Model 793.

00 System Software l
User Information and
Software Reference

100-068-917 D
 Copyright information © 2003 MTS Systems Corporation. All rights reserved.

Trademark information MicroConsole, MTS, RPC, Temposonics, and TestWare are

registered trademarks of MTS Systems Corporation.

FlexTest, MPT, Station Builder, Station Manager, and TestStar are

trademarks of MTS Systems Corporation.

Adobe is a registered trademark of Adobe Systems Inc.

Acrobat is a trademark of Adobe Systems Inc.

Lotus 1-2-3 is a registered trademark of Lotus Development

Corporation.

Microsoft, Windows, and Windows NT are registered trademarks of

Microsoft Corporation.

Software verification MTS software is developed using established quality practices in

and validation accordance with the requirements detailed in the ISO 9001
standards. Because MTS authored software is delivered in binary
format, it is not user accessible. This software will not change over
time. Many releases are written to be backwards compatible,
creating another form of verification.

The status and validity of MTS' operating software is also checked

during system verification and routine calibration of MTS hardware.
These controlled calibration processes compare the final test results
after statistical analysis against the predicted response of the
calibration standards. With these established methods, MTS assures
its customers that MTS products meet MTS' exacting quality
standards when initially installed and will continue to perform as
intended over time.

Publication information Manual Part Number Publication Date

100-068-917 B November 2002
100-068-917 C March 2003
100-068-917 D August 2003
Contents

Contents
Preface 19

Conventions 20
Technical Support 23

Chapter 1 Introduction 27

About System Performance 29

Chapter 2 Station Builder 31

Application Overview 32
About Station Configuration Files 34
Getting Started with Station Builder 36
How to Start the Station Builder Application 36
How to Create Your Station Configuration File 36
Allocating Controller Resources 37
About Your Controller Resources 37
How to Allocate Hardware Resources 38
Creating Program Channels 40
About Program Channels 40
About Calculated Outputs 42
About Update Rates 42
About the Power Control 44
How to Create a Program and Control Channel 44
How to Create a Program with Feedback Channel 48
How to Create a Command Plus Error Channel 52
How to Create a Program-Only Channel 55
How to Program a Eurotherm Temperature Controller 58
Creating Control Modes 60

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 About Calculated Inputs 61
Contents

How to Create a PIDF Control Mode 62

How to Create a CLC Control Mode 63
How to Create Dual Compensation Control Modes 64
About Signal Stabilization 65
How to Create a Control Mode Stabilization Signal 65
Creating Calculated Resources 66
How to Create a Calculated Output Resource 67
How to Create a Calculated Input Resource 68
Creating Readouts 69
About Readouts 69
How to Create a Readout 69
Creating Digital Inputs 70
About Digital Inputs 70
How to Create Digital Inputs 70
Creating Digital Outputs 71
About Digital Outputs 71
How to Create Digital Outputs 71
Creating Auxiliary Inputs 72
About Auxiliary Inputs 72
How to Create an Auxiliary Input 73
Enabling External Command Inputs 74
About External Command Inputs 74
How to Enable an External Command Input 74
Setting Up Remote Setpoint Adjust 75
How to Set Up a Remote Setpoint Adjust Control 75
Working with Station Configuration Files 76
How to Open a Station Configuration File 76
How to Save a Station Configuration File 77
How to Preview a Station Configuration File 78
How to Print a Station Configuration File 78
Creating Stations to Run Concurrently 79
How to Create Stations that Run Concurrently 80

4 793.00 System Software

 Station Builder Window 81

Contents
Main Menus 83
File Menu 84
Print Preview Toolbar 88
Window Menu 91
Help Menu 92
Toolbar 93
Station Configuration Window 94
Navigation Pane 95
Channels Panel 97
General Tab 99
Control Modes Tab 100
Edit Dual Compensation Modes Window 102
External Command Tab 104
Auxiliary Inputs Panel 105
Readouts Panel 107
Digital Inputs Panel 108
Digital Outputs Panel 109
Calculated Outputs Panel 110
Remote Setpoints Panel 112

Chapter 3 Station Manager 115

Application Overview 119

Getting Started with Station Manager 121
How to Start the Station Manager Application 121
About the Demonstration Mode 122
How to Start the Demonstration Mode 122
Configuration Files and Parameter Sets 123
About Configuration Files 123
About Station Parameter Sets 123
How to Open a Station Configuration File 124
How to Save a Parameter Set Under a New Name 126
How to Delete a Parameter Set 126
How to Open a Different Parameter Set 127

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 How to Preview a Parameter Set 128
Contents

How to Print a Parameter Set 128

How to Determine What Parameter Set is Being Used 128
Setting Access Levels 129
About Access Levels 129
How to Go to a Higher Access Level 129
Station Views 130
About Station Views 130
How to Save a View 130
How to Restore a Saved View 130
How to Restore a Default View 130
Calibrating Sensors and Configuring Feedback 131
About Sensors 131
Calibrating sensors 132
Before You Begin 133
About Sensor Calibration Files 134
How to Create a Sensor File 135
How to Assign a Sensor File 141
Saving Sensor File Data 143
About the Transducer ID Modules 145
How to Assign a Sensor with a Transducer ID Module 146
How to Save Data to a Transducer ID Module 147
How to Configure an Externally Conditioned Feedback Signal 148
About Offset 149
How to Offset a Feedback Signal 150
About Electrical Zero Offset 152
More About Electrical Zero 153
How to Shift a Conditioner’s Electrical Zero 155
Working with Readout Devices 158
About Readout Devices 158
About the Scope 159
How to Set Up a Time Plot on the Scope 159
How to Set Up a Frequency Plot on the Scope 160
How to Set Up an X/Y Plot on the Scope 161
About Auto-Scale, Rescale, and Same Scale 162
How to Auto-Scale 162

6 793.00 System Software

 How to Rescale 163

Contents
How to Same Scale 164
How to Offset Scope Signals 165
How to Adjust the Scope’s Time Scale 166
How to Examine Stored Time Plot Signals 167
How to Change the Time Scale When Examining Time Plot Signals 168
How to “Sync” Current Channel Selections on Scope 169
How to Change the Scope’s Appearance 170
About Meters 172
How to Configure a Meter 173
How to Add a Meter 174
How to Delete a Meter 175
About the Station Signals Panel 176
How to Display Station Signals 177
How to Edit the Signal Lists 178
About Monitoring Signals Using External Readout Devices 179
How to Configure a Signal for External Readout 179
Working with External Commands 181
About External Command Inputs 181
How to Enable and Run External Command Inputs 181
Applying Hydraulics and Clearing Interlocks 183
About Station Hydraulics 183
How to Apply Hydraulics 185
How to Turn Off Hydraulics 185
About Interlocks and Saturated Signals 186
How to Apply Hydraulics When a Channel’s Feedback is Saturated 190
How to Manually Position the Actuator 192
Working with Compensators 194
About Compensators 194
About Null Pacing 195
How to Configure the Null Pacing Compensator 196
About PVC 198
How to Configure PVC 199
About APC 201
How to Configure APC 202
About AIC 204

793.00 System Software 7

 How to Configure AIC 206
Contents

How to Tune AIC 208

About ALC 215
How to Configure ALC 217
About PVP 219
How to Configure PVP 220
Running Tests 222
About Detectors 223
About Limit Detectors 226
How to Set Limit Detectors 227
How to Monitor Limit Detectors 230
About Hardware Limit Detectors 231
How to Set Hardware Limit Detectors 231
How to Monitor Hardware Limit Detectors 234
About Error Detectors 235
How to Set Error Detectors 236
How to Monitor Error Detectors 238
About Sensor Ranges and Detectors 239
About Digital Inputs/Outputs 243
About Digital Inputs 243
How to Configure Responses to Digital Input Signals 245
About the Event-Action Editor Window 246
How to Define a Custom Action 247
How to Manually Control Digital Output Signals 248
About Shunt Calibration 250
How to Perform a Shunt Calibration 251
About Program Outputs 253
How to Adjust Program Output Signals 253
How to Program with the Function Generator 255
How to Adjust Setpoint and Span During a Test 257
About the Optional Remote Setpoint Adjust 258
How to Configure Remote Setpoint Adjust Controls 258
About Channel Groups 259
How to Create a Master Command Group 261
How to Select a Master Command Group 262
Defining a Master Span Group 263

8 793.00 System Software

 Using Rig Command (Park/Ride) 264

Contents
Working with Message Logs 266
About Message Logs 266
How to Open a Message Log 267
How to Print a Message Log 268
How to Print the Message Log to File 268
How to Add a User Entry to the Message Log 269
How to Delete a User Entry from the Message Log 270
How to Define Which Messages Get Logged 271
How to Manually Archive a Message Log 272
Station Manager Controls and Displays 273
Menu Bar 274
Station Manager Window Toolbar 275
Access Level 277
Station Manager Window Message Pane 278
File Menu 279
Open Station Window 281
Open Parameter Set Window 283
Save Parameters As Window 284
Delete Parameter Set Window 285
Print Preview Window 286
Print Preview Toolbar 287
Print Parameters to File Window 288
Display Menu 289
Station Setup Window 290
Station Setup Window/Channel Status Panel Tabs 295
Channel Summary Tab 295
Fullscale Tab 297
Tuning Tab 298
Drive Tab 299
Compensators Tab 302
Calibration Tab 308
Station Setup Window/Inputs Panel Tabs 310
Sensor Tab 310
Calibration Tab 313
Calibration Tab for a Calculated Input 318

793.00 System Software 9

 Shunt Tab 319
Contents

Offset/Zero Tab 321

Limits Tab 323
Hardware Limits Tab 325
Station Setup Window/Drive Panel—Two Stage Valves 327
Station Setup Window/Drive Panel—Three Stage Valves 329
Valve Tab for Three Stage Valve Drivers 329
Inner Loop Tab for Three Stage Valve Drivers 333
Conditioner Tab for Three-Stage Valve Drivers 334
Calculated Drive Signals Not Assigned Hardware 336
Station Setup Window/Tuning Panel Tabs 337
Adjustments Tab—PIDF Control Modes 337
Adjustments Tab—CLC Control Modes 339
Filter Tab 341
Station Setup Window/Compensators Panel Tabs 343
Null Pacing Tab 343
PVC Tab 346
APC Tab 348
AIC Tab 350
ALC Tab 353
PVP Tab 355
Station Setup Window/Sync Current Channel 357
Station Setup Window/Readouts Panels 358
Readouts Summary Panel 358
Readout Adjust Panel 359
Station Setup Window/Auxiliary Inputs Panels 360
Auxiliary Inputs Summary Panel 360
Auxiliary Inputs Panel Tabs 361
Station Setup Window/Station Signals Panel Tabs 363
Values Tab 363
Hardware Tab 364
Fullscale Tab 365
Calibration Tab 366
Station Setup Window/Digital Input/Outputs Panel Tabs 367
Inputs Summary Tab 367
Outputs Summary Tab 368

10 793.00 System Software

 Digital Inputs Panel 369

Contents
Digital Outputs Panel 372
Station Setup Window/Detectors Panel Tabs 373
Detectors Summary Tabs 373
Limits Summary Tab 375
Upper Limits /Lower Limits Tabs 376
Error Summary Tab 378
Outer Error/Inner Error Tabs 380
Hardware Limits Tab 382
Station Setup Window/Calculations Panels 384
Calculated Outputs Panel/Values Tab 384
Calculated Outputs Panel/Fullscale Tab 385
Calculated Outputs Panel/Drive Tab 386
Calculated Output/Calculation Tab 387
Calculated Output/Drive Tab 388
Calculation Parameters Panel 389
Station Setup Window/Remote Setpoints Panels 390
Remote Setpoint Knob Panel 391
Meters Window 392
Meter Setup Window 394
Scope Window 395
Setup for Scope Window 398
Graph Settings Tab 398
Trace Settings Tab 400
Frequency Mode Tab 401
Message Logs Window 403
Message Log Add Entry Window 406
Message Log Print Window 407
Applications Menu 408
Tools Menu 409
Station Options Window 410
Station Log Tab 410
Unit Selection Tab 412
Directories Tab 414
Station View Options Tab 416

793.00 System Software 11

 Channel Options Window 418
Contents

Master Span Tab 418

External Command Tab 420
Master Command Tab 421
Command Options Tab 423
Signal Lists Tab 433
RSC Tab 435
Detector Lists Tab 437
Rig Commands Tab 439
Channel Lists Tab 441
Sensor File Editor Window 443
Linearization Data Window 447
Event-Action Editor Window 449
Define Actions Tab 449
Action Lists Tab 458
Calculation Editor Window 460
Calculation Definition Panels 462
Calculation Grammar 466
Parameters Definition Panel 478
Unit Assignment Set Editor Window 480
Help Menu 483
Application Controls Panels 484
Function Generator Control Panel 486
External Command Control Panel 494
Auto-Tuning Control Panel 496
Station Controls Panel 499
Station Controls Panel Toolbar 502
Signal Auto Offset Window 504
Detectors Window 505
Digital I/Os Window 509
Inputs Tab 509
Outputs Tab 510
Manual Command Window 511
Using Manual Command Park/Ride 513
Setpoint and Span Window 514
Remote Setpoint Adjust Window 516

12 793.00 System Software

Chapter 4 Basic TestWare 519

Contents
Application Overview 520
About Test Files 522
Getting Started with Basic TestWare 523
How to Start the Basic TestWare Application 523
How to Create a Basic TestWare Test 523
Defining the Test Command 524
About Test Commands 524
How to Define a Cyclic Command 525
How to Define a Monotonic Command 526
Configuring Data Acquisition 527
About Data Acquisition 527
More About Data Files and Buffers 528
How to Configure Timed Data Acquisition 530
How to Configure Peak/Valley Data Acquisition 532
How to Configure Running Max/Min Data Acquisition 533
How to Configure Level Crossing Data Acquisition 534
Configuring Peak Detectors 535
About Peak Detectors 535
How to Configure Peak Detectors 536
Configuring Return Home 538
About Return Home 538
How to Define the Home Position 539
How to Use the Home Control 539
Configuring Test Counters 540
About Test Counters 540
How to Configure a Test Counter 541
Running Your Test 542
How to Start a Basic TestWare Test 543
How to Hold a Basic TestWare Test 543
How to Stop a Basic TestWare Test 543
Working with Test Files 544
How to Open a Test File 545
How to Save a Test File 545

793.00 System Software 13

 How to Preview a Test 546
Contents

Print Preview Toolbar 547

How to Print a Test 547
Using the Message Logs Window 548
Working With Message Logs 550
How to Open a Message Log 551
How to Print a Message Log 552
How to Print the Message Log to File 552
How to Add a User Entry to the Message Log 553
How to Delete a User Entry from the Message Log 554
How to Define What Messages Are Logged 555
How to Manually Archive All of the Messages in the Message Log 556
How to Manually Archive Part of the Messages in the Message Log 556
Basic TestWare Windows 557
Basic TestWare Toolbar 560
Open Test Window 561
Save Test/Save Test As Window 562
Test Setup Window 563
Options Editor Window 579
Message Logs Window 580

Chapter 5 Tuning 583

About Tuning 584

If You’ve Never Tuned Before 585
When to Tune 586
Control Mode Characteristics 588
How the Tuning Controls Work 590
Creating a Tuning Program 598
Other Considerations 601
Monitoring Waveforms 602
Tuning Your System 606
About Tuning 606
Setting the Servovalve Polarity 608
How to Set Servovalve Polarity 609

14 793.00 System Software

 How to Tune the Inner Loop of Three-Stage Valves 615

Contents
Inner Loop Signals 622
About Valve Balance 623
How to Check and Adjust Valve Balance 623
How to Balance Dual Valves 625
About Dither 629
How to Check and Adjust Dither Amplitude 630
About Tuning the Outer Loop 634
About Auto-Tuning 635
How to Auto-Tune Control Modes 636
About Manual Tuning 641
Manual Tuning Guidelines 642
Tuning Displacement 643
Tuning Force 650
About Channel Limited Channel (CLC) Control Modes 656
How to Tune a CLC Control Mode 658
About Dual Compensation Control Modes 660
How to Tune a Dual Compensation Control Mode 663
About Tuning Filters 666
How to Enable a Tuning Filter 667

Chapter 6 Station Desktop Organizer 669

Overview 670
Starting the Station Desktop Organizer 671
How to Start the Station Desktop Organizer Manually 671
How to Start the Station Desktop Organizer Automatically 671
Positioning the Station Desktop Organizer 673
How to Move the Station Desktop Organizer Taskbar 673
Setting Up the Station Desktop Organizer 674
How to Access the Station Desktop Organizer Menu 674
Using the Station Desktop Organizer 677
How to Hide Station Windows 677
How to Display Hidden Station Windows 677
How to Start an Application from the Station Desktop Organizer 677

793.00 System Software 15

 How to Quit the Station Desktop Organizer 678
Contents

How to Refresh the Station Desktop Organizer Display 678

Station Desktop Organizer Controls and Indicators 679
Station Buttons and Action Menus 680
Hide and Show Buttons 681
Stop Button 682
Status Indicators 683

Chapter 7 Remote Station Controller (RSC) 685

About the Remote Station Controller 686

Defining the RSC (.HWI File) 687
Cabling the RSC to the Controller 688
Enabling a Remote Station Controller 689
How To Enable an RSC 689
RSC Controls and Indicators 690
Station Manager Page 699
MultiPurpose TestWare Page 702
Message Window Displays 703
Signal Lists and Pages 704
How to Create Signal Lists 704
How to Edit Signal Lists 705
How to Create Signal Pages 706

16 793.00 System Software

Appendix A Acceleration Compensation 707

Contents
Appendix B Command Line Options and Shortcuts 711

Station Manager Shortcuts 712

Station Builder Shortcuts 714
System Loader Shortcuts 715
Basic TestWare Shortcuts 717
Decorator-Based vs. Precedence-Based Formats 719
Decorator-Based Command Line Format 719
Precedence-Based Command Line Format 721
Creating a Shortcut 724
How to Create a Shortcut 724
Editing the Shortcut Command Line 725
How to Edit the Shortcut Command Line 725

Appendix C 793.00 Aero Options 727

A/B Compare 728

Extended Limits 731
Group Detector Option 733
Import/Export Support 735
Exporting Data 735
Importing Data 738
File Format 741

Index 743

793.00 System Software 17

Contents

18 793.00 System Software

Preface
Safety first! Before you attempt to use your MTS product or system, read and
understand the Safety manual. Like an automobile, your test system is
very useful—but if misused, it is capable of deadly force. You should
always maintain a healthy respect for it.

