from the load cell under the section marked Unranged Inputs
6. Select off under Cal Relay to take the calibration ressitor out of the circuit.
To check an Extensometer or deflectometer;

1. Select Sensor for the Strain 1 (or strain 2) channel under the section labeled Input Multiplexer.
2. Select the appropriate excitation for the Strain 1 (or strain 2) channel under the section labeled
Excitation. (Usually 5 volts)
3. Read the voltage from the extensometer under the section marked Unranged Inputs.
4. The voltage readings should vary from zero (closed position) to ten (fully open position).
To check status signals apart from TestWorks;

1. Find the section labeled Hardware Status.
2. For the physical limits a black square indicates the following;
Upper Limit. Upper physical limit active.
Lower Limit. Lower physical limit active.
3. For the load channel a black square indicates the following;
Pos Overload. Tension overload from load cell.
Neg Overload. Compression overload from load cell.
4. For the motor servo controller a black square indicates the following;
Amp Fault. Motor servo controller is in fault condition.
5. PWM Timeout Motor servo controller is disabled. NOTE: The servo disables after 5 seconds if a
test is not in progress and the handset is not used.
6. To check the auxiliary button on the handset a black square indicates;
Aux Button Auxiliary button on the handset is depressed.
To check the clutch relay;

1. Locate the section labeled Clutch.
2. Select High.
3. Move the crosshead with the handset and notice the speed.
4. Select low. Listen for relay click.
5. Move the crosshead with the handset. The speed should be approximately 10 times slower.
To check the motor and ballscrew encoders;

1. Select the button labeled Reset Encoders.
2. Locate the section labeled Encoder Inputs. The values should be zero.
3. Move the crosshead with the handset.
4. The number of pulses form each encoder is displayed.
To check the timer;

1. Locate the section labeled Timer.
2. The time since the ADC Control Panel has been initiated is displayed in milliseconds.

To check firmware, GMCC, and GFCC revisions and serial numbers;
1. Locate the button labeled System Info.
2. Click on it with the mouse.
To display debug messages;

1. Locate the button labeled Debug Msgs.
2. Click on it with the mouse.
To reset electronics;
1. Locate the Reset buttons on the bottom of the screen.
2. Click on Reset System to reinitialize all of the electronics.
3. Click on Reset Encoders to zero the Encoder Inputs display.
4. Click on Reset Servo Amp to reinitialize the motor servo controller.

Diagnost.exe Manual
Software Description:
Basic Diagnostics
These tests are the customer level tests. For more detailed tests and results see the Advanced
Diagnostics and QC Tests menus.
1) Full Diagnostics:
The following sequence of tests will be done as required to determine the source of
failure.
a) Memory Test:
Repeatedly reads and verifies sections of ADC PC card memory and checks that
the PC card CPU continues to operate, thus ensuring that the memory arbitration
circuitry is functioning properly.
b) System Test:
Performs a loopback test with the ADC frame connected to the ADC PC card via
a cable.
c) ADC Loopback Test:
Performs a loopback test with a loopback connector attached to the ADC PC
card.
d) Cable Test:
Performs a loopback test with a loopback connector attached to one end of the
cable and the ADC PC card connected to the other end of the cable.
A loopback test does the following procedures for system, ADC loopback and cable
tests.
a) Inputs a fixed data stream into the quadrature inputs and verifies that the
counters are reading the data correctly.
b) Loops analog outputs back into analog inputs and verifies that the gain and
offset accuracy are within normal operating range for each channel.
A loopback test does these additional procedures listed below for system
tests.
c) Tests that the overload detection circuitry is working correctly.
d) Verifies that the watchdog timer circuitry in the frame electronics is operating
correctly. The watchdog timer monitors activity from the ADC PC card and
stops motion if the ADC PC card ceases to send an expected command
sequence within the expected time.
Depending on the outcome of the system, ADC loopback and cable tests, the
software will determine if the ADC PC card, ADC frame card or cable is faulty.
2) System Electronics:
This performs only the system electronics tests described above.
3) ADC Loopback:
This performs only the ADC loopback tests described above.
Advanced Diagnostics
1) Password
The Basic Diagnostics menu is always enabled. The correct password must be
entered to enable the other menu items. There are three different levels of
passwords. One password enables the QC Tests menu and the Path menu item
under the Advanced Diagnostics menu. The second password enables all menu
items except for the Test Fixture and Calibrate Frame Electronics menu items
under the Advanced Diagnostics menu. The third password enables all menu
items.
2) Path
The user enters in the path that they want the results files stored in.
3) ADC Loopback:
Performs the following diagnostics with the loopback connector attached to the ADC
PC card.
a) Offset:
Loops analog outputs back into analog inputs and verifies that the offset accuracy
is within normal operating range for each channel.
b) Gain:
Loops analog outputs back into analog inputs and verifies that the gain accuracy is
within normal operating range for each channel.
c) Quadrature Inputs:
Inputs a fixed data stream into the quadrature inputs and verifies that the counters
are reading the data correctly.
d) Memory:
e) EEPROM Read:
Reads contents of ADC PC card EEPROM and verifies checksum.
4) ADC Test Fixture:

This menu item performs all tests and tuning procedures necessary for checking out and tuning a
new frame card without user intervention, using a special test fixture. A check box dialog allows
selection of individual tests; normally, the complete procedure with all tests enabled is run. The tests
are as follows:
a) System Electronics:
Performs the diagnostics with the ADC PC card connected to the ADC Frame via a
cable. The ADC frame card provides internal loopback for the following tests. The
tests are done 10 cycles.
a1) Offset:
Loops analog outputs back into analog inputs and verifies that the offset accuracy
is within normal operating range for each channel.
a2) Gain:
Loops analog outputs back into analog inputs and verifies that the gain accuracy is
within normal operating range for each channel.
a3) Quadrature Inputs:
Inputs a fixed data stream into the quadrature inputs and verifies that the counters
are reading the data correctly.
a4) Memory:
a5) EEPROM Read:
Reads contents of ADC frame card EEPROM and verifies checksum.
a6) Hardware Overload Detection:
Verifies that the overload detection circuitry is working correctly.
a7) Watchdog Timer:
Verifies that the watchdog timer circuitry in the frame electronics is operating
correctly.
b) Digital I/O:
The digital output is wrapped around in the test fixture to both the digital input and
the three encoder channels. The test outputs a pattern on the digital output bits
and verifies that it is read back correctly on the digital input and encoder inputs.
c) Set Trim Coefficients:
Calculates the offset and gain adjustments and stores the new settings in the
EEPROM. The existing trim coefficients and calibration date stored in the EEPROM
will be cleared and replaced with the new offset and gain adjustments and date.
This test requires a voltmeter connected to the system.
d) Verify Trim Coefficients:
Verifies the offset and gain adjustments stored in the EEPROM by comparing
readings from the ADC and voltmeter and calculating and displaying the offset error
and gain error. An analog output channel fails the test if any of the offset or gain
errors calculated for each PGA are greater than the allowable error for that PGA.
This test requires a voltmeter connected to the system. The trim coefficients are
verified 5 times.
e) Sensor Inputs
Verifies for each of three sensor input channels that:
a) Each excitation voltage is within range
b) The gain of the input instrumentation amp is within range
c) The calibration relay functions correctly.
A sensor input channel fails at a particular excitation if the error is greater than 1%.
5) Sensor Inputs:
Verifies for each of three sensor input channels that:
a) Each excitation voltage is within range
b) The gain of the input instrumentation amp is within range
c) The calibration relay functions correctly
A sensor input channel fails at a particular excitation if the error is greater than 1%.
6) Calibrate Frame Electronics:

For tests b-c below, a voltmeter needs to be connected to a com port on the PC and to an analog
output channel on the ADC Frame card as instructed. The RS232 port on the voltmeter needs to be
enabled and set to the default parameters.
a) Display Trim Coefficients:
Displays trim coefficients stored in the EEPROM.
b) Verify Trim Coefficients:
Verifies the offset and gain adjustments stored in the EEPROM by comparing
readings from the ADC and voltmeter and calculating and displaying the offset error
and gain error. An analog output channel fails the test if any of the offset or gain
errors calculated for each PGA are greater than the allowable error for that PGA.
c) Set and Verify Trim Coefficients:
Calculates the offset and gain adjustments and stores the new settings in the
EEPROM and then verifies the adjustments. The existing trim coefficients and
calibration date stored in the EEPROM will be cleared and replaced with the new
offset and gain adjustments and date. The new trim coefficients are verified as
described in part b above.
d) Reinitialize ADC Frame card EEPROM:
Reinitializes the contents of ADC Frame card EEPROM. The trim coefficients
and calibration date will be cleared.
e) Reinitialize ADC PC card EEPROM:
Reinitializes the contents of ADC PC card EEPROM.
7) ADC Control Panel:

The control panel allows you to directly set all output and control ports on the ADC
(e.g. analog and digital outputs) and to view all input and status ports (e.g. analog and digital
outputs, signal multiplexers, etc.). Analog values can be entered and viewed as either volts or
converter counts. Note that the excitation of a sensor input channel must be set to a non-zero
voltage before the channel can be read.
8) Speed Accuracy:
The user enters in the desired speed(mm/min.), clutch, distance (ball screw counts), direction,
overload detection selection and job number. The test determines the actual crosshead speed and
percent error. The test fails if the error is greater than 0.1%.
9) Encoder:
The crosshead moves at up at full speed at high clutch for 10 inches and then down at 10% of full
speed at low clutch for 10 inches. The ball screw revolutions of error are determined for each move
segment. The test fails if the error is greater than 0.005 ball screw revolutions.
10) Memory Address:
The user enters in the ADC PC card serial number. The test writes a pattern through the entire
128K of ADC PC card RAM and verifies that it was written and read correctly. The pattern is varied
to test each of the 16 RAM address lines. The test cycles 10 times through the 16 address lines.
The test fails if a read or write error occurs.
QC Tests
1) Password
The Basic Diagnostics menu is always enabled. The correct password must be
entered to enable the other menu items. There are three different levels of
passwords. One password enables the QC Tests menu and the Path menu item
under the Advanced Diagnostics menu. The second password enables all menu
items except for the Test Fixture and Calibrate Frame Electronics menu items
under the Advanced Diagnostics menu. The third password enables all menu
items.
2) Environment
This is the same as in TestWorks for Windows. Make sure the correct machine type,
board and port address are selected. Also make sure the correct .CNF file for the
machine is installed in the TW300 directory.
3)System Electronics:
Performs the diagnostics with the ADC PC card connected to the ADC Frame via a
cable. The ADC frame card provides internal loopback for these tests.
a) Offset:
See description under PC loopback offset test.
b) Gain:
See description under PC loopback gain test.
c) Quadrature Inputs:
See description under PC loopback quadrature inputs test.
d) Memory:
See description under customer level memory test.
e) EEPROM Read:
Reads contents of ADC frame card EEPROM and verifies checksum.
f) Hardware Overload Detection:
Verifies that the overload detection circuitry is working correctly.
g) Watchdog Timer:
Verifies that the watchdog timer circuitry in the frame electronics is operating
correctly.
If the QC test box is checked, the above tests are performed 10 cycles.
4) Cycle:
The cycle test moves the crosshead up and down at a chosen speed, distance, initial direction,
clutch, speed profile, time limit , overload detection selection and job number. Preset defaults are
used for the inputs if the QC test check box is checked. The test passes if the test is stopped
prematurely by the user or an error occurs for non-continuous testing. For continuous testing, the
test fails only if an error occurs.
5) Position Accuracy:
The user inputs the speed, clutch, distance, initial direction overload detection selection and job
number. Preset defaults are used for the inputs if the QC test check box is checked. The test
compares the distance the crosshead moved up and down with the dial indicator readings and
calculates the errors. The test fails if the error is greater than 0.01 mm for either move segment.
6) QC Speed Accuracy:
The user inputs the job number and overload detection selection. The crosshead moves up at full
speed, high clutch for 20 sec. The crosshead moves down at 400 ball screw counts/min. at low
clutch for 2 hours. The speed is calculated and error is calculated. The test fails if the error is
greater than 0.10% for either move segment.
7) Calibrate Load Cell:

The user enters in the job number, full scale value, calibration value and sensitivity of the load
cell. The load cell is calibrated. Then a weight is hung and compared to the expected weight.
8) Compression Maximum Load:

A compression test is done with the crosshead moving down in low clutch at -2.54 mm/min. until
reach -30 lb. Then the crosshead moves down at -0.127 mm/min. until the maximum load(-120% of
machine capacity) is reached. After reaching the maximum load the crosshead moves up at 1.27
mm/min. to the beginning position. Also, a compliance test on the load and extension between the
load of -50 lb. and -120% of the machine capacity is done. The compression maximum load test will
fail if any of the following four conditions occur:
a) Maximum load does not reach -120% of machine capacity
b) Compliance standard error is greater than 3.2
c) Slope ratio is less than 1.1
d) Yield is greater than 20% of the maximum slope
9) Tension Maximum Load:

A tension test is done with the crosshead moving up in low clutch at 2.54 mm/min. until reach 30
lb. Then the crosshead moves up at 0.127 mm/min. until the maximum load(120% of machine
capacity) is reached. After reaching the maximum load the crosshead moves down at -1.27 mm/min.
to the beginning position. Also, a compliance test on the load and extension between the load of 50
lb. and 120% of the machine capacity is done. The tension maximum load test will fail if any of the
following four conditions occur:
a) Maximum load does not reach 120% of machine capacity
b) Compliance standard error is greater than 3.2
c) Slope ratio is less than 1.1
d) Yield is greater than 20% of the maximum slope
Note:
Most tests can be stopped prematurely by the user by clicking on the Stop Test or Cancel button or
by pressing the space bar. In addition to the test failure reasons stated earlier, a test will also fail if
an error occurs during executing a command or during the initialization of the ADC board. The
results of the tests can be saved to a file and/or printed. See work instruction 409442W for ADC
Diagnostics Software QC Tests instructions.

Error Messages
ADC Frame card EEPROM contents not valid

Frame card EEPROM not initialized at factory or Frame card EEPROM accidentally erased.
DO NOT ship this machine with this card.
ADC Frame card failed tests.

Self-Explanatory.
ADC frame not connected

GMCC is unable to communicate with GFCC.
ADC Loopback tests failed

Self-Explanatory.
ADC PC card contents don't match actual data.

ADC PC card fails to respond
PC is unable to communicate with GMCC.
Check DIP switches on GMCC and/or try another GMCC address
ADC PC card EEPROM contents not valid

PC card EEPROM not initialized at factory.
More likely this error message will appear when there is a memory conflict in the PC with the
GMCC. Try another GMCC address.
ADC PC card failed tests.

Self-Explanatory.
Amp fault error

GFCC received a fault signal from the servo amp, typically current overload.
Cable failed tests.

Loopback test passed with loopback connector directly on GMCC but failed when loopback
connector attached to cable.
Checksum error in test cycle number

Data error reading EEPROM. Probably GMCC is having problems communicationg with
GFCC.
Commport data error. Make sure voltmeter is set to 9600 baud rate
Unable to build comm. Error: status number, error number
Unable to close commport. Error: status number, error number
Unable to flush comm. Error: status number, error number
Unable to open comm. Error:comm device id
Unable to read from commport. Error: status number, error number
Unable to set com state. Error: status number, error number
Unable to write to commport. Error: status number
Unable to write to commport. Error: status number, error number
Unable to communicate with voltmeter
Unable to take reading from voltmeter
Unable to terminate communication with voltmeter
Voltmeter connection error. Make sure voltmeter inputs are connected to analog out number.
Voltmeter connection error. Unable to continue test.
Voltmeter not set up properly for setting/verifying trim coefficients.
Could not find SENSOR.INI file

DIAGNOST.INI file does not exist.
File not found in directory with diagnost.exe.
Could not load, \CNF filename\

Could not load .CNF file
cnf file not found in directory with diagnost.exe.
Check that the cnf file is given the same name that the diagnostics is looking for.
Could not read Opt file

twopt.inf file not found in directory with diagnost.exe.
Could not read system definition file

sintech.sdf file not found in directory with diagnost.exe.
Crosshead status error

Test aborted due to limit, overload, etc.
Message describing specific error condition message will follow this.
Did not complete the expected number of cycles.

Test failed because it was aborted or encountered an error.
Error at offset 0x____ Expected 0x____ read 0x____

Identifies where memory test failed.
Error executing command

GMCC fails to respond to PC command.
Error in test cycle number

Self-Explanatory.
Error in opening firmware file.

adcfirm.bin file not found in directory with diagnost.exe.
Expected 0x____ but read 0x____ at offset 0x____

Identifies where memory test failed.
Failed slope ratio

Tension/Compression test fails if compliance curve slope is less than 1.1
Failed std. error

Tension/Compression test fails if compliance curve standard error is greater than 3.2
Failed to reach max load

Tension/Compression test ended before reaching 120% of machine capacity.
Failed yield
Tension/Compression test fails if yield is greater than 20% of max. slope.

Hardware overload detection failed in test cycle number
GFCC did not respond correctly to a simulated load cell overload condition
Hung weight reading not valid.

Load measured by GFCC is not within 10% of the expected weight.
Incorrect calibration.
GFCC Load calibration circuit not operating correctly, bad load cell, or bad wiring.
Invalid speed entered

Entered speed cannot be run in clutch selected.
Lack of memory for firmware code.