Improper installation, operation, or maintenance of MTS equipment in

your test system can result in hazardous conditions that can cause
severe personal injury or death, and damage to your equipment and
specimen. Again, read and understand the Safety manual before you
continue. It is very important that you remain aware of hazards that

Preface
apply to your system.

Other MTS manuals In addition to this manual, you may receive additional MTS manuals in
paper or electronic form.

If you have purchased a test system, it may include an MTS System

Documentation CD. This CD contains an electronic copy of all MTS
manuals that pertain to your test system, including controller manuals,
hydraulic and mechanical component manuals, assembly drawings and
parts lists, and operation and preventive maintenance manuals.

Contents Conventions 20
Technical Support 23

Model 793.00 System Software Preface 19

 Conventions

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

Hazard conventions As necessary, hazard notices may be embedded in this manual. These
notices contain safety information that is specific to the task to be
performed. Hazard notices immediately precede the step or procedure
that may lead to an associated hazard. Read all hazard notices carefully
and follow the directions that are given. Three different levels of
hazard notices may appear in your manuals. Following are examples
of all three levels.
Preface

Note For general safety information, see the Safety manual included with
your system.

Danger notices Danger notices indicate the presence of a hazard which will cause
severe personal injury, death, or substantial property damage if the
danger is ignored. For example:

DANGER
High intensity light and dangerous radiation are emitted by class 3B
lasers.

Viewing a class 3b laser directly or viewing it using optical instruments

will cause immediate and severe injury.

Avoid eye or skin exposure to the laser beam. Ensure that all power to the
laser is off before attempting any maintenance, service, or adjustment
procedures.

20 Preface Model 793.00 System Software

 Conventions

Warning notices Warning notices indicate the presence of a hazard which can cause
severe personal injury, death, or substantial property damage if the
warning is ignored. For example:

WARNING Hazardous fumes can accumulate in the test chamber as a result of

testing.

Breathing hazardous fumes can cause nausea, fainting, or death.

Ensure that the chamber is properly ventilated before you open the chamber
door or put your head or hands into the chamber. To do this, ensure that the
temperature controller is off and allow sufficient time for the ventilation
system to completely exchange the atmosphere within the chamber.

Preface
Caution notices Caution notices indicate the presence of a hazard which will or can
cause minor personal injury, cause minor equipment damage, or
endanger test integrity if the caution is ignored. For example:

CAUTION This specimen can develop sharp edges as a result of testing.

Handling the specimen with unprotected hands can result in cuts and
slivers.

Always wear protective gloves when you handle the specimen.

Model 793.00 System Software Preface 21

 Conventions

Other conventions Other conventions used in your manuals are described below:

Notes Notes provide additional information about operating your system or

highlight easily overlooked items. For example:

Note Resources that are put back on the hardware lists show up at the
end of the list.

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

Illustrations Illustrations appear in this manual to clarify text. It is important for you
to be aware that these illustrations are examples only and do not
necessarily represent your actual system configuration, test application,
or software.
Preface

Electronic manual This manual is available as an electronic document in the Portable

conventions Document File (PDF) format. It can be viewed on any computer that
has Adobe Acrobat Reader installed.

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

22 Preface Model 793.00 System Software

 Technical Support

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

If you cannot find answers to your technical questions from these

sources, you can use the internet, telephone, or fax to contact MTS for
assistance. You can also fill out the Problem Submittal Form that is
available on the MTS web site and in the back of many MTS manuals
that are distributed in paper form.

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

MTS web site The MTS web site gives you access to our technical support staff by
www.mts.com means of a Problem Submittal Form and a Technical Support link.

• Problem Submittal Form:

www.mts.com > Contact MTS > Problem Submittal Form

• Technical Support:
www.mts.com > Contact MTS > Technical Support

E-mail: [email protected]

Telephone HELPLine 800-328-2255

Weekdays 7:00 A.M. to 6:00 P.M.,
Central Time

Fax 952-937-4515
Please include an MTS contact name if possible.

Model 793.00 System Software Preface 23

 Technical Support

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

Know your site number The site number contains your company number and identifies your
and system number equipment type (material testing, simulation, and so forth). The
number is usually written on a label on your MTS equipment before
the system leaves MTS. If you do not have or do not know your MTS
site number, contact your MTS sales engineer.

Example site number: 571167

When you have more than one MTS system, the system number
identifies which system you are calling about. You can find your job
number in the papers sent to you when you ordered your system.
Preface

Example system number: US1.42460

Know information from If you have contacted MTS about this problem before, we can recall
prior technical your file. You will need to tell us the:
assistance • MTS notification number

• Name of the person who helped you

Identify the problem Describe the problem you are experiencing and know the answers to
the following questions.

• How long has the problem been occurring?

• Can you reproduce the problem?

• Were any hardware or software changes made to the system

before the problem started?

• What are the model and serial numbers of the suspect equipment?

24 Preface Model 793.00 System Software

 Technical Support

Know relevant computer If you are experiencing a computer problem, have the following
information information available.

• Manufacturer’s name and model number

• Operating software type and service patch information. Examples:

– Windows XP Service Pack 1 (SP1)

– Windows 2000 Service Pack 3 (SP3)

– Windows NT 4.0 Service Pack 7 (SP7)

• Amount of system memory. Example: 640 MB of RAM.

• Amount of free space on the hard drive in which the application

resides. Example: 11.2 GB free space, or 72% free space.

Preface
• Current status of hard-drive fragmentation. Example: 3% total
fragmentation.

Know relevant software For software application problems, have the following information
information available.

• The software application’s name, version number, build number,

and if available, software patch number. This information is
displayed briefly when you launch the application, and can
typically be found in the “About” selection in the “Help” menu.

Example: Station Manager, Version 3.3A, Build 1190, Patch 4

• It is also helpful if the names of other non-MTS applications that

are running on your computer, such as screen savers, keyboard
enhancers, print spoolers, and so forth are known and available.

If you contact MTS Your call will be registered by a HELPLine agent if you are calling
by phone within the United States or Canada. Before connecting you with a
technical support specialist, your agent will ask you for your site
number, name, company, company address, and the phone number
where you can normally be reached.

Model 793.00 System Software Preface 25

 Technical Support

Identify system type To assist your HELPLine agent with connecting you to the most
qualified technical support specialist available, identify your system as
one of the following types:

• Electromechanical materials test system

• Hydromechanical materials test system

• Vehicles test system

• Vehicles component test system

• Aero test system

Be prepared to Prepare yourself for troubleshooting while on the phone.

troubleshoot
Preface

• Call from a telephone close to the system so that you can try
implementing suggestions made over the phone.

• Have the original operating and application software media

available.

• If you are not familiar with all aspects of the equipment operation,
have an experienced user nearby to assist you.

Write down relevant Prepare yourself in case we need to call you back.
information
• Remember to ask for the notification number.

• Record the name of the person who helped you.

• Write down any specific instructions to be followed, such as data

recording or performance monitoring.

After you call MTS logs and tracks all calls to ensure that you receive assistance and
that action is taken regarding your problem or request. If you have
questions about the status of your problem or have additional
information to report, please contact MTS again.

Problem Submittal In addition to the Problem Submittal Form on the MTS web site, there
Form in MTS manuals is also a paper version of this form (postage paid) in the back of many
MTS manuals. Use this form to communicate problems you are
experiencing with your MTS software, hardware, manuals, or service.
This form includes check boxes that allow you to indicate the urgency
of your problem and your expectation of an acceptable response time.
We guarantee a timely response—your feedback is important to us.

26 Preface Model 793.00 System Software

Chapter 1
Introduction
Model 793.00 System Software is a bundle of applications that perform
various test activities for the following MTS Controllers: TestStar™ IIs,
TestStar™ IIm, TestStar™ IIs AP, FlexTest™ IIm, FlexTest™ GT, FlexTest™
II CTC, FlexTest™ II CTM, and FlexTest™ SE.

Standard applications The Model 793.00 System Software bundle consists of the following
standard applications:

• Station Builder™—A station design application. This application

allows you to allocate controller resources, such as valve drivers
and conditioners, to station configuration files.

• Station Manager™—A sophisticated controller application. This

application maintains station servo control, and allows you to
perform typical test operations, such as:

– Monitor station interlocks and control hydraulic or

electromechanical station power.

– Optimize and monitor the various analog and digital signals

sent to and from your controller.

Introduction
– Run, hold, and stop tests.

– Create parameter sets that define the operational

characteristics, such as sensor ranges and conditioner gains,
of the station resources in your station configuration files.

• Basic TestWare®—A simple test design application. This

application allows you to create simple monotonic and cyclic tests
and to acquire data.

• Station Desktop Organizer—An application management utility.

This utility allows you to manage the windows and displays
associated with Series 793 software applications. This utility is
useful for reducing screen clutter when you work with multiple
stations simultaneously.

Model 793.00 System Software 27

 Options The following products are available as options with the Model 793.00
System Software bundle:

• Model 793.10 MultiPurpose TestWare® (MPT)—A sophisticated

test design application. This application allows you to build test
procedures by defining and linking modular test activities together
and assigning triggering relationships between each activity.
Note MPT is standard with FlexTest IIm and FlexTest CTM systems.

• Model 793.11 Profile Editor™—A sophisticated arbitrary

waveform design application. This application allows you to
create arbitrary waveforms that can be played-out with the
MultiPurpose TestWare application.

• Model 793.12 Trend Process and Trend Monitoring—A

specialized analysis application designed for use with MPT that
allows you to monitor trend data that has been recorded in real
time.

• Model 793.14 Fatigue Process and Fatigue Monitoring—A

specialized analysis application that allows you to monitor fatigue
data that has been recorded in real time.

• Remote Setpoint Adjust—An enhancement that allows you to

use one or more encoders on a station to control the setpoints of
control channels (available for FlexTest IIm, FlexTest II CTC, and
FlexTest GT only).
Introduction

• Other Series 793 applications as available.

28 Model 793.00 System Software

 About System Performance

About System Performance

The following table illustrates typical system performance values for
various station/channel configurations of MTS FlexTest and TestStar
Controllers:

System Rates1
NUMBER OF NUMBER OF POTENTIAL
CONTROLLER POTENTIAL STATIONS CONTROL CHANNELS SYSTEM RATE (HZ)
FlexTest SE 1 1 2048

FlexTest SE2 1 2 6144

TestStar IIs 1 1 6144

TestStar IIm 4 3-4 4096

TestStar IIm 4 5-8 2048

TestStar IIm 2 2 6144

FlexTest IIm 4 16 1024

FlexTest GT 4 5-8 2048

FlexTest GT 4 3-4 4096

Introduction
FlexTest GT 2 2 6144

FlexTest II CTC 4 4 4096

FlexTest II CTM 4 8 2048

FlexTest II CTM 4 16 1024

1. System performance is based on MTS Model 498.96 processor boards. Factors that adversely
affect data acquisition rates include host computer processor speed, controller processor speed,
the number of readouts displayed, and the number of channels of data acquisition.

2. Applies only to FlexTest SE Controllers equipped with MTS Model 498.96-1B/2B processor
boards.

Model 793.00 System Software 29

 About System Performance

RPC Sampling Rates For RPC systems, as the selected system rate decreases, addition
sampling rates are available. The following table illustrates this
relationship.

RPC Sampling Rates

SYSTEM SAMPLING RATES
RATE

4096 204.8 409.6 512 1024 2048

2048 102.4 204.8 409.6 512 1024 2048

1024 102.4 128 204.8 256 409.6 512 1024

Introduction

30 Model 793.00 System Software

Chapter 2
Station Builder
Learning about Application Overview 32
Station Builder About Station Configuration Files 34
Getting Started with Station Builder 36
Performing common Allocating Controller Resources 37
tasks Creating Program Channels 40
Creating Control Modes 60
Creating Calculated Resources 66
Creating Readouts 69
Creating Digital Inputs 70
Creating Digital Outputs 71
Creating Auxiliary Inputs 72
Enabling External Command Inputs 74
Setting Up Remote Setpoint Adjust 75
Working with Station Configuration Files 76
Creating Stations to Run Concurrently 79
Window and control Station Builder Window 81
descriptions Main Menus 83
Toolbar 93
Station Configuration Window 94
Navigation Pane 95
Channels Panel 97
Auxiliary Inputs Panel 105
Readouts Panel 107
Station Builder
Digital Inputs Panel 108
Digital Outputs Panel 109
Calculated Outputs Panel 110
Remote Setpoints Panel 112

Model 793.00 System Software 31

 Application Overview

Application Overview
The Station Builder application lets you allocate all or a portion of your
controller resources to create station configuration files.

Station Builder main window

Menu bar Toolbar

Application panels
Controller resources
Station Builder

Navigation pane

32 Model 793.00 System Software

 Application Overview

With the Station Builder window controls you can allocate controller
resources such as valve drivers, conditioners, analog I/O, digital I/O,
and hydraulic control resources to create the following station
resources:

• Channels—used to send programming signals to servovalves and

external controllers.

• Auxiliary Inputs—used to monitor signals for data acquisition or

display.

• Readouts—used to send analog signals to external readout

devices such as oscilloscopes and meters.

• Digital Inputs—used to receive digital logic signals from external

devices.

• Digital Outputs—used to send digital logic signals to external

devices.

• Calculated Outputs—used to apply user-defined, algebraic

formulas to selected output signal values to generate new,
calculated output signal values.

• Calculated Inputs—used with calculated resources to apply

user-defined, algebraic formulas to selected input signal values to
generate new, calculated input signal values.

• Remote Setpoints—used to set up the Remote Setpoint Adjust

(RSA) controls (optional, stand-alone hardware controls used to
control actuator setpoints).

Once you have allocated the resources you need, you save your
configuration to a station configuration file. For more information, see
“About Station Configuration Files” on page 34.

For more information on the Station Builder controls, see “Station

Builder Window” on page 81.

Station Builder

Model 793.00 System Software 33

 About Station Configuration Files

About Station Configuration Files

A station configuration file (or .cfg file) is a text file that defines the
controller resources allocated to a particular station.

The default location for saved configuration files is:

APPLICATION DEFAULT CONFIGURATION FILE PATH

FlexTest II CTC c:\ftiictc\config
FlexTest II CTM c:\ftiictm\config
FlexTest IIm c:\ftiim\config
FlexTest GT c:\ftiigt\config
TestStar IIs AP c:\tsiisap\config
TestStar IIm c:\tsiim\config
TestStar IIs c:\tsiis\config
FlexTest SE c:\ftse\config

If you plan to run tests that require different controller resources or if

you want to run tests on multiple stations simultaneously, you will
have to create multiple configuration files.

File setup Depending on the type of test you perform, the station configuration
files you create will vary in their complexity.

For example, if you want to provide simple programming to an

external controller, you may need only to allocate a single analog
output resource.
Station Builder

34 Model 793.00 System Software

 About Station Configuration Files

However, if you want to maintain closed-loop control on one or more

channels, you will probably need to allocate resources for:

• Multiple outgoing program signals

• Multiple incoming feedback signals

• A hydraulic power source

• Auxiliary inputs

• Readouts
For more information on creating your station configuration files, see
“Getting Started with Station Builder” on page 36. For information on
opening, saving, previewing, and printing station configuration files,
see “Working with Station Configuration Files” on page 76.

Available resources The resources displayed in the Station Builder resource lists are
defined by the hardware interface file (or .hwi file) installed with your
system software. For more information, see “About Your Controller
Resources” on page 37.

Station Builder

Model 793.00 System Software 35

 Getting Started with Station Builder

Getting Started with Station Builder

How to Start the Station Builder Application
There are two ways to start the Station Builder application.

Method 1 On the Station Manager Applications menu, click Station Builder.

Method 2 Start the Station Builder application from the Station Desktop
Organizer. See “How to Start an Application from the Station Desktop
Organizer” on page 675.

When you start the Station Builder application, the main window
opens with a new, untitled station configuration.

How to Create Your Station Configuration File

Refer to the following sections to create your station configuration file:

• “Creating Program Channels” on page 40

• “Creating Control Modes” on page 60

• “About Signal Stabilization” on page 65

• “Creating Calculated Resources” on page 66

• “Creating Readouts” on page 69

• “Creating Digital Inputs” on page 70

• “Creating Digital Outputs” on page 71

• “Creating Auxiliary Inputs” on page 72

• “Enabling External Command Inputs” on page 74

If you are creating multiple stations that will be controlled or

programmed simultaneously, see “Creating Stations to Run
Concurrently” on page 79.
Station Builder

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 Allocating Controller Resources

Allocating Controller Resources

About Your Controller Resources
The .hwi file The resources in your Station Builder resource lists are defined by the
hardware interface file (or .hwi file) installed with your system
software. The .hwi file defines what internal components are available
to your controller, which controller slots they are installed in, and
which rear-panel connectors they are accessed through.

Your .hwi file is created at the factory according to the resources

included with your controller. It may be necessary to edit this file if
system resources are added, removed, or repositioned in the test
chassis.

For detailed information on the .hwi file installed with your TestStar IIs
system software, refer to manual PN 150585-XX (TestStar IIs Controller
Installation and Calibration). For detailed information on the .hwi file
installed with your TestStar IIm or FlexTest GT system software, refer
to manual PN 100-020-488 (Model 493.10/793.00 Controller Installation
and Calibration). For information on FlexTest IIm or FlexTest II CTM
.hwi files, contact MTS.

WARNING An incorrect .hwi file can result in improper system response and
sudden actuator movements.

Sudden actuator movements can result in personal injury or damage to

equipment.

The .hwi file is a critical system component. Only qualified personnel should
edit the .hwi file. Always make a backup copy of the file before editing it.

Input and output In addition to the normal input and output resources installed in your
calculations controller, you can also assign calculated inputs and outputs to be used
as control feedback, as auxiliary inputs, or to drive output resources.
For more information, see “About Calculated Resources” on page 66.
Station Builder

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 Allocating Controller Resources

How to Allocate Hardware Resources

1. In the Hardware Resources list, select the hardware resource
you want to allocate and then click +.

2. In the Display Name box, change the channel resource name as

desired.
Note It is good practice to keep your channel resource names short,
since long names may not be visible in all windows.

3. In the Internal Name box, type or select an internal name for the
channel resource.

Click the desired resource and click + to allocate it.

Click – to return the selected resource to the resource list.

Display Name vs. The Display Name is the name of the channel resource as you would
Internal Name like it to appear in the navigation pane. Typically, this name is
changed to describe a test channel more precisely.

For example, if you have a system with front and rear channels you
may choose to change the display names as follows:
Station Builder

The Internal Name is the channel resource name that will be used
internally by other software applications for channel and signal
mapping. Typically, this name is not changed.

38 Model 793.00 System Software

 Allocating Controller Resources

Not changing internal names allows better portability of the station

configuration to other systems, especially when assigning multilingual
display names.

Note If the internal name is changed it will not change your display name
choice unless the internal and display name is the same.

In the Station Configuration window you can select Show Internal

Names to replace Display Names with Internal Names in the
navigation pane.

Not Selected

Selected

Station Builder

Model 793.00 System Software 39

 Creating Program Channels

Creating Program Channels

About Program Channels
You use program channels to send commands to external servovalves
and controllers. The system software supports these types of program
channels: Program and Control, Program with Feedback, Command
Plus Error, and Program-Only channels.

Program and Control Program and Control channels are used to maintain closed-loop
channels control of an actuator. This channel type is selected automatically
when you allocate a valve driver resource. For more information, see
“How to Create a Program and Control Channel” on page 44.

Note FlexTest II CTM and TestStar II AP programmers do not typically use

Program and Control channels.

Controller

Command +
Valve Drive Load Frame/
PIDF Driver Actuator
-

Conditioner
Feedback
Station Builder

40 Model 793.00 System Software

 Creating Program Channels

Program with Program with Feedback channels are used to program external
Feedback channels controllers while monitoring feedback for command compensation or
data acquisition. In this channel configuration, the external controller
maintains closed-loop control. For more information, see “How to
Create a Program with Feedback Channel” on page 48.

Controller External Controller

Command +
Drive
PIDF
-

Feedback

Command Plus Error Command Plus Error channels are used to send programming to
channels external controllers and correct the error between the command and
feedback by adding the error into the command. In this channel
configuration, the external controller maintains closed-loop control.
For more information, see “How to Create a Command Plus Error
Channel” on page 52.

Note This type of channel is normally used to control the pressurization of

aircraft chambers.

External Pressure
Controller
Controller
Command + Command Error
Pressure
Plus Error Chamber
+ +

-
Pressure
Feedback
Station Builder

Model 793.00 System Software 41

 Creating Program Channels

Program-Only Program-Only channels are used to send programming to an external

channels controller. In this channel configuration, the external controller
maintains closed-loop control. For more information, see “How to
Create a Program-Only Channel” on page 55.

Controller External Controller

Command Error

Feedback

About Calculated Outputs

In addition to the regular output resources installed in your controller,
you can also use a calculated output to drive a valve or other output
resource. Calculated output values are determined by evaluating a
user-defined mathematical expression that uses the values of other
signals. For information on creating new calculations, see “Creating
Calculated Resources” on page 66.

About Update Rates

You must specify the update rate for each program channel you
define. Update rate options include System Rate and Low Rate.
Station Builder

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 Creating Program Channels

System rate The system rate specified in the .hwi file is the normal rate used for
testing. This rate varies with the type of controller you are using. Refer
to “About System Performance” on page 29 for system rate
information.

Low rate In some instances, it may be desirable to program an external

controller at a low rate to conserve processor resources. Typically,
low-rate channels are used with devices that do not require frequent
setpoint updates such as temperature controllers.

Your system’s low rate is defined in your .hwi file as the Low System
Rate. The default low rate for all systems is 25.6 Hz.

Update rates using Serial connectors on the rear panel of the FlexTest and TestStar
serial connectors controllers support two-way communication with Eurotherm Model
2200 and 2400 Temperature Controllers.

When programming a Eurotherm temperature controller over a serial

connection, though the actual update rate is 0.5 Hz input and 1 Hz
output, Low Rate is automatically selected as the update rate.

For more information on programming Eurotherm temperature

controllers, see “How to Program a Eurotherm Temperature Controller”
on page 58.

Station Builder

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 Creating Program Channels

About the Power Control

FlexTest IIm/CTC On FlexTest IIm/CTC controllers, up to four hydraulic service
controllers manifolds can be connected to J28A–J28D on the rear panel of the
Model 497.05 Hydraulic Control Panel.

If desired, you can allocate the same HSM resource to multiple

FlexTest IIm channels.

GT/TestStar IIm On GT/TestStar IIm controllers, the HSM is connected to J28A-J28B on

controllers the Model 493.74 HSM transition board mounted in the rear panel
chassis. Each HSM transition board controls up to two stations and the
chassis supports up to four stations.

TestStar IIs On TestStar IIs controllers, the HSM is connected to J20 (proportional)
controllers or J28 (solenoid) on the rear panel of the TestStar IIs chassis.

If your TestStar IIs system is connected directly to an HPU, select HPU

in the Power list.

FlexTest SE On FlexTest SE controllers, the HSM is connected to J28 on the Model

controllers 493.42 System I/O board mounted in the rear panel chassis. The
System I/O board controls a single HSM.

How to Create a Program and Control Channel

1. “Allocate and name the output resource” on page 45.

2. “Specify the channel type” on page 46.

3. “Specify the station power source” on page 46.

4. “Specify the update rate” on page 47.

5. “Enable optional compensators” on page 47.

6. “Define the control feedbacks” on page 47.

Station Builder

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 Creating Program Channels

Task 1 Allocate and name the output resource

The type of controller you have determines the valve drivers and
analog output resources that appear in the Output Hardware
Resources list.

• A valve driver is an internal electronic module that controls a

servovalve. (Valve drivers are not available with CTM or AP
programmers.)

• Analog outputs are connectors located on the chassis rear panel.

Analog output resources can be used to send commands to an
external valve driver or external controller (±10 volts output).

• A calculated output is a value generated by a user-defined

algebraic formula. For more information, see “About Calculated
Outputs” on page 42.

To allocate a program channel resource:

1. In the Station Builder navigation pane, select Channels.

2. On the Output Hardware Resources list, select the resource you

want to allocate, and then click +.

3. In the Internal Name box, select or type the desired name.

4. Optional—in the Display Name box, type the desired name.

Note For more information on naming your hardware resources, see
“How to Allocate Hardware Resources” on page 38. It is good
practice to keep your resource names short, since long names
may not be visible in all windows.

Station Builder

Available hardware resources

Allocate a resource by clicking +.
Return a resource by clicking –.

Model 793.00 System Software 45

 Creating Program Channels

Task 2 Specify the channel type

In the Type list, select Program and Control.

Note If you allocate a valve driver, Program and Control is selected

automatically.

In the Type list, select the desired channel type.

Task 3 Specify the station power source

1. Click the General tab.

2. In the Power list, select the desired power source for this channel.
Note For more information on Power selections, see “About the Power
Control” on page 44.
Station Builder

In the Power list, select the station power source.

46 Model 793.00 System Software

 Creating Program Channels

Task 4 Specify the update rate

On the General tab, select the desired update rate in the Update Rate
list.

Note For more information on system rates, see “About Update Rates”
on page 42.

Set the Update Rate.

Task 5 Enable optional compensators

On the General tab:

• Select the APC check box to enable the APC (amplitude and
phase control) compensator for the selected channel.

• Select the AIC check box to enable the AIC (adaptive inverse
control) compensator for the selected channel.
Note If you did not purchase the APC or AIC compensator options, the
boxes will be unavailable.

Select the compensator

check box to enable it for the
current channel.

Station Builder

Task 6 Define the control feedbacks

See “Creating Control Modes” on page 60.

Model 793.00 System Software 47

 Creating Program Channels

How to Create a Program with Feedback Channel

1. “Allocate and name the output resource” on page 48.

2. “Specify the channel type” on page 49.

3. “Specify the update rate” on page 49.

4. Optional—“Enable optional compensators” on page 50.

5. “Define the feedback signal” on page 51.

Task 1 Allocate and name the output resource

1. In the Station Builder navigation pane, select Channels.

2. On the Output Hardware Resources list, select the resource you

want to allocate, and then click +.

3. In the Internal Name box, select or type the desired name.

4. Optional—in the Display Name box, type the desired name.

Note For more information on naming your hardware resources, see
“How to Allocate Hardware Resources” on page 38. It is good
practice to keep your resource names short, since long names
may not be visible in all windows.

Available hardware resources

Allocate a resource by clicking +.
Return a resource by clicking –.
Station Builder

48 Model 793.00 System Software

 Creating Program Channels

Task 2 Specify the channel type

In the Type list, select Program w/Feedback.

In the Type list, click the desired channel type.

Task 3 Specify the update rate

On the General tab, select the desired update rate in the Update Rate
list.

Note For more information on system rates, see “About Update Rates”
on page 42.

Set the Update Rate.

Station Builder

Model 793.00 System Software 49

 Creating Program Channels

Task 4 Enable optional compensators

On the General tab:

• Select APC to enable the APC (amplitude and phase control)

compensator for the selected channel.

• Select AIC to enable the AIC (adaptive inverse control)

compensator for the selected channel.
Note If you did not purchase the APC or AIC compensator options, the
boxes will be unavailable.

Select the compensator

check box to enable it for
the current channel.
Station Builder

50 Model 793.00 System Software

 Creating Program Channels

Task 5 Define the feedback signal

1. Click the Control Modes tab.

2. Allocate an analog input resource, rename it as desired, and

define the dimension and units for the feedback signal.
Note This feedback signal can be used for command compensation or
data acquisition.

Note For more information on control modes, see “Creating Control

Modes” on page 60.

On the Control Modes tab, allocate a feedback

resource, and set the dimension and units.

Station Builder

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 Creating Program Channels

How to Create a Command Plus Error Channel

1. “Allocate and name the output resource” on page 52.

2. “Specify the channel type” on page 53.

3. “Specify the update rate” on page 53.

4. “Define the feedback signal” on page 54.

Task 1 Allocate and name the output resource

1. In the Station Builder navigation pane, select Channels.

2. On the Output Hardware Resources list, select the resource you

want to allocate, and then click +.

3. In the Internal Name box, select or type the desired name.

4. Optional—in the Display Name box, type the desired name.

Note For more information on naming your hardware resources, see
“How to Allocate Hardware Resources” on page 38. It is good
practice to keep your resource names short, since long names
may not be visible in all windows.

Available hardware resources

Allocate a resource by clicking +.
Return a resource by clicking –.
Station Builder

52 Model 793.00 System Software

 Creating Program Channels

Task 2 Specify the channel type

In the Type list, select Command Plus Error.

In the Type list, click the desired channel type.

Task 3 Specify the update rate

On the General tab, select the desired update rate in the Update Rate
list.

Note For more information on system rates, see “About Update Rates”
on page 42.

Set the Update Rate.

Station Builder

Model 793.00 System Software 53

 Creating Program Channels

Task 4 Define the feedback signal

1. Click the Control Modes tab.

2. Allocate an analog input resource, rename it as desired, and

define the dimension and units for the error signal.

On the Control Modes tab, allocate a feedback resource for the

external controller error signal, and set the dimension and units.

Note For more information on control modes, see “Creating Control

Modes” on page 60
Station Builder

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 Creating Program Channels

How to Create a Program-Only Channel

1. “Allocate and name the output resource” on page 55.

2. “Specify the channel type” on page 56.

3. “Specify the update rate” on page 57.

4. “Specify the dimension and units of the program signal” on page

57.

Task 1 Allocate and name the output resource

1. In the Station Builder navigation pane, select Channels.

2. On the Output Hardware Resources list, select the resource you

want to allocate, and then click +.

3. In the Internal Name box, select or type the desired name.

4. Optional—in the Display Name box, type the desired name.

Note For more information on naming your hardware resources, see
“How to Allocate Hardware Resources” on page 38. It is good
practice to keep your resource names short, since long names
may not be visible in all windows.

Available hardware resources

Allocate a resource by clicking +.
Return a resource by clicking –.

Station Builder

Model 793.00 System Software 55

 Creating Program Channels

Task 2 Specify the channel type

In the Type list, select Program Only.

In the Type list, click the desired channel type.

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56 Model 793.00 System Software

 Creating Program Channels

Task 3 Specify the update rate

On the General tab, select the desired update rate in the Update Rate
list.

Note For more information on system rates, see “About Update Rates”
on page 42.

Set the Update Rate.

Task 4 Specify the dimension and units of the program signal

On the General tab, set the dimension and display units of the
outgoing program signal.

Note This control is only displayed for Program-Only channels.

Set the dimension and display units for the

outgoing program signal.
Station Builder

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 Creating Program Channels

How to Program a Eurotherm Temperature Controller

For TestStar IIs and TestStar IIs AP controllers, the J51 connector (on
the back of the controller chassis) supports two-way communication
with Eurotherm Series 2200/2400 Temperature Controllers. Special
resources must be added to the .hwi file to accommodate this
configuration.

For FlexTest IIm, FlexTest GT, or TestStar IIm controllers, use the
J50A–J50D serial connectors on either the 498 RS-485 transition
module (FlexTest IIm) or 493.71 transition module (FlexTest GT,
TestStar IIm) to program and control one or more Series 2200/2400
Eurotherm Temperature Controllers.

For FlexTest SE controllers, use the Debug Serial Port on the Model
498.96 Processor module via a RS232/RS485 Converter to connect to
one or more Eurotherm Temperature Controllers.

Follow these steps to program a Eurotherm controller:

1. Create a new or open an existing station configuration file.

2. In the Station Builder navigation pane, select Channels

3. In the Output Hardware Resources list, select Temp Control

1-Output, and then click +.
Note When you allocate this resource, the channel type will be set to
Program w/Feedback and the update rate will be set to Low
Rate automatically.

4. Click the Control Modes tab.

5. In the Input Hardware Resources list, select Temp Control

1-Input, and then click +.

6. In the Internal Name box, select or type the desired resource

name.
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 Creating Program Channels

Add the Analog Output

resource and rename it.

Channel type and

update rate are
selected automatically.

Allocate and rename the

temperature controller input
resource.

Specify the dimension and

units for the program.

7. Optional—in the Display Name box, type the desired display

name (example: Temperature).

8. Specify the Dimension and Display Units for the program signal
(example: Temperature/deg_C).

9. Optional—If you will monitor thermocouple feedback for data

acquisition, connect the external thermocouple output. Open the
Auxiliary Inputs panel to allocate an additional auxiliary input as
shown below.

To monitor an additional
thermocouple feedback,
allocate an additional input
resource as an auxiliary
data channel.
Station Builder

10. Save the station configuration file.

Model 793.00 System Software 59

 Creating Program Channels

Creating Control Modes

About Control Modes You must define at least one control mode for each Program and
Control channel you create. The system software supports the
following types of control modes:

• PIDF control modes

Use PIDF control modes for normal testing. Proportional, integral,

derivative, and feed forward gain adjustments are available to tune
the servo-loop response. See “How to Create a PIDF Control
Mode” on page 62.

• CLC (channel limited channel) control modes

Use CLC control modes for specimen installation and removal.