PC has insufficient memory to run.
Loopback connected
Running loopback test: GMCC detects loopback connector OK.
Otherwise: GMCC encountered error attempting to initialize GFCC.
Loopback connector not attached

Running loopback test: GMCC did not detect loopback connector.
May possibly occur if serial bus did not initialize correctly, so retry the test.
Lower limit error

Test stopped because GFCC detected lower limit tripped.
Machine type not found in sensor.ini.

Machine name matching the current machine type not found in sensor.ini.
Negative overload error

GFCC detected load cell compression overload.
This may occur if the load cell has a large negative offset, is not connected (or load cell wiring
is bad) or if the sensitivity is not correctly entered.
No calibration date.
Frame card EEPROM not initialized at factory or Frame card EEPROM accidentally erased.
DO NOT ship this machine with this card.
Positive overload error

GFCC detected load cell tension overload.
This may occur if the load cell has a large positive offset, is not connected (or load cell wiring
is bad) or if the sensitivity is not correctly entered.
Read error at address 0x____: wrote 0x____, read 0x____

Identifies where memory address test failed.
Status register error: ADC frame stopped responding.

GMCC is unable to communicate with GFCC.
Status register error: ADC PC card hardware failure.

Self-explanatory.

Status register error: Command failure.
Status register error: Command parameter invalid.
GMCC or software failure.
Status register error: EEPROM read error.

In System Electronics test: error reading GFCC EEPROM.
In PC Loopback test: error reading GMCC EEPROM.
Status register error: Invalid EEPROM.

In System Electronics test: read bad data from GFCC EEPROM.
Stopped testing
Self-Explanatory.
System connected
GMCC detects GFCC OK.
System tests failed

Self-Explanatory.
Timed out moving crosshead to target.

Timed out moving crosshead
Timed out ramping
Motor is not running or ball screw encoder not reading any motion.
Timed out processing command.

Unable to initialize ADC PC card.
PC is unable to communicate with GMCC.
Unable to initialize EEPROM.

Unable to write to EEPROM. EEPROM may be write protected.
Unknown status register error.

GMCC command returned unexpected value; GMCC firmware probably crashed.
Upper limit error

Test stopped because GFCC detected upper limit tripped.
Watchdog timer test failed in test cycle number

Watchdog timer circuitry on GFCC did not resond correctly to a simluated timeout.
Write error at address 0x____ wrote 0x____, read 0x____

Identifies where memory address test failed.

ADC Field Service Manual: Applications Engineering JANUARY 1996

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ADC

Field Service Manual

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 1

ADC SYSTEM COMPONENTS ..............................................................................................................................................6

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 2

MTS EM Technical Support

Phone: (919) 677-1610 (Direct)

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 3

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 4

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 5

SW1 - Bus mode

SW2..SW4 - Memory base address

SW5, SW6 - I/O port address

SW7, SW8 - Interrupt port

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 6

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 7

Analog Input channels and Autoranging

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 8

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 9

Implementation of the variable load channel low-pass filter.

Time Cutoff 400

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 11

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 12

DIP Switch Settings

For ADC/DFCC Frames (part# 2000164) has original rev a firmware

DIP Switch 3: Max. PWM

DIP Switch 4: Frame Type

Typical DIP Switch Settings

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 13

For ADC only (part# 00.01162)

DIP Switch 3, 4: Max. PWM

Typical DIP Switch Settings

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 14

Electrical Specification for Digital Input

Electrical Specification for Digital Output

Commanding Testworks to send a 1 to Digital output port #1 results in conductivity between

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 15

Example 1: Switch input Example 2: Input fromTTL

Example 3: Phototransistor input

Example 4: Output to TTL Example 5: Output to relay

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 16

Connections for Optical Limits

Connections for Mechanical Limits

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 17

VCC (+5V DC)

RENEW OPTICAL LIMITS

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 18

Clutch Relay Connections for Clutch Relay Connections for

Proprietary Information : MTS Systems Corporation : 07/12/99 : Page 19

Board Rev First ship Mfr Description Effect

GFCC 3 QMD original production board

GCPC * A QMD original production board

* Genghis Connector Panel Card

Feature: Limit detection level cleanup

Feature: Diagnostic LED

Feature: Support for Synergie & Renew systems

Feature: Analog Handset Feedback

Feature: Excitation current limiting