Channel limited channel modes require two feedback signals. The
first one is used as the active feedback (it is normally
displacement) and the second one is used as the limiting feedback
(it is normally force). When you command the actuator with a
channel limited channel mode, the controller will not allow the
actuator to exceed limits specified on either the master or limiting
channels. See “How to Create a CLC Control Mode” on page 63.
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 Creating Program Channels

• Dual Compensation control modes

Use a dual compensation control mode when you want to provide

programming and control on a channel whose feedback is
unsuitable for maintaining closed-loop control.
Note Sensor feedback may be unsuitable as control feedback if it is
too noisy (e.g. force feedback), or if it possesses only dynamic
characteristics (e.g. accelerometer feedback).

Dual compensation modes require two feedback signals. The

primary feedback is a more stable signal that is used by the PIDF
controller to maintain closed-loop control. The secondary
feedback is used for command compensation, and is the
dimension you actually program in. See “How to Create Dual
Compensation Control Modes” on page 64.
Note Dual compensation is also known as “mixed-mode”
compensation.

About Calculated Inputs

In addition to the regular input resources installed in your controller,
you can also assign a calculated input for control feedback or data
acquisition.

Calculated input values are determined by applying a user-defined

mathematical equation to the specified signal values. For information
on creating new calculations, see “Creating Calculated Resources” on
page 66.

License requirements Calculated inputs and calculated outputs are optional features which
require separate licenses. For example, you may have a calculated
inputs license and not have a calculated outputs license.

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 Creating Program Channels

How to Create a PIDF Control Mode

1. In the Station Builder navigation pane, expand the Channels list,
and then select the channel this mode will be used on.

2. On the Control Modes tab, select the desired input hardware

resource or input calculation, and then click +.

• If the feedback signal will be conditioned by your controller,

you should allocate an AC or DC conditioner resource.

• If you are using an externally conditioned signal, you should

allocate an analog input resource.

• If you are using calculated inputs for control feedback or data

acquisition, you should allocate a <<Calculated>> resource.

When you allocate an AC conditioner feedback resource in the

Station Builder application, the application automatically renames
the resource Displacement, and sets the dimension to Length.
When you allocate a DC conditioner resource, the application
automatically renames the resource Force, and sets the dimension
to Force.

3. In the Internal Name box, select or type the desired name.

4. Optional—in the Display Name box, type the desired name.

Note For more information on naming hardware resources, see “How to
Allocate Hardware Resources” on page 38. Keep your resource
names short, since long may not be visible in all windows.

5. Set the Dimension and Display Units for the feedback signal.
Station Builder

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 Creating Program Channels

How to Create a CLC Control Mode

CLC control modes require two feedback signals; one from each of the
first two control modes on the CLC-controlled channel. Before creating
a CLC control mode, ensure that these feedbacks signals have been
allocated and appropriately named.

1. In the Station Builder navigation pane, expand the Channels list,

and then select the channel CLC control mode will be used on.

2. Select the Include CLC control mode check box.

CLC control mode automatically uses the feedback signals from the
first two control modes on the selected channel. The first feedback
selected in Station Builder is the active feedback (typically
displacement). The second feedback selected is the limiting feedback
(typically force).

CLC mode is automatically named, based on the name of the first two
control modes. This name does not appear on the Station Builder’s
channel control mode list, though it is displayed in the control mode
lists on Station Manager and other applications.

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 Creating Program Channels

How to Create Dual Compensation Control Modes

Dual Compensation control modes require two feedback signals; a
more stable primary feedback (for PIDF closed-loop control), and a
secondary feedback (for command compensation). Before creating a
dual compensation control mode, ensure that you have defined
channel control mode or auxiliary input feedback signals appropriate
for dual-compensation control.

1. In the Station Builder navigation pane, expand the Channels list,

and then select the channel this mode will be used on.

2. In the Station Builder navigation pane, select the feedback signal

you want to use as the dual-compensation mode’s primary
feedback.
Note The primary feedback signal (typically displacement) is used to
maintain closed-loop control. This signal will be designated as
the Base control mode on the Edit Dual Compensation
Modes window.
3. On the panel, select Edit under Dual Compensation Modes.

4. In the Available Signals list, select the feedback signal you want to
use as the dual-compensation mode’s secondary feedback (this
will also be the dimension you program in), and then click +.

5. In the Edit Dual Compensation Modes window:

A. Select the Compensation Type, and then click OK.

B. Rename the dual compensation mode as appropriate.

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 Creating Program Channels

Allocate the
Click OK to create the dual
feedback signal to
Select the type of compensation mode.
be used by the
compensation control. compensator.

About Signal Stabilization

Feedback signals can be integrated into the composite command to act
as a stabilizing factor. These stabilization signals are primarily used in:

• High-mass systems equipped with Delta P (differential pressure)

sensors

• High-speed systems equipped with accelerometers

How to Create a Control Mode Stabilization Signal

1. In the Station Builder navigation pane, select the mode you want
to stabilize.

2. In the Input Hardware Resources list, select the analog input

resource that will accommodate the stabilization signal, and then
click + in the Stabilization group box.
Station Builder

For example, allocate a DC conditioner for a delta P sensor input.

Allocate an analog input resource for an externally-conditioned
accelerometer input.

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 Creating Program Channels

3. Rename the stabilization resource as required.

Note If you are using stabilization feedback for more than one control
mode on a channel, it is important that you assign a unique
name to each stabilization signal. Doing this will avoid duplicate
naming conflicts (and the resulting error messages).

4. Set the Dimension and Display Units for the stabilization signal.

Allocate a resource for

stabilization feedback.
Delta P sensors typically use
DC conditioners.
Accelerometers are typically
conditioned externally.

Creating Calculated Resources

About Calculated In order to use calculated inputs and outputs in your test, you must
Resources add calculated resources to your station with the Station Builder
application.

Calculated inputs A resource labeled <<Calculated>> appears in the hardware list for
control modes, stabilization feedback, external command inputs, and
auxiliary inputs. This resource is not removed from the list when it is
assigned, so that it can be used as many times as necessary.

When you open the station with the Station Manager application, any
input resources that are mapped to the <<Calculated>> resource are
created as calculated input channels. Some calculated input channels
will be defined relative to a control channel, while others will be in the
auxiliary list.
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Calculated outputs You can create a calculated output by assigning the <<Calculated>>
resource as your programming output resource.

Note Control channels mapped to the <<Calculated>> resource will not

have an equation, rather they will produce a signal that will be
referenced in other equations.

You can also use the Station Builder Calculated Outputs panel to add
calculated output resources to your station.

Once you have defined the calculation resources needed to run your
test, you must use the Station Manager application to specify the
equation used for each calculation. For more information, see
“Calculation Editor Window” on page 459.

License requirements Calculated inputs and calculated outputs are optional features which
require separate licenses. For example, you may have a calculated
inputs license and not have an calculated outputs license.

How to Create a Calculated Output Resource

1. In the Station Builder navigation pane, select Calculated
Outputs.

2. On the Hardware Resources list, select the resource you want to

allocate, and then click +.

3. In the Internal Name box, select or type the desired name.

4. Optional—in the Display Name box, type the desired name.

5. Set the Dimension and Display Units for the calculated output
signal.

You will define the calculation with the Station Manager application.
For more information, see “Calculation Editor Window” on page 459.

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 Creating Program Channels

How to Create a Calculated Input Resource

Control mode inputs To create a calculated input resource for control modes, complete the
following procedure:

1. In the Station Builder navigation pane, select Channels.

2. On the Control Modes tab, select the <<Calculated>> resource

from the Input Hardware Resources list, , and then click +.

3. In the Internal Name box, select or type the desired name.

4. Optional—in the Display Name box, type the desired name.

5. Set the Dimension and Display Units for the calculated input
signal.

Auxiliary inputs To create a calculated input resource for auxiliary inputs, complete the
following procedure:

1. In the Station Builder navigation pane, select Auxiliary Inputs

2. On the Hardware Resources list, select the <<Calculated>>

resource, and then click +.

3. In the Internal Name box, select or type the desired name.

4. Optional—in the Display Name box, type the desired name.

5. Set the Dimension and Display Units for the calculated input
signal.

You will define the calculation with the Station Manager

application. For more information, see “Calculation Editor
Window” on page 459.
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 Creating Readouts

Creating Readouts
About Readouts
Readouts are used to send station signals to external readout devices
such as oscilloscopes and meters.

How to Create a Readout

1. In the Station Builder navigation pane, select Readouts.

2. On the Hardware Resources list, select the resource you want to

send station signals through, and then click +.

3. In the Internal Name box, select or type the desired name.

4. Optional—in the Display Name box, type the desired name.

Allocate an analog output resource.

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 Creating Digital Inputs

Creating Digital Inputs

About Digital Inputs
You use digital input resources to monitor digital signals from external
switches.

Digital inputs can be monitored from the Station Manager Digital I/Os
window, or with the MPT Digital Input process.

How to Create Digital Inputs

1. In the Station Builder navigation pane, select Digital Inputs.

2. On the Hardware Resources list, select the resource you want to

monitor digital inputs through, and then click +.

3. In the Internal Name box, select or type the desired name.

4. Optional—in the Display Name box, type the desired name.

Allocate a digital input resource.

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Creating Digital Outputs

About Digital Outputs
You use digital output resources to send digital signals to external
switches and logic devices.

Digital outputs can be monitored and changed from the Station Manager
Digital I/Os window, or with the MPT Digital Output process.

How to Create Digital Outputs

1. In the Station Builder navigation pane, select Digital Outputs.

2. On the Hardware Resources list, select the resource you want to

send digital outputs through, and then click +.

3. In the Internal Name box, select or type the desired name.

4. Optional—in the Display Name box, type the desired name.

Allocate a digital output resource.

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 Creating Auxiliary Inputs

Creating Auxiliary Inputs

About Auxiliary Inputs
Auxiliary inputs are used to monitor sensor feedback or analog inputs
for readout or data acquisition.

You can monitor auxiliary input signals on the built-in Station Manager
scope and meters. You can acquire data on auxiliary input signals with
the Basic TestWare and MultiPurpose TestWare applications.

Note On the scope and meters, auxiliary input signals that start with the
same name as a control channel will be displayed in the control
channel's signal list (instead of in the Others signal list). To ensure
that your auxiliary input signals appear in the Others signal list, use
a unique name for your auxiliary input signals.

Reconfigurable signals As an option, you can define certain auxiliary inputs as reconfigurable.
If you check the Reconfigurable checkbox, the signal name and
dimension can be changed in Station Manager, without returning to
Station Builder. You must be at the Configuration access level in
Station Manager to make these signal configuration changes.

The Print Preview window, in both Station Builder and Station

Manager, shows if an auxiliary input has been defined as
reconfigurable.

If required, define
signal as
reconfigurable
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How to Create an Auxiliary Input

1. In the Station Builder navigation pane, select Auxiliary Inputs.

2. On the Hardware Resources list, select the resource you want to

monitor the auxiliary input signal with, and then click +.

3. In the Internal Name box, select or type the desired name.

4. Optional—in the Display Name box, type the desired name.

5. Set the Dimension and Display Units for the auxiliary input
signal.

Allocate the analog input resources

you want to use for auxiliary data.

6. For systems with the reconfigurable signal option, a

Reconfigurable checkbox is displayed. Check this box if you will
need to change the name or dimension of your signal in Station
Manager.

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 Enabling External Command Inputs

Enabling External Command Inputs

About External Command Inputs
Your controller can process programming received from an external
controller or function generator while maintaining all other closed-loop
control functions.

Note Your controller cannot recognize mode switches in external program

input signals.

How to Enable an External Command Input

1. In the Station Builder navigation pane, select Channels.

2. Select the channel that the external input will be associated with.

3. On the External Command tab, allocate an analog input

resource to accommodate the command signal input, and then
rename it.

4. Set the Dimension and Display Units for the input signal.

Allocate an analog input

resource for external command
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Setting Up Remote Setpoint Adjust

About Remote A Remote Setpoint Adjust (RSA) control is an optional, stand-alone
Setpoint Adjust hardware device that uses an encoder to control actuator setpoints.
Access the Remote Setpoints panel to allocate an encoder resource
(and its associated RSA control).
As an option, an Enable Switch tab allows you to assign a digital
input for a switch to turn the RSA control on and off.

How to Set Up a Remote Setpoint Adjust Control

1. In the Station Builder navigation pane, select Remote Setpoints
to display the Remote Setpoints panel and Enable Switch tab.

2. On the Encoder Resources list, select the encoder resource you

want to use, and then click +.

3. In the Internal Name box, select or type the desired name for the
RSA control knob.

4. Optional—in the Display Name box, type the desired name for
the RSA control knob.

5. Optional—on the Enable Switch tab, select the Digital Switch

Resource list to allocate a digital input for an RSA control on/off
switch. As required, in the Display Name box, type the desired
name for the RSA switch.

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 Working with Station Configuration Files

Working with Station Configuration Files

How to Open a Station Configuration File
1. On the File menu, select Open.

2. In the Open Configuration window, select the desired .cfg file,

and then click Open.

Click the file and

then click Open.
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How to Save a Station Configuration File

On the File menu, select Save. To save the file with a different name,
select Save As.

Name the file and

then click Save.

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 Working with Station Configuration Files

How to Preview a Station Configuration File

On the File menu, select Print Preview to view the station
configuration file on-screen.A toolbar facilitates access and display of
configuration file changes. See “Print Preview Toolbar” on page 88.

Print Preview window

Note Items preceded by an asterisk (*) have been modified since the
configuration file opened. In addition, you can choose to highlight
these changes by selecting the Enable Change Highlighting icon
on the Print Preview toolbar.

How to Print a Station Configuration File

Station Builder

Click the Print icon on the Station Builder Print Preview window
toolbar or click Print icon on the Station Builder toolbar, to print the
current station configuration.

Click Print to File on the Station Builder File menu to save the current
station configuration as a separate text file.

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 Creating Stations to Run Concurrently

Creating Stations to Run Concurrently

If you plan to run tests on multiple stations simultaneously, you must
make sure each station allocates unique controller resources.

Note Multi-station testing is supported by FlexTest IIm, FlexTest CTM,

TestStar IIm, FlexTest CTC and FlexTest GT hardware only.

The Station Builder application allows you to open (or create) multiple
configuration files at the same time.

All open stations allocate resources from the same resource pool (.hwi
file). To avoid resource conflicts, resources already allocated in one
open station are removed from the resource lists of other open
stations. When you close a station, the resources defined in that station
are returned to the resource lists of the other open stations.

If you attempt to open a configuration file that defines resources used

by another open configuration file, the Station Builder application
displays an error. For example, if a station that defines the 497.15 VD-6
in chassis 2 is open, and you try to open another station that defines
the same valve driver, the following error message appears:

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 Creating Stations to Run Concurrently

How to Create Stations that Run Concurrently

1. Create your first station configuration file.

2. While your first station configuration file is open, select New on

the File menu to create your next station.

A new configuration file will open, however, the resources allocated to

the first station will be removed from the resource lists of your new
station configuration file.

Editing concurrent When editing a station that is running concurrently, it is recommended

stations that all other concurrent station configurations be opened as “read
only” files. This helps prevent you from saving accidental changes that
might be made to the “read only” files during the editing process.
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 Station Builder Window

Station Builder Window

Main Menus—manage your configuration Toolbar—the toolbar buttons provide quick

files with the commands on the main menus. access to common commands and windows.

Navigation Pane—the station Your hardware

resources you create are organized resources.
here. Panels—station resource Station Builder
properties are specified here.

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 Station Builder Window

The Station Builder window displays Station Builder Configuration

windows.

Station Builder Window

ITEM DESCRIPTION
Main Menu bar Provides menus to manage the Station Builder application.
Toolbar Provides quick access to common Station Builder commands.
Station Configuration Displays the currently selected station configuration. Use this
Window window to create and display station configurations.
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 Station Builder Window

Main Menus

Electronic Documentation
New
About
Open
Close Cascade
Save Tile
Save As Arrange Icons
Print Station Toolbar
Print Preview Status Bar
Printer Setup
Print to File
System Resources
Exit

The Main Menu bar provides menus to manage the Station Builder
application. The toolbar has some of the more frequently used
commands.

Main Menu Bar

ITEM DESCRIPTION
File Has commands that open, save, and print station configurations.
Window Has commands that change the Station Builder window’s
appearance.
Help Has commands that access electronic documentation and application
version number information.

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 Station Builder Window

File Menu

This menu’s commands create, open, save, and print station

configurations.

File Menu
ITEM DESCRIPTION
New Opens a new, untitled station configuration.
Open Displays the Open Configuration window.
Close Closes the current Station Configuration window.
Save Saves the current station configuration file.
Save As Displays the Save Configuration As window.
Print Station Prints the station configuration.
Print Preview Displays the Station Builder Print Preview window.
Printer Setup Displays the printer setup window for your printer.
Print to File Displays the Print to File window.
System Resources Displays the System Resources window.
Station Builder

Exit Quits the Station Builder application.

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 Station Builder Window

Open Configuration
Window

Path File > Open

This window opens existing station configuration files.

Open Configuration Window

ITEM DESCRIPTION
Look In Selects directories and drives where configuration files are located.
File Name Displays the selected file’s name.
Files Of Type Selects the type of files displayed. The extension for configuration
files is (*.cfg).
Open As Read-Only Opens a read-only copy of the selected station configuration file. A
read-only file can be edited, but needs a new name to be saved.

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 Station Builder Window

Save Configuration As
Window

Path File > Save or Save As

This window specifies the file name and location of the configuration
file being saved.

Selecting Save to save a new, unnamed station configuration also

displays this window.

Save Configuration As Window

ITEM DESCRIPTION
Save In Selects the location where the configuration file is saved.
File Name Specifies the name of the station configuration file being saved.
Save As Type Selects the file type. The default Configuration File (*.cfg) selection
automatically appends a .cfg extension to the file name.
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Station Builder Print

Preview Window

Path File > Print Preview

This window displays an on-screen preview of the configuration file

printout. A toolbar facilitates access and display of configuration file
changes.

Asterisks (*) identify items modified since the configuration file was
last loaded or saved. In addition, you can choose to highlight these Station Builder
changes by selecting the Enable Change Highlighting icon on the
Print Preview toolbar.

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 Station Builder Window

Print Preview Toolbar

Enable/Disable Change Highlighting

Refresh Print
Previous Change
Next Change

Print Preview Toolbar

ITEM DESCRIPTION
Next Change Goes to the next change on the Print Preview window.
Previous Change Goes to the previous change on the Print Preview window.
Refresh Allows you to see current configuration set changes without closing and
reopening the Print Preview window. If change highlighting is enabled,
the current configurations changes are highlighted.
Enable/Disable Change Allows you to enable or disable highlighting of configuration changes.
Highlighting

Print Prints the current configuration file.

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 Station Builder Window

Print to File Window

Path File > Print to File

This window saves configuration files as text (*.txt) files.

Print Configuration to File Window

ITEM DESCRIPTION
Save In Selects the location where the text file is saved.
File Name Specifies the name of the text file.
Files Of Type Selects the file type. The default Text File (*.txt) selection
automatically appends a .txt extension to the file name.

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 Station Builder Window

System Resources
Window

Path File > System Resources

Click + for more detail

Click - for less detail

This window displays a tree view of all system resources.

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 Station Builder Window

Window Menu

This menu’s commands change the appearance of the Station Builder

application.

Window Menu
ITEM DESCRIPTION
Cascade Cascades open Station Configuration windows.
Tile Tiles open Station Configuration windows.
Arrange Icons Places minimized Station Configuration windows at the bottom of
the Station Builder window.
Toolbar Displays and hides the Station Builder window’s toolbar.
Status Bar Displays and hides the Station Builder window’s Status Bar.
Open Stations Lists the file names of open station configurations. Select a name to
display the file’s Station Configuration window.

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 Station Builder Window

Help Menu

This menu’s commands access electronic documentation and display

general application information.

Help Menu
ITEM DESCRIPTION
Electronic Documentation Opens electronic documentation help.
About Opens the About Station Builder window.

This window displays the Station Builder application version number

and copyright information.
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 Station Builder Window

Toolbar
Save
Help
Open Print Preview

Print Station
System Resources

Toolbar buttons provide quick access to common commands and

windows. The Main Menu also has these commands.

Toolbar
ITEM DESCRIPTION
Open Displays the Open Configuration window, used to open existing
station builder configurations.
Save Saves the station configuration under its current name. Opens the
Save Configuration As window if the station is not yet named.
Print Station Prints the station configuration.
Print Preview Displays a print preview of the station configuration.
System Resources Opens the System Resources window which displays a tree view of
all system resources.
Help Displays on-line help.

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 Station Configuration Window

Station Configuration Window

Navigation Pane Panels

The Station Configuration window creates, displays, and modifies

station configurations.

Station Configuration Window

ITEM DESCRIPTION
Navigation Pane Displays a tree view, by resource type, of the station configuration.
Selections within the pane determine what Station Configuration
panels display.
Station Builder

Panels Define the resources used in the station configuration. Panels change
depending on the resource type selected in the navigation pane.

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Navigation Pane

Tree View Configuration name

Resource Types

The navigation pane displays a tree view of the station configuration.

The view is organized by how station resources are used.

Navigation Pane (part 1 of 2)

ITEM DESCRIPTION
Show Internal Name Identifies each assigned resource in the Tree View by its Internal
name rather than its Display name.
The Station Configuration panels’ Internal name and Display
name entries name assigned resources.
Tree View Displays an expandable view of the station configuration, organized
by how station resources are used.

Selecting a resource displays Station Configuration window panels

appropriate for the type of resource selected.

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 Station Configuration Window

Navigation Pane (part 2 of 2)

ITEM DESCRIPTION
Resource Type Your system may not have every Resource Type listed below.
Channels—select to display the Channels panel, which assigns
input and output hardware resources to your station configuration.
Auxiliary Inputs—select to display the Auxiliary Inputs panel,
which assigns resources whose input signals supply additional test
data.
Readouts—select to display the Readouts panel, which assigns
resources whose output signals go to external analog readout
devices, typically meters and oscilloscopes.
Digital Inputs—select to display the Digital Inputs panel, which
assigns resources to input signals from external logic devices and
switches.
Digital Outputs—select to display the Digital Outputs panel,
which assigns resources to output signals to external logic devices
and switches.
Calculated Outputs—select to display the Calculated Outputs
panel, which assigns a resource to output a signal resulting from a
user-defined calculation.
Remote Setpoints—select to display the Remote Setpoints panel,
which assigns resources to input signals from Remote Setpoint
Adjustment (RSA) controls.

Expanding channel Defining a resource places a plus (+) sign next to its Resource Type.
lists Click on the plus sign to see the defined resources.

Expand
Contract

No resources defined
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Channels Panel
Path Navigation pane > Channels

This panel assigns resources whose signals create control channels.

Channels Panel (part 1 of 2)

ITEM DESCRIPTION
Display Name Gives the channel a name used for display purposes. Names can
Station Builder
have up to 30 characters.
Internal Name Gives the channel a name used for internal purposes. Names can
have up to 30 characters.

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 Station Configuration Window

Channels Panel (part 2 of 2)

ITEM DESCRIPTION
Resource Identifies the hardware or calculated resource used to output the
program or command signal.
Type Selects the channel type. See “About Program Channels” on page 40.
Prefix signal names with For single-channel stations: Clearing this checkbox removes the
channel name channel name from the display name of all signals on the channel.
For multiple-channel stations: Clearing this checkbox removes
the channel name from the display name of all feedback and
mode-specific signals.
Note For multiple-channel stations, the channel prefix will not be
removed from channel-specific signals.

The default setting for this signal name attribute is “checked”.

Include CLC Control Mode Creates a Channel-Limited-Channel (CLC) control mode to be used
when installing and removing specimens. CLC is for Program and
Control channels only.
Two control modes must be defined on the channel before this CLC
control mode becomes available.

Creates a new channel, assigning the highlighted Output Hardware

Resource to the channel.

Eliminates the channel and returns the Resource to Output

Hardware Resources.

Swaps the current Resource selection with the item highlighted in

Output Hardware Resources.
General This tab specifies the channel’s general characteristics.
Control Modes This tab specifies the channel’s control modes.
External Command This tab specifies an external command source for the channel.
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General Tab
Path Navigation pane > Channels > Channels panel > General tab

Tab for a Type selection of:

• Program and Control
• Program w/ Feedback
• Command Plus Error

Tab for a Type selection of:

• Program Only

This tab specifies the general characteristics of a control channel.

General Tab
ITEM DESCRIPTION
Power Specifies the channel’s power source. See “About the Power Control”
on page 44 for more about this control.
Update Rate Specifies the channel’s update rate. see “About Update Rates” on
page 42 for more about system rates.
Compensators Makes selected compensation available on the channel. This is an
option and these controls may not be available on your system.
APC Select to enable Amplitude and Phase Control (APC).
AIC Select to enable Adaptive Inverse Control (AIC).
Dimension Sets the dimension represented by the program signal of a Program
Station Builder
Only channel.
Display Units Sets the display units used with the Dimension selection.

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 Station Configuration Window

Control Modes Tab

Path Navigation pane > Channels > Channels panel >
Control Modes tab

This tab assigns the resources that produce control mode, stabilization,
and dual compensation signals.

Control Modes Tab (part 1 of 2)

ITEM DESCRIPTION
Display name Gives the control mode a name used for display purposes. Names
can have up to 30 characters.
Internal name Gives the control mode a name used for internal purposes. Names
can have up to 30 characters.
Resource Identifies the input hardware resource (or calculated resource)
supplying the feedback signal used in the control mode.
Station Builder

Creates a new control mode, assigning the highlighted Input

Hardware Resource as the Resource that inputs the control mode
feedback signal.

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 Station Configuration Window

Control Modes Tab (part 2 of 2)

ITEM DESCRIPTION

Eliminates the control mode, returning the Resource to Input

Hardware Resources.

Swaps the current Resource with the highlighted Input Hardware

Resources selection.
Dimension Sets the dimension represented by the feedback signal.
Display Units Sets the display units used with the Dimension selection.
Stabilization Assigns the resource that inputs a signal used by the control mode
for stabilization.
Display Name Gives the stabilization signal input by the Resource a name used for
display purposes. Names can have up to 30 characters.
Internal Name Gives the stabilization signal input by the Resource a name used for
internal purposes. Names can have up to 30 characters.
Resource Identifies the hardware or calculated resource that inputs the
stabilizing signal.

Assigns the highlighted Input Hardware Resources as the

Resource for the stabilization signal.

Returns the Resource to Input Hardware Resources.

Dimension Sets the dimension represented by the stabilization signal.

Display Units Sets the display units used with the Dimension selection.
Dual Compensation Modes Identifies the control mode’s dual compensation modes.
Edit Opens the Edit Dual Compensation Modes window, used to
enable dual compensation modes.
Note The Edit button will be inactive until at least one control mode,
and either a second control mode or an auxiliary data channel is
defined.
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 Station Configuration Window

Edit Dual Compensation Modes Window

Path Navigation pane > Channels > Channels panel >
Control Modes tab > Edit

This window assigns the resources that produce dual compensation

signals.

Dual Compensation Modes Window (part 1 of 2)

ITEM DESCRIPTION
Base Control Mode Identifies the channel and the feedback signal going to the PIDF
controller.
Dual Compensation Modes Defines dual compensation modes.
Display Name Gives the control mode a name for display purposes. (In the default
name, the signal supplied to the compensator comes first.) Names
can have up to 30 characters.
Internal Name Gives the control mode a name for internal purposes. (In the default
name, the signal supplied to the compensator appears first.) Names
can have up to 30 characters.
Station Builder

Resource Identifies the feedback signal going to the compensator.

Compensation Lists the defined dual compensation modes that use this base control
Modes (unlabeled) mode.

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Dual Compensation Modes Window (part 2 of 2)

ITEM DESCRIPTION
Compensation Selects the type of compensation applied by the compensator.
Type
Amplitude Control Only—applies only amplitude control
compensation.
Mean and Amplitude Control—applies mean and amplitude
compensation.

Creates a new mode, assigning the highlighted Available Signals as

the Resource for the compensation feedback signal.

Eliminates the current mode, returning the Resource to Available

Signals.

Swaps the currently selected Resource with the Available Signals

selection.

Moves up or down in the Compensation Modes list, allowing you

to select one of the defined compensation modes.

Available Signals Lists signals that can be selected to supply feedback to the
compensator.

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 Station Configuration Window

External Command Tab

Path Navigation pane > Channels > Channels panel
> External Command tab

This tab assigns the resources that input external commands from an
external controller or function generator. This external signal can be
used to command the channel.

External Command Tab

ITEM DESCRIPTION
Display Name Gives the external command signal input by the Resource a name
used for display purposes. Names can have up to 30 characters.
Internal Name Gives the external command signal input by the Resource a name
used for internal purposes. Names can have up to 30 characters.
Resource Identifies the hardware or calculated resource that inputs the
external command signal.

Allocates the resource selected in Input Hardware Resources.

Returns the Resource to Input Hardware Resources.

Dimension Sets the dimension represented by the external command signal.

Display Units Sets the display units used with the Dimension selection.
Station Builder

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Auxiliary Inputs Panel

Path Navigation pane > Auxiliary Inputs

This panel assigns resources to input auxiliary signals.

Auxiliary Inputs Panel (part 1 of 2)

ITEM DESCRIPTION
Display Name Gives the auxiliary signal input by the Resource a name used for
display purposes. Names can have 30 characters.
Internal Name Gives the auxiliary signal input by the Resource a name used for
internal purposes. Names can have 30 characters.
Resource Identifies the hardware or calculated resource that inputs the
auxiliary signal.
Hardware Resources Lists hardware and calculated resources that can be selected to input
auxiliary signals.

Creates the auxiliary input, assigning the hardware or calculated

resource highlighted in Hardware Resources as the Resource that
inputs the auxiliary signal.

Eliminates the auxiliary input, returning the Resource to Hardware

Resources.

Swaps the current Resource with the highlighted Hardware

Station Builder
Resources selection.
Dimension Selects the dimensions represented by the auxiliary input signal.

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 Station Configuration Window

Auxiliary Inputs Panel (part 2 of 2)

ITEM DESCRIPTION
Display Units Selects the display units used with the Dimension selection.
Reconfigurable This checkbox is displayed for systems with the reconfigurable signal
option. When checked, the designated auxiliary input signal name
and dimension can be changed in Station Manager. See
“Reconfigurable signals” on page 72.
Station Builder

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Readouts Panel
Path Navigation pane > Readouts

This panel defines analog readout signals.

Readouts Panel
ITEM DESCRIPTION
Display Name The name of the readout signal output by the selected Resource
and used for display purposes. Signals can be given new names of
up to 30 characters.
Internal Name The name of the readout signal output by the selected Resource
and used for internal purposes. Signals can be given new names of
up to 30 characters.
Resource Identifies the hardware that outputs the analog readout signal.
Hardware Resources Lists available analog output hardware resources.

Makes the Hardware Resources selection the Resource that

outputs the readout signal.

Returns the Resource to Hardware Resources.

Swaps the current Resource with the highlighted Hardware

Resources selection.

Station Builder

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Digital Inputs Panel

Path Navigation pane > Digital Inputs

This panel defines digital input signals.

Digital Inputs Panel

ITEM DESCRIPTION
Display Name The name of the digital signal input by the selected Resource and
used for display purposes. Signals can be given new names of up to
30 characters.
Internal Name The name of the digital signal input by the selected Resource and
used for internal purposes. Signals can be given new names of up to
30 characters.
Resource Identifies the hardware that inputs the digital signal.
Hardware Resources Lists available digital input hardware resources.

Allocates the current Hardware Resources selection as the

Resource that inputs the digital signal.

Returns the selected Resource to Hardware Resources.

Swaps the current Resource with the highlighted Hardware

Resources selection.
Station Builder

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 Station Configuration Window

Digital Outputs Panel

Path Navigation pane > Digital Outputs

This panel defines digital output signals.

Digital Output Panel

ITEM DESCRIPTION
Display Name The name of the digital signal output by the selected Resource and
used for display purposes. Signals can be given new names of up to
30 characters.
Internal Name The name of the digital signal output by the selected Resource and
used for internal purposes. Signals can be given new names of up to
30 characters.
Resource Identifies the hardware that outputs the digital signal.
Hardware Resources Lists available digital output hardware resources.

Allocates the current Hardware Resources selection as the

Resource that outputs the digital signal.

Returns the Resource to Hardware Resources. Station Builder

Swaps the current Resource with the highlighted Hardware

Resources selection.

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 Station Configuration Window

Calculated Outputs Panel

Path Navigation pane > Calculated Outputs

Use the Calculated Outputs panel to identify each calculated output for
your test. In Station Manager, each calculated output identifies an
equation which can be used to define a calculated output signal.

Calculated Outputs Panel (part 1 of 2)

ITEM DESCRIPTION
Display Name The name of the calculated output used for display purposes. Signals
can be given new names of up to 30 characters.
Internal Name The name of the calculated output used for internal purposes.
Signals can be given new names of up to 30 characters.
Resource Typically used to identify the hardware that receives the calculated
output signal defined by an equation created in Station Manager. A
Calculated resource may also be selected.
Hardware Resources Lists available hardware or calculated resources.

Allocates the current Hardware Resources selection as the

Resource receives the calculated output signal.
Station Builder

Returns the Resource to Hardware Resources.

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Calculated Outputs Panel (part 2 of 2)

ITEM DESCRIPTION

Swaps the current Resource with the highlighted Hardware

Resources selection.

Dimension Selects the dimensions represented by the calculated output signal.

Display Units Selects the display units used with the Dimension selection.

Station Builder

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 Station Configuration Window

Remote Setpoints Panel

Path Navigation pane > Remote Setpoints

A Remote Setpoint Adjust (RSA) control is an optional, stand-alone

hardware device that uses an encoder to control actuator setpoints.
Access the Remote Setpoints panel to allocate an encoder resource
(and its associated RSA control).
As an option, an Enable Switch tab allows you to assign a digital
input for a switch to turn the RSA control on and off.
Station Builder

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Remote Setpoints Panel

ITEM DESCRIPTION
Display Name The name of the RSA control knob for display purposes. You can use
up to 30 characters.
Internal Name The name of the RSA control knob used for internal purposes. You
can use up to 30 characters.
Resource Identifies the selected encoder resource.
Encoder Resources Lists available encoder resources.

Allocates the resource selected in Encoder Resources.

Returns the Resource to Encoder Resources.

Swaps the current Resource with the highlighted Encoder

Resources selection.

Enable Switch tab Opens the Enable Switch tab which allows you to allocate a digital
input for an RSA on/off switch.
Display Name The name of the RSA on/off switch for display purposes. You can
use up to 30 characters.
Internal Name The name of the RSA on/off switch used for internal purposes. You
can use up to 30 characters.
Resource Identifies the selected digital switch resource.
Encoder Lists available Digital Switch resources.
Resources

Station Builder

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Station Builder

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 Station Manager
Chapter 3
Station Manager
Performing common Application Overview 119
tasks Getting Started with Station Manager 121
Configuration Files and Parameter Sets 123
How to Open a Station Configuration File 124
Setting Access Levels 129
Station Views 130
Calibrating Sensors and Configuring Feedback 131
How to Create a Sensor File 135
How to Assign a Sensor File 141
How to Assign a Sensor with a Transducer ID Module 146
How to Configure an Externally Conditioned Feedback Signal
148
How to Offset a Feedback Signal 150
Working with Readout Devices 158
How to Display Station Signals 177
How to Configure a Signal for External Readout 179
Working with External Commands 181
How to Enable and Run External Command Inputs 181
Applying Hydraulics and Clearing Interlocks 183
Working with Compensators 194
Running Tests 222
About Detectors 223
About Limit Detectors 226
How to Set Limit Detectors 227
How to Monitor Hardware Limit Detectors 234
About Error Detectors 235

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How to Set Error Detectors 236

How to Monitor Error Detectors 238
About Sensor Ranges and Detectors 239
About Digital Inputs/Outputs 243
About Digital Inputs 243
How to Configure Responses to Digital Input Signals 245
About the Event-Action Editor Window 246
How to Define a Custom Action 247
How to Manually Control Digital Output Signals 248
About Shunt Calibration 250
How to Perform a Shunt Calibration 251
About Program Outputs 253
How to Adjust Program Output Signals 253
How to Program with the Function Generator 255
How to Adjust Setpoint and Span During a Test 257
About the Optional Remote Setpoint Adjust 258
How to Configure Remote Setpoint Adjust Controls 258
About Channel Groups 259
How to Create a Master Command Group 261
How to Select a Master Command Group 262
Defining a Master Span Group 263
Using Rig Command (Park/Ride) 264
About Message Logs 266
How to Open a Message Log 267
How to Print a Message Log 268
How to Print the Message Log to File 268
How to Add a User Entry to the Message Log 269
How to Delete a User Entry from the Message Log 270
How to Define Which Messages Get Logged 271
How to Manually Archive a Message Log 272

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Window and control Station Manager Controls and Displays 273
descriptions Menu Bar 274
Station Manager Window Toolbar 275
Access Level 277
Station Manager Window Message Pane 278
File Menu 279
Open Station Window 281
Open Parameter Set Window 283
Save Parameters As Window 284
Delete Parameter Set Window 285
Delete Parameter Set Window 285
Print Preview Window 286
Print Parameters to File Window 288
Display Menu 289
Station Setup Window 290
Station Setup Window/Channel Status Panel Tabs 295
Station Setup Window/Inputs Panel Tabs 310
Station Setup Window/Drive Panel—Two Stage Valves 327
Station Setup Window/Drive Panel—Three Stage Valves 329
Station Setup Window/Tuning Panel Tabs 337
Station Setup Window/Compensators Panel Tabs 343
Station Setup Window/Readouts Panels 358
Station Setup Window/Auxiliary Inputs Panels 360
Station Setup Window/Station Signals Panel Tabs 363
Station Setup Window/Digital Input/Outputs Panel Tabs 367
Station Setup Window/Detectors Panel Tabs 373
Station Setup Window/Calculations Panels 384
Station Setup Window/Remote Setpoints Panels 390

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Station Manager

Meters Window 392

Scope Window 395
Setup for Scope Window 398
Message Logs Window 403
Message Log Add Entry Window 406
Message Log Print Window 407
Applications Menu 408
Tools Menu 409
Station Options Window 410
Channel Options Window 418
Sensor File Editor Window 442
Linearization Data Window 446
Event-Action Editor Window 448
Calculation Editor Window 459
Calculation Definition Panels 461
Parameters Definition Panel 477
Unit Assignment Set Editor Window 479
Help Menu 482
Application Controls Panels 483
Function Generator Control Panel 485
External Command Control Panel 493
Auto-Tuning Control Panel 495
Station Controls Panel 498
Station Controls Panel Toolbar 501
Signal Auto Offset Window 503
Detectors Window 504
Digital I/Os Window 508
Manual Command Window 510
Setpoint and Span Window 513
Remote Setpoint Adjust Window 515

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 Application Overview

Station Manager
Application Overview
The Station Manager application lets you:

• Create station parameter sets by assigning operational parameters

to the controller resources defined in station configuration files.

• Perform basic testing activities such as activating drive power,

gaining manual control of the actuator to install the specimen,
monitoring station signals, and starting and stopping tests.

Station Manager main window

Menu bar
Toolbar

Application
control panel

Station Controls panel

Message pane

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Station Manager

With the Station Manager window controls you can:

• Perform system calibration and tuning.

• Configure limit and error detectors.

• Define and apply an algebraic formula to a signal in order to

generate a calculated signal value.

• Configure signal compensation and stabilization.

• Control hydraulic pressure to the test station.

• Apply simple programs with the built-in function generator.

• Manage the execution of BTW and MPT tests.

• Monitor signals on the built-in scopes and meters.

All of the Station Manager application settings can be saved to a station
parameter set.

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 Getting Started with Station Manager

Station Manager
Getting Started with Station Manager
How to Start the Station Manager Application
Use the Windows Start menu to select the following:

Programs > MTS FlexTest or TestStar > Station Manager

When you first start the Station Manager application, the following
happens:

1. The System Loader utility starts and establishes a real-time

connection with your hardware components.

If the System Loader utility does not connect to the controller, an

error message appears and the Station Manager application quits.
Note On FlexTest™ series controllers, the Desktop Organizer utility starts
and displays the organizer taskbar.

2. The Station Manager application starts, and displays an Open

Station window.

For information on how to open a .cfg file, see ““How to Open a

Station Configuration File” on page 124.

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Station Manager

About the Demonstration Mode

The demonstration mode simulates a connection with your hardware
components allowing you to run the system software without applying
station power.

Use the Demo System Loader utility to start the demonstration mode if
you want to test a new station configuration or learn to use the system
software controls.

“Simulation” appears in the window status bars when in the

demonstration mode.

How to Start the Demonstration Mode

1. Start the Demo System Loader utility:

Start > Programs > MTS FlexTest or TestStar > Tools > Demo
System Loader

2. Start the Station Manager application:

Start > Programs > MTS FlexTest or TestStar > Station

Manager

When the Station Manager application starts, the Open Station

window appears automatically.

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 Configuration Files and Parameter Sets

Station Manager
Configuration Files and Parameter Sets
About Configuration Files
Station configuration files (extension .cfg) define how the Station
Manager application uses system resources in test stations. The Station
Builder application defines station configurations. For more about
defining station configurations, see Chapter 2, “Station Builder”.

About Station Parameter Sets

A station parameter set contains the settings needed by a station
configuration to run a test. These settings include everything from
tuning values to detector settings.

When you close a station configuration, you are prompted to save the
changes to the parameter set selected when the station opened.

The same station configuration may need different settings to run

different tests. You can create and save these settings in up to 15
parameter sets. When you open the station configuration, you can
select the appropriate parameter set needed to run the test.

Select the set

needed for your
test

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Station Manager

How to Open a Station Configuration File

1. Start the Station Manager application.

The Station Manager application will display the Open Station

window.
Note Before opening Station Manager, station power must be off and any
ongoing test must be stopped. You may also need to shut down
some applications connected to the station before you can open the
station.

2. In the Open Station window:

A. Select the name of the desired station configuration file.

B. In Parameter Sets, select the desired parameter set if

available.

C. Click to specify the station Interlock Chain.

Note Station Manager saves the last used interlock chain to the station
configuration file, and will attempt to restore it if currently available.

D. Optional—Click to Enable Remote Station Control (RSC).

For FlexTest™ series systems that include multiple RSCs, the

selected Interlock Chain determines which RSC will be
enabled.

RSC is not available in the Demonstration mode.

E. Click Open to open the configuration file.

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Station Manager
Select a station
configuration file

Select the
interlock chain

Select a parameter set Optional—Click

to enable RSC

See “Open Station Window” on page 281 for more information.

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 Configuration Files and Parameter Sets
Station Manager

How to Save a Parameter Set Under a New Name

1. In the Station Manager window’s File menu, select Save
Parameters As.

2. In the Save Parameters As window:

A. Enter the New Parameter Name.

B. Click Save.
Note Use the Station Manager window’s File menu Save
Parameters command to save updated parameter values
without changing the parameter set’s name.

How to Delete a Parameter Set

1. In the Station Manager window’s File menu, select Delete
Parameters.

2. In the Delete Parameter Set window:

A. Select the parameter set to be deleted.

B. Click Delete.

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Station Manager
How to Open a Different Parameter Set
1. In the Station Manager window’s File menu, select Open
Parameters.

2. In the Open Parameters Set window:

A. Select the desired parameter set.

B. Click Open.

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Station Manager

How to Preview a Parameter Set

In the Station Manager window’s File menu, select Print Preview to
display the Station Manager Print Preview window.

Note Asterisks (*) identify items modified since the configuration file was
last saved. You can choose to highlight these modified items. Use
the Station Manager window’s File menu Save Parameters
command to save these changes.

How to Print a Parameter Set

Click the Print icon on the Station Manager Print Preview window
toolbar or select Print Parameters in the Station Manager window’s
File menu.

How to Determine What Parameter Set is Being Used

The Station Manager window’s title bar displays both the station
configuration and parameter set being used.

Station Configuration and Parameter Set

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 Setting Access Levels

Station Manager
Setting Access Levels
About Access Levels
The access level determines what controls you can access. There are
four levels:

• Operator—Not password protected

• Tuning—Password protected with a default password of Tuning

• Calibration—Password protected with a default password of

Calibration

• Configuration—Password protected with a default password of

Configuration

Access to the Tuning, Calibration, and Configuration access levels

is protected by case-sensitive passwords, which can be selected during
the software installation. See “Access Level” on page 277 for more
information.

Note Calibration and Configuration are at the same access level. Going
from Configuration to Calibration (or vice versa) requires a
password.

How to Go to a Higher Access Level

1. In the Station Manager window’s toolbar, select the desired
access level.

2. In the Password Validation window:

A. Enter the proper access level password.

B. Click OK.

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 Station Views
Station Manager

Station Views
About Station Views
To avoid reopening windows and displays each time you reopen a
station configuration, save the desktop layout as a station view. When
you restore a saved view, the windows reposition automatically.

Each time the Station Manager application closes, it saves the current
station view as the default view. When you reopen the station it
appears with the windows repositioned as they were when the station
was last closed. This allows a user to always revert to the last saved
station.

You can also restore a default view by selecting Restore Default

View, as described below. This function repositions the station
windows to where they were the last time the station was closed.

How to Save a View

In the Station Manager window’s File menu, select Save View.

How to Restore a Saved View

In the Station Manager window’s File menu, select Restore Saved
View.

How to Restore a Default View

In the Station Manager window’s File menu, select Restore Default
View.

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 Calibrating Sensors and Configuring Feedback

Station Manager
Calibrating Sensors and Configuring Feedback
About Sensors
.Your system’s sensors convert measured mechanical values, such as
force, displacement, and pressure, into electrical signals that after
conditioning, are suitable for feedback for closed-loop control.

In the Station Builder application, you allocate the proper controller

resources to allow either internal or external signal conditioning. For
more about allocating resources, see “Allocating Controller Resources”
on page 37.

• Signals can be conditioned internally if your controller is

equipped with built-in conditioners.

• Signals must be conditioned externally if your controller does not

have built-in conditioners.

Excitation
Signal Feedback
Sensor Conditioner Signal
Module
Sensor
Signal

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Station Manager

Calibrating sensors
All sensors require calibration to ensure that their outputs accurately
represent the physical condition they are sensing.

Sensors included with your test system are usually factory-calibrated,

and the corresponding sensor calibration files are included with your
system software. If you change a sensor or add a new sensor to your
system, you must calibrate the new sensor/conditioner pair against a
standard to ensure the sensor’s accuracy.

Sensor calibration procedures are detailed in Chapter 6, Calibration of

the 493.10/793.00 Controller Service Manual.

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Station Manager
Before You Begin
Before you start sensor calibration, be sure the following are true:

• The sensors are properly connected to the controller

(refer to the cabling information in your Controller Service
manual).

• A station configuration file has been created that includes the

hardware resources associated with the sensors you want to
calibrate.

• The Station Manager program is running and the appropriate

station configuration file is open.

• You have completed an initial, nominal tuning of the sensor

channel you are calibrating. This is especially important if you
have not calibrated the sensor before.

• The hydraulics are warmed up (see System warm-up below).

• Gain is set to 1 on the Drive panel Conditioner tab (3-stage

servovalves only).

• You know your signal polarity (see Signal polarity below).

System warm-up Be sure that both the hydraulic fluid and the servovalve are at
operating temperature before calibration. Remove any specimen and
run the system in displacement control for at least 30 minutes using a
80% full-scale length command at about 0.1 Hz.

Refer to “How To Warm Up the System Hydraulics” on page 546 for a

detailed warm-up procedure.

Signal polarity Some test systems are configured to extend the actuator in response to
a positive command, while other test systems are configured to retract
the actuator in response to a positive command. Conditioner polarity
determines feedback polarity.

You must know how your test system is configured so you can
determine the appropriate polarity for the values used in this chapter.

See “Setting the Servovalve Polarity” on page 542 for more information

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About Sensor Calibration Files

Sensor calibration files have .scf extensions and are usually stored in
the “Calib” directory. A sensor calibration file includes the following
information:

• Sensor model, type, serial number, and calibration date

• Calibrated range information

• Calibration equipment information

• Calibration type

• Conditioner serial number, model number, excitation voltage, and

other conditioner parameters
You can use the Sensor File Editor window to create and save sensor
calibration files for each sensor/conditioner pair in your system. For
more information, see “How to Create a Sensor File” on page 135.

After you create an .scf file, you must assign it to the correct incoming
sensor signal. For more information, see “How to Assign a Sensor File”
on page 141.

If you are using an externally conditioned feedback signal, you can

use the Station Manager application’s calibration controls to adjust the
gain, full-scale values, and polarity of the incoming sensor signal. See
“How to Configure an Externally Conditioned Feedback Signal” on
page 148.

Additional See “Station Manager Controls and Displays” on page 273 for a
information complete description of this application’s controls and indicators.

For more about the controls referenced in this section, see:

• “Sensor File Editor Window” on page 442.

• “Station Setup Window/Inputs Panel Tabs” on page 310.

• “Manual Command Window” on page 510.

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Station Manager
How to Create a Sensor File
Note You can create new sensor (.scf) files from any access level.You
must be at the Calibration access level to edit any existing sensor
file.

This task is slightly different if you are using a full-range conditioner

(e.g., Model 493.25 DUC). Note these variations in the following
procedure:

1. In the Station Manager window’s Tools menu, select Sensor

File Editor.

2. On the Sensor File Editor toolbar, click the Open button, and
then New.

3. In the Sensor File Editor window, set the File Definition:

4. Specify conditioner from the Conditioner Type list.

Several conditioners may be listed. Select the type (Model #) of

conditioner that is connected to the sensor you are calibrating.
Note All conditioner entries are disabled until you select a conditioner
type.

Select the
Conditioner
Type
Select the
Dimension

Define at least
one range or
enable Full
Scale
conditioning, and
set its Fullscale
Min/Max values

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Station Manager

5. Select the signal Dimension.

6. Enter any additional information.

This step is optional. The sensor calibration file can include

general information about the sensor and conditioner. The
information helps link a specific sensor/conditioner pair to the
calibration data.
A. Enter the sensor serial number.

B. Enter the conditioner serial number.

C. Enter the last time the sensor was calibrated. If you are
calibrating the sensor, enter today’s date.

D. Identify the hardware resource.

E. You can enter any information you wish in the General

Information field. For example, you may want to enter the
sensor model number, its full-scale capacity, or some type of
identifier you may use in your lab.

Range definition Range definition depends on the conditioner type and calibration type
selected. If you select a full-range conditioner (e.g., Model 493.25
DUC) you can only define a single range. Selecting a full-range
conditioner also allows you to choose Gain/Linearization; in
addition to Gain/Delta K, mV/V Pos Tension, or mV/V Pos Comp
calibration types when defining your conditioner’s range.

For multi-range conditioners, you can choose Gain/Delta K in

addition to the mV/V Pos Tension and mV/V Pos Comp calibration
types for each of your range definitions.

Procedures for Gain/Linearization, Gain/Delta K, mV/V Pos

Tension, or mV/V Pos Comp range definition are described here.

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Station Manager
Gain/linearization Selecting Gain/Linearization for full-range conditioner allows you to
define the conditioner range using a linearization data table as follows:

Important Using linearization data requires specific conditioner zeroing

practices. Ensure that Electrical Zero Lock on the
Offset/Zero submenu is set to Lock. After completing
calibration, readjustment of electrical zero will change the
point at which linearization takes place, disturbing other
calibration settings (especially delta k).

1. Under Range Definition, define a range.

By default, Range 1 is entered. Highlight the name Range 1 and

change it to something meaningful.

2. Specify the Fullscale Min/Max values of the range.

Select the units for the range, and then enter the values for the
upper and lower ranges.
Note The system software supports non symmetrical full scales. This
means you do not have to center the range around zero, but the
value 0.0 must be in the range. For example, you can set the
full-scale maximum to +10 cm and the full-scale minimum to +3 cm.

3. Select Gain/Linearization from the Cal Type list.

4. Locate the calibration data sheet for the appropriate full-range

conditioner.

5. Click Linearization Data to open the Linearization Data

window.

6. Enter Standard and Conditioner data from the conditioner’s

calibration data sheet.

7. Set the initial Conditioner Calibration Values for the full-range

conditioner.

8. On the Sensor File Editor toolbar, click the Save button, and
then Save As to display the Save Sensor File As window. See
“Saving Sensor File Data” on page 143

9. Type an appropriate file name, and then click OK.

Note If you attempt to save changes to an existing sensor file, and you
are not at the Calibration access level, the following message will
be displayed, requiring you to open the Calibration access level or
save to a new file.

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Station Manager

10. Close the Sensor File Editor when you are done.
Note If you are editing the sensor file from the Sensor tab on the Station
Setup window Inputs panel, click the Save button to save your
changes.

Gain/Delta K Gain/Delta K can be selected for range definition for both full-range
and multi-range conditioners.

1. Select Gain/Delta-K from the Cal Type list.

2. Under Range Definition, define a range.

By default Range 1 is entered. Highlight the name Range 1 and

change it to something meaningful.

Example: Suppose you are setting up a calibration file for a ±10

cm range. You may want to name the full-scale range “10 cm”.

3. Specify the Fullscale Min/Max values of the range.

Select the units for the range, and then enter the values for the
upper and lower ranges.
Note The system software supports non symmetrical full scales. This
means you do not have to center the range around zero, but the
value 0.0 must be in the range. For example, you can set the
full-scale maximum to +10 cm and the full-scale minimum to +3 cm.

4. Set the initial Conditioner Calibration Values for the range.

5. Define any additional ranges (If applicable).

Click Add to add another range to the calibration file. Up to 10

ranges can be included in a calibration file. Repeat the range
definition procedure for each range you want to calibrate.

6. On the Sensor File Editor toolbar, click the Save button, and
then Save As to display the Save Sensor File As window. See
“Saving Sensor File Data” on page 143

7. Type an appropriate file name, and then click OK.

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Station Manager
Note If you attempt to save changes to an existing sensor file, and you
are not at the Calibration access level, the following message will
be displayed, requiring you to open the Calibration access level or
save to a new file.

8. Close the Sensor File Editor when you are done.

Note If you are editing the sensor file from the Sensor tab on the Station
Setup window Inputs panel, click the Save button to save your
changes.

mV/V Pos Tension or For both full-range and multi-range conditioners, mV/V Pos Tension
mV/V Pos Comp or mV/V Pos Comp can be selected for range definition.

1. Select mV/V Pos Tension or mV/V Pos Comp from the Cal
Type list.

2. Under Range Definition, define a range.

By default Range 1 is entered. Highlight the name Range 1 and

change it to something meaningful.

3. Specify the Fullscale Min/Max values of the range.

Select the units for the range, and then enter the values for the
upper and lower ranges.
Note The system software supports non symmetrical full scales. This
means you do not have to center the range around zero, but the
value 0.0 must be in the range. For example, you can set the
full-scale maximum to +10 cm and the full-scale minimum to +3 cm.

4. Set the initial Conditioner Calibration Values for the range.

5. Define any additional ranges (If applicable).

Click Add to add another range to the calibration file. Up to 10

ranges can be included in a calibration file. Repeat the range
definition procedure for each range you want to calibrate.

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6. On the Sensor File Editor toolbar, click the Save button, and
then Save As to display the Save Sensor File As window. See
“Saving Sensor File Data” on page 143.

7. Type an appropriate file name, and then click OK.

Note If you attempt to save changes to an existing sensor file, and you
are not at the Calibration access level, the following message will
be displayed, requiring you to open the Calibration access level or
save to a new file.

8. Close the Sensor File Editor when you are done.

Note If you are editing the sensor file from the Sensor tab on the Station
Setup window Inputs panel, click the Save button to save your
changes.

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How to Assign a Sensor File
This task links a sensor calibration file to a hardware resource;
assigning calibration data for the input signal definition.

1. In the Station Manager window’s toolbar, select a User Level of

Calibration.

2. In the Station Manager window’s Display menu, select Station

Setup to display the Station Setup window.

3. In the Station Setup window’s navigation pane, locate and select

the signal to be assigned a sensor file.

4. In the Station Setup, click the Channel Input Signals icon, and
then the Sensor tab.

A. Select the desired Sensor File.

B. Click Assign.

Select a sensor signal

Select a range

Select a sensor file

Assign the file

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Note If you assign (None) for a sensor file the following message is
displayed:

5. Select a range.

Under Current Range on the Sensor tab, select the range you
want to calibrate. To add a new sensor range, enter a name in
Range Name, and then click Add.
Note When you finish calibrating this range, you will want to return to this
step to select another range. All ranges should be calibrated.

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Saving Sensor File Data
Depending on the type of sensor data you have modified, you can
save the sensor calibration information to a sensor calibration file, to a
parameter set, or to a Transducer ID.

A single range of sensor information can be saved in the parameter set.

For more information, see “About Sensor Calibration Files” on page
134 and “About the Transducer ID Modules” on page 145.

When saving sensor data you should consider the type of sensor data
you have modified and whether it is being saved to an assigned sensor
file. There are two types of sensor calibration data:

• Sensor data saved to a parameter set (such as sensor values that

have been manually set to a conditioner input)

• Sensor data saved to a sensor calibration file (.scf)

If you are updating sensor data of an assigned sensor file, you must
have the Calibration access level selected.

Saving data Typically, you can save sensor calibration data by pressing Save on the
Station Setup Inputs panel (Calibration tab).

If you have modified calibration data that is saved to a parameter set

(no sensor file assigned), exiting the Calibration access level before
saving will display the following message:

Click Cancel to return to the Calibration access level. Clicking OK

sets the selected access level without saving to a parameter set.

If you have modified assigned sensor data that is saved to a sensor

calibration (.scf) file, exiting the Calibration access level before saving
also opens Save Sensor Files.

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Select All, the default setting on the Save Sensor Files window,
allows you to save all changed sensor files. Click OK to save all sensor
files and leave Calibration.

If you do not want to save changes to a particular sensor file, click that
sensor file. Click Deselect All if you do not want to save any modified
sensor files. Click Cancel to return to the Calibration access level.

If you have not elected to save all modified sensor files, clicking OK
on Save Sensor Files will display the following warning:

Clicking OK on this warning window will exit the Calibration access

level without saving the modified sensor files you failed to select.
Clicking Cancel returns you to the Calibration access level.

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About the Transducer ID Modules
Transducer ID modules (optional), located at the ends of Series 493
Conditioner cables, can store calibration data. Transducer ID modules
make it easier to change sensors since the calibration information stays
with the sensors (not available for FlexTest™ IIm/CTC/CTM).

l
A transducer ID module includes:

• A transducer ID circuit with calibration information.

• A molded, removable cover.

• A shunt calibration resistor.

• Up to three bridge completion resistors.

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How to Assign a Sensor with a Transducer ID Module

The following procedure applies to 493 Series Conditioners with
Transducer ID modules.

1. In the Station Manager window’s toolbar, select an access level

of Tuning.

2. In the Station Manager window’s Display menu, select Station

Setup.

3. In the Station Setup window’s navigation pane, locate and select

the Channels control mode resource to be assigned the sensor
with the Transducer ID module.

4. In the Station Setup window, click .

5. In the Inputs panel, click the Sensor tab.

6. In the Sensor tab:

A. Select (Transducer ID).

B. Click Show Trans ID to display the Transducer ID contents.

Verify that the correct sensor is being assigned.

C. Click Assign.

Select a signal

Select (Transducer ID)

Assign the sensor

Verify the ID

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How to Save Data to a Transducer ID Module
1. In the Station Manager window’s toolbar, select an access level
of Calibration.

2. In the Display menu, select Station Setup.

3. In the Station Setup window’s navigation pane, locate and select

the Channels control mode resource with the Transducer ID
module whose data you want to change.

4. In the Station Setup window, click .

5. In the Inputs panel, click the Calibration tab.

6. In the Calibration tab:

A. Update the calibration information.

B. Click Save to store the new values in the Transducer ID

module.

Change values

Save values

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How to Configure an Externally Conditioned Feedback

Signal
A temperature controller is an example of a device that inputs an
externally conditioned feedback signal.

1. In the Station Manager window’s toolbar, select an access level

of Calibration.

2. In the Station Manager window’s Display menu, select Station

Setup.

3. In the Station Setup window’s navigation pane, locate and select

the Channels resource providing the externally conditioned
feedback signal.

4. In the Station Setup window, click .

5. In the Inputs panel, click the Calibration tab.

6. In the Station Setup window’s Calibration tab, set the signal’s

Fullscale Min/Max, Polarity, and Gain.

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About Offset
Your calibrated sensor output may be affected by external factors such
as specimen size, test component forces, and cable length. You can
compensate for these external factors by offsetting the feedback signal.

For example, suppose your LVDT output is 1 cm when the actuator is

at its null, midstroke position. You can compensate for this positive
LVDT output by offsetting the feedback signal –1 cm.

The Station Manager application’s Offset controls zero the conditioner’s

output without shifting the conditioner’s electrical zero reference. An
auto offset can be applied to the current control feedback with station
pressure applied.

Since the range centers around the sensor’s calibrated electrical zero,
an offset limits the usable range in the direction you shift it. For
example, in a ±2 cm range, offsetting the signal -1 cm from its zero
position results in control ranges of +1 cm on the positive side and
–3 cm on the negative side.

Controller/Application
Conditioner
Sensor Conditioner Digital
Voltage Voltage Signal
Gain A/D

Electrical Zero Offset

The offset applies to the feedback signal.

You specify the offset in engineering units.

Offset considerations Consider these items before offsetting a feedback signal:

• Offset alters the feedback signal used by the digital (PIDF)

controller and is included in the closed-loop control calculations.

• Offset cannot be used to clear interlocks tripped by signal

saturation.

• Offset is limited to ±½ the current full-scale range.

• The usable range is limited in the direction that zero is offset.

If you want to offset the sensor signal in the conditioner, see “About
Electrical Zero Offset” on page 152.

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How to Offset a Feedback Signal

You can apply an auto offset or a manual offset to the feedback signal.

Auto offset 1. In the Station Manager window’s toolbar, select an access level
of Calibration.

2. In the Station Manager window’s Display menu, select Station

Setup.

3. In the Station Setup window’s navigation pane, locate and select

the resource supplying the sensor signal that needs an offset.

4. In the Station Setup window, click .

5. In the Inputs panel, click the Offset/Zero tab.

6. In the Offset/Zero tab:

A. If Auto Offset Lock is selected, clear it.

B. Click Auto Offset.

Manual Offset shows the offset applied to produce the

Current Value.

If the Manual Offset value exceeds half of the signal’s

full-scale range, the system interlocks and removes station
power.

C. Select the Auto Offset Lock to make the Auto Offset

controls unavailable at the access levels of Tuning and
Operator.

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Manual offset If the desired amount of offset is known, select it with the Manual
Offset slider.

WARNING Immediate and unexpected actuator response is possible when you

apply a manual offset to your system.

Sudden actuator movement can cause injury and equipment damage.

If the Current Value displayed on the Offset/Zero tab is zero, a manual

offset will cause the actuator to move to the new zero position.

Never apply a manual offset to a sensor being used by the active control
mode while station power is on.

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About Electrical Zero Offset

If you want to shift a small, calibrated sensor range away from the
sensor’s calibrated electrical zero, you can offset the sensor’s electrical
output in the conditioner.

A traditional offset shifts the feedback signal and an electrical zero

offset shifts the conditioner signal.

An electrical zero offset cannot be applied to a conditioner used in an

active control mode with hydraulic pressure applied.

Controller/Application
Conditioner
Sensor Conditioner Digital
Voltage Voltage Signal
Gain A/D

Electrical Zero Offset

The electrical zero offset applies to the conditioner signal.

You specify electrical zero adjustments in volts.

Electrical zero Consider the following before shifting the electrical zero:
considerations
• Unlike the Calibration tab’s conditioner Zero controls, electrical
zero values are not used in the delta K calculation.

• The shifted electrical zero position is not a calibrated zero

position.

• You can shift the conditioner’s electrical zero to any position

within the sensor’s full-scale capacity, but your usable range is
limited by the sensor’s calibrated full-scale capacity.

Linearization data Using linearization data requires specific conditioner zeroing practices.
Ensure that Electrical Zero Lock is checked on the Offset/Zero tab
of the Inputs panel. Leaving electrical zero unlocked will invalidate
data collected during linearization routines.

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More About Electrical Zero
Displacement sensors and their corresponding conditioners are
typically calibrated so the conditioner’s feedback is zero volts at the
middle of the actuator’s operating range.

Conditioner Electrical Zero

Sensors are typically

calibrated with the
conditioner’s electrical zero at
the midstroke position

0 volts + 10 volts – 10 volts

at midstroke at full tension at full compression

Range 1 Range 2

Calibrated sensor ranges center

around the conditioner’s electrical zero
Assume we have an LVDT with the
following calibrated ranges:
Range 1 = ±4 cm (full scale)
Range 2 = ±1 cm

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In some situations, you may want to shift the conditioner’s electrical

zero. For example, suppose after installing your specimen, the
resulting feedback saturates in Range 2, the smaller sensor range.
Normally, you could regain control of the saturated channel by
switching to Range 1, the larger range, or by switching from a
displacement to a force control mode.

However, if you wanted to use Range 2 for optimal signal resolution,

you could shift the electrical zero to bring the feedback out of
saturation.

After installing our specimen, the feedback

is saturated for Range 2, the smaller range

We can shift the electrical zero to bring

the Range 2 feedback out of saturation
Range 2
(±1 cm)

Sensor Feedback = + 1.3 cm

saturated feedback for Range 2 (±1 cm)
Shift the electrical zero

Sensor Feedback = 0 cm
at installed position after shifting zero

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How to Shift a Conditioner’s Electrical Zero
Before shifting the conditioner’s electrical zero, you must first position
the actuator at the desired location and disable the station power or
switch to another control mode.

If it is not possible to switch to a different control mode or you cannot

disable station power, use offset instead of electrical zero. See “About
Offset” on page 149.

You can apply an auto zero or a manual zero to shift a conditioner’s

electrical zero.

Auto zero 1. In the Station Manager window’s toolbar, select an access level
of Calibration.

2. Apply station power.

3. Use the Manual Command window to position the actuator at

the desired electrical zero position:

A. In the Station Controls panel toolbar, click to display

the Manual Command window.

B. In this window, select the desired Channel and a Control

Mode of displacement.

C. Select Enable Manual Command.

D. Use the Manual Cmd slider to move the actuator to the new
zero position.

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4. With the actuator in the new zero position, either switch to a

different control mode or shut off station power.

Leave the Enable Manual Command enabled and make sure

that the actuator does not move.

5. Select the displacement signal that needs the electrical offset:

A. In the Station Manager window’s Display menu, select

Station Setup.

B. In the Station Setup window’s navigation pane, locate and

select the Channels or Auxiliary Inputs resource whose
sensor signal needs the offset.

6. In the Inputs panel, click the Offset/Zero tab.

7. In the Offset/Zero tab, apply the electrical offset:

A. Clear the Electrical Zero Lock if it is selected.

B. Click Auto Zero to apply the electrical offset.

Manual Zero shows the offset applied to produce the

Current Value.

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C. Select Electrical Zero Lock to make these controls
unavailable at access levels of Tuning and Operator.

8. Clear the Manual Command window’s Enable Manual

Command.

Manual zero Use the Manual Zero slider to manually shift the conditioner’s
electrical zero.

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Working with Readout Devices

About Readout Devices
Readout options The Station Manager application provides Scope and Meters windows
and a Signals panel for monitoring signals.

• The Scope window works like an oscilloscope. See “About the

Scope” on page 159.

• The Meters window works like a DVM meter. See “About Meters”
on page 172.

• The Station Signals panel can display the values of all incoming
and outgoing signals. See “About the Station Signals Panel” on
page 176.

• The Signal Auto Offset window can display the values of all
incoming and outgoing signals. See “Signal Auto Offset Window”
on page 503.

External readout You can also send signals to an external readout device. See “About
options Monitoring Signals Using External Readout Devices” on page 179.

Additional See “Station Manager Controls and Displays” on page 273 for a
information complete description of this application’s controls and indicators.

For specifics about the controls referenced in this section, see:

• “Station Setup Window/Readouts Panels” on page 358.

• “Meters Window” on page 392.

• “Scope Window” on page 395.

• “Setup for Scope Window” on page 398.

• “Signal Lists Tab” on page 432.

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About the Scope
The Station Manager application’s Scope window works like an
oscilloscope. You can use the scope to plot signals against time,
frequency, or another signal. A single station can support two scopes.

How to Set Up a Time Plot on the Scope

1. In the Station Manager window’s toolbar, click once to

display a single Scope window.

2. In the Scope window:

A. For Channel, select the channels whose signals are to be

monitored.

B. For Signal, select the signals you want to monitor.

C. For Plot Mode, select Time.

D. In the toolbar, click .

3. In the Setup for Scope window, set up the scope display using
the Graph Settings and Trace Settings tab controls.

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How to Set Up a Frequency Plot on the Scope

1. In the Station Manager window’s toolbar, click .

2. In the Scope window:

A. For Channel, select the channels whose signals are to be

monitored.

B. For Signal, select the signals you want to monitor.

C. For Plot Mode, select Frequency.

D. In the toolbar, click .

3. In the Setup for Scope window, set up the scope display using
the Graph Settings, Trace Settings, and Frequency Mode tab
controls.

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How to Set Up an X/Y Plot on the Scope
An X/Y plot displays the first signal on the vertical axis and the second
signal on the horizontal axis. A typical use for an X/Y plot is to display
hysteresis by plotting a force signal against a displacement signal.

1. In the Station Manager window’s toolbar, click .

2. In the Scope window:

A. For Channel, select the channels whose signals are to be

monitored. The first Channel selection plots on the vertical
axis; the second Channel selection plots on the horizontal
axis.

B. For Signal, select the signals you want to monitor.

C. For Plot Mode, select X/Y Plot.

D. In the toolbar, click .

3. In the Setup for Scope window, set up the scope display using
the Graph Settings and Trace Settings tab controls.

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About Auto-Scale, Rescale, and Same Scale

The Scope window’s toolbar has Auto-Scale, Rescale, and Same Scale
buttons to deal with changing signal amplitudes.

Rescale

Auto-Scale Same Scale

How to Auto-Scale

Click to set the Scope window to automatically increase its

Units/Div to accommodate a signal’s increasing signal amplitudes.

changes to to indicate active auto-scaling.

Auto-Scale increases Units/Div

• Auto-Scale accommodates increasing signal amplitudes but does

not rescale the Scope for decreasing signal amplitudes.

• Use Rescale to accommodate decreased amplitudes.

• To preserve Offset, click . In the Setup for Scope window’s

Auto-Scale Modes, select Sensitivity.

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How to Rescale

Click whenever you need to immediately increase or decrease

the Scope window’s Units/Div to accommodate a signal’s changed
amplitudes.

Rescale increases or decreases Units/Div to match signal

• Once rescaled, Unit/Div do not change to accommodate

increasing signal amplitudes except when you change the field

• Use Auto-Scale to accommodate increasing signal amplitudes

Note Pressing Rescale does not turn off Auto-Scale.

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How to Same Scale

Click to apply the Units/Div and Offset used by the first channel
to the second channel.

changes to to indicate the same scale has been applied.

Same Scale—both Channels have the same Units/Div and Offset

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How to Offset Scope Signals
Offset defines the Scope window grid’s midpoints. Applying an
Offset shifts the grid’s zero reference points up and down in the
Scope window.

To apply an offset, type in an Offset value and press your PC’s Enter
key.

No Offset

Zero reference
at midpoint

1mm Offset

1mm now at midpoint

Zero reference moves down

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How to Adjust the Scope’s Time Scale

When the Scope window displays a Plot Mode of Time, type in a
Trace Time value to change the x-axis Time scale.

The Time scale can be changed with the Scope running or stopped.

2.00 sec Trace Time

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How to Examine Stored Time Plot Signals
The Scope stores trace time history data in a temporary circular buffer.
When the Scope stops, you can use its Time Slider Bar to examine this
stored signal data.

To examine stored Time Plot signal data:

1. Click to stop the Scope.

Stopping the Scope makes the Time Slider Bar available.

2. Move the Time Slider Bar to the left to examine stored data.

Stop

Move

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How to Change the Time Scale When Examining Time Plot Signals
Method 1 1. Double-click the Time Slider Bar.

2. In the Time Range Select window, enter new Time scale values.

Method 2 Adjust the shuttle size on the Time Slider Bar.

Method 1:
Enter new values

Click to identify the x-y point

Method 2:
Resize the shuttle

Note When the Scope restarts, the Time scale resizes itself to the Trace
Time value and the circular buffer gets erased.

To more closely examine time plot signals you can:

• Use the scale slider bars (right side of display) to change signal
scale.

• Click Rescale to immediately increase the Scope window’s

Units/Div.

• Use the vertical “cursor” bar for an display of exact X, Y data

points.

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How to “Sync” Current Channel Selections on Scope
The Sync Current Channel feature effectively “synchronizes” channel
selection for the function generator and scope. This feature facilitates
the set up and tuning of systems with a large number of channels.

To “synchronize” channel selections for the scope and function

generator:

1. Click the two-state Sync Station Channel button on the

Scope Toolbar to set the “sync” state.

Click to set “sync”

state

2. Click the Station Setup Sync Current Channel button on the

Channel Buttons panel.

This applies the current channel selections on the Station Setup to

both Channel selections on a scope display and to the function
generator.
Note If the function generator is running or is in group mode, clicking the
Sync Current Channel button will not make any changes to the
function generator.

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How to Change the Scope’s Appearance

1. In the Station Manager window’s toolbar, click once to

display a single Scope window.

Note To display a second scope, click Create Scope on the Scope icon
pull-down menu.

2. In the Scope window’s toolbar, click to display the Setup

for Scope window.

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3. In the Setup for Scope window, click the Graph Settings tab
and on that tab:

A. Select Show Grid to display a scope grid.

B. Select Enable Auto-Sizing.

C. Use the Color Selections control to set the Grid Color and
Background Color.

4. In the Setup for Scope window, click the Trace Settings tab and
on that tab:

A. For each Trace, select a Line Style and Line Color.

B. For Limit Lines, select None, Detector Limits or User

Specified.

For User Specified lines, set the Upper Limit and the
Lower Limit.

5. In the Setup for Scope window, click the Frequency Mode tab
and on that tab:
Note The Frequency Mode tab is only available when the selected Plot
Mode is Frequency

A. Select a Sampling Rate.

B. Select a Buffer Size.

6. Close the Setup for Scope window.

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About Meters
The Station Manager application has four types of meters to monitor
signal values. Up to 16 meters can be displayed in two windows,
depending on the system installed.

• Timed meters—Display signal values at timed intervals.

• Peak/Valley meters—Display the peak and valley values for the

most recent cycle monitored.

• Mean/Amplitude—Display the midpoint value and the difference

between the peak and valley values for the most recent cycle
monitored.

• Running Max/Min—Display the highest and lowest values

reached while the meter is running.
Meters displaying command signals use the dimension and units of the
channel’s active control mode.

Meter controls
Meter Toolbar
Meter Setup button Displays the
name of signal
being monitored

All Meter windows have the following toolbar controls:

• Click to start the meters in the window.

• Click to stop the meters in the window.

• Click to reset the meters in the window.

• Click to arrange meters horizontally, vertically, or in a grid.

• Click to add a meter to the window.

Drag the Meter window’s corner or edge to resize the meter display.

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How to Configure a Meter
1. On the Station Manager window’s toolbar, select Create Meters
on the Meters icon pull-down menu.

Select Create Meters again to display a second Meters window.

2. In the Meters window, click the Meter Setup button.

Click

3. Use the Meter Setup window to define the meter:

A. For Meter Type, select Timed, Peak/Valley,

Mean/Amplitude, or Running Max/Min.

B. For Signal Selection, select the desired Channel name and

Signal type.

C. For Display Mode, select Engineering Units or Volts.

D. Set a Display Resolution.

Note The default Display Resolution is 4.

E. For Peak/Valley and Mean/Amplitude meters, set the

Sensitivity.

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How to Add a Meter

When a meter is added to the active Meters window it is a copy of the
currently active meter, with identical setup parameters.

In the active Meters window, click the Add Meter button.

Click

Meter Added

You can create up to 16 meters by successively clicking the Add Meter

button. If a second Meters window is displayed, the total number of
meters added between the two Meters windows is limited to 16.

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How to Delete a Meter
The last meter in the Meter window cannot be deleted.

1. In the meter to be deleted, click the Meter Setup button.

Click

Click

Two meters displayed

One meter displayed

2. In the Meter Setup window, click Delete.

Close the Meter Setup window.

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About the Station Signals Panel

The Station Setup window has a Station Signals panel. Use the
Station Signals panel to monitor controller signals.

This panel has four tabs:

• The Values tab displays the current values for the selected signals.

• The Hardware tab displays the controller Resource and rear

panel Connector used by the selected signals.

• The Fullscale tab displays the full scale minimum and maximum
values for selected signals. Values can be edited at the
Calibration access level.

• The Calibration tab displays the calibration values for the

selected signals. Values can be edited at the Calibration access
level.

Selects
signals

Use the Channel Option window’s Signal Lists tab to change the
default signals that display in the Station Signals panel. For more
information, see “How to Edit the Signal Lists” on page 178.

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How to Display Station Signals
1. In the Station Manager window’s Display menu, select Station
Setup.

2. In the Station Setup window’s navigation pane, click Station

Signals.

3. In the Station Signals panel:

– In the pull-down list, select a signal list.

– Click the Values tab to display current signal values.

– Click the Hardware tab to display the controller Resource

and Connector for each signal.

– Click the Fullscale tab to display the signals’ full scale

minimum and maximum values. Values can be edited at the
Calibration access level.

– Click the Calibration tab to display the signals’ calibration

values.Values can be edited at the Calibration access level.

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How to Edit the Signal Lists

1. In the Station Manager window’s Tools menu, select Channel
Options.

2. In the Channel Options window, click the Signal Lists tab.

3. In the Signal Lists tab:

A. Create a new signal list or edit an existing signal list:

– To create a new signals list, click Add and enter the new
list’s Name.

– To edit an existing list, select its name.

B. Use the and buttons to move signals

between Available Signals and Included.

C. Use the and buttons to change the order of signals

displayed in the Included list.

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About Monitoring Signals Using External Readout Devices
Station signals can be monitored using external scopes and meters
connected to TestStar™ and FlexTest™ series controller outputs.

• On TestStar™ IIs and TestStar™ IIs AP controllers, monitor signals

from connectors J71 and J72.

• On all FlexTest™ and TestStar™ IIm controllers, monitor signals

from the Analog Output board’s BNC connectors.

• On automated FTSE controllers monitor signals from the Monitor

1 and Monitor 2 connectors on the front panel.

To externally monitor a signal, you must first use the Station Builder
application to assign a resource to output signals. For more
information, see “Creating Readouts” on page 69.

How to Configure a Signal for External Readout

1. In the Station Manager window’s Display menu, select Station
Setup.

2. In the Station Setup window’s navigation pane, locate and select

the Readouts resource to be used to output the signal.

Selecting a Readouts resource displays the Station Setup

window’s Readout panel.

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3. In the Readout panel, configure a signal for readout.

A. For Signal, select the signal.

B. Set the Gain and Offset as needed.

Note With Gain = 1 and Offset = 0 V (default values): a positive full-scale
signal = +10 volts and a negative full-scale signal = -10 volts.

4. To save signal values, in the Station Manager window’s File

menu, select Save Parameters.

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Working with External Commands
About External Command Inputs
Your controller can process programming received from an external
controller or function generator while maintaining all other closed-loop
control functions.

Note Your controller cannot recognize mode switches in external program

input signals.

Channels must be configured in the Station Builder application to

accept external program commands. For more information, see
“Enabling External Command Inputs” on page 74.

How to Enable and Run External Command Inputs

To enable an external command source, perform the following:

1. Cable your controller to the external command source.

2. Allocate external command resources.

Use Station Builder to configure controller channels to accept

external program commands. See “Enabling External Command
Inputs” on page 74 for a detailed procedure.

3. Adjust the command signal.

A. Open your station configuration file in Station Manager.

B. On the Station Manager Toolbar, select Calibration in the

User Level access box, and then enter the required password.

C. On the Station Manager Display menu, select Station Setup.

D. In the navigation pane, select the channel associated with the

external input.

E. Click the Calibration tab, and set the external command

full-scale min/max values, signal polarity, and gain.

F. On the Limits tab, set limits and detector actions.

G. On the Offset/Zero tab, apply offset as needed.

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4. Start the external command.

A. On the Station Manager application controls panel, click the

External Command icon to open the External Command
control panel. See “External Command Control Panel” on
page 493 for more information about this control panel.

Note Ensure that the external programmer is connected before pressing

run.

B. On the control panel Channel list, click the channel you will
apply the external command to.

C. On the Control Mode list, click the control mode.

D. Set the external command Target Setpoint.

E. Optional—Select Soft Start/Stop. This option ramps the

external command from 0 to 100% over two seconds when
you click Start and tapers the command from 100 to 0%
when you click Stop.

F. Click the Program Run button on the Station Controls panel.

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Applying Hydraulics and Clearing Interlocks
About Station Hydraulics
Typically, a hydraulic power unit (HPU) provides hydraulic pressure
while a hydraulic service manifold (HSM) controls the application of
HPU pressure to the test station.

Typically, the Station Manager window’s Station Controls panel has

both HPU and HSM controls.

On test systems that use house hydraulic power, the Station Controls
panel may have just HSM controls. On some small test systems without
an HSM, the Station Controls panel may have just HPU controls.

Note A station interlock prevents an HSM start but permits an HPU start.
The HSM is a station resource and cannot start when a station
interlock is active. An HPU is considered an external device and can
be started with an active station interlock (even if it has caused the
interlock).

Systems without On test systems that do not control hydraulic power, the Station
hydraulic power Controls panel displays a “No power configured” and has an
Interlock button to apply interlocks. A station with no HPU or HSM
assigned must be interlocked before a new parameter set can be
loaded. The Interlock button can be used to generate this required
interlock.

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System with calculated Systems that use calculated outputs to drive servovalves connected to
outputs multiple independent HSMs may experience control problems. For
example, a road simulator with the lateral and longitudinal drive
actuators connected to two different HSMs may experience
unexpected motion on one corner when only one HSM is turned on.
WARNING For systems with calculated outputs and multiple independent HSMs,
turning on only one HSM can result in unexpected or exaggerated
actuator motion.

Unexpected or exaggerated actuator motion can injure anyone in its

path.

For these systems, always use the All Off, All Low, and All High buttons on
the Station Controls panel for hydraulic control.

Additional See “Station Manager Controls and Displays” on page 273 for a
information complete description of this application’s controls and indicators.

For specifics on the controls referenced in this section, see:

• “Station Setup Window/Inputs Panel Tabs” on page 310.

• “Station Controls Panel” on page 498.

• “Manual Command Window” on page 510.

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How to Apply Hydraulics
In the Station Manager window’s Station Controls panel:

1. Click Reset to clear interlocks.

If the interlock remains on, identify the cause of the interlock

using the Message Logs window on the Station Manager
window and then correct the cause.

WARNING Applying hydraulics can result in sudden actuator motion.

A moving actuator can injure anyone in its path.

Always clear the actuator area before applying hydraulics.

2. Turn on the HPU, clicking HPU Power Low and then HPU
Power High.

Buttons stop flashing when pressure is reached.

Note A station interlock prevents an HSM start but permits an HPU start.
The HSM is a station resource and cannot start when a station
interlock is active. An HPU is considered an external device and can
be started with an active station interlock (even if it has caused the
interlock).

3. Turn on the HSM, clicking HSM Power Low and then HSM
Power High.

When possible, use low pressure to install specimens.

How to Turn Off Hydraulics

In the Station Manager window’s Station Controls panel:

• To turn off the HSM, click HSM Power Low and then HSM
Power Off.

• To turn off the HPU, click HPU Power Low and then HPU Power
Off.

• To simultaneously turn off both the HSM and HPU, click All Off.

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About Interlocks and Saturated Signals

Interlocks are safety features used to stop programming or disable
power to a test station if certain conditions are not met.

Systems typically have mechanical, software, and hydraulic interlocks.

Out-of-range • On FlexTest™ IIm, FlexTest™ CTC, and FlexTest™ CTM systems, a

feedback feedback signal is out of range when it exceeds 100%, but is less
than ±120% of its current range.

• On TestStar™ IIs, TestStar™ IIs AP, FlexTest™ GT, TestStar™ IIm,

and FlexTest™ SE controllers, a feedback signal is out of range if it
exceeds 100%, but is less than ±105% of its current range.

An out-of-range feedback signal lights a yellow Station Limits

indicator in the Station Manager window’s Station Controls panel.

Saturated feedback • On FlexTest™ IIm, FlexTest™ CTC, and FlexTest™ CTM systems,
the feedback signal is saturated when it exceeds ±120% of its
current range.

• On TestStar™ IIs, TestStar™ IIm, TestStar™ IIs AP, FlexTest™ GT,

and FlexTest™ SE systems, the feedback signal is saturated when
it exceeds ±105% of its current range.

A saturated active feedback signal lights a red Station Limits indicator

and sets an Interlock in the Station Manager window’s Station
Controls panel.

When a saturated active feedback signal sets an interlock, station

power is removed from the station. Once that occurs, you must adjust
the saturated signal within its operating range before you can apply
and maintain power to the station.

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Note A saturated signal not used by active mode will not turn station
power off.

For more about dealing with saturated feedback signals, see “How to
Apply Hydraulics When a Channel’s Feedback is Saturated” on page
190.

When calculated input Sometimes the active feedback signal used for a control mode is a
signals become calculated input. A calculated input is derived from sensor feedback
saturated that is modified by a mathematical function.

When a calculated input is used as active feedback and becomes

saturated, it is because one or more of the sensor signals used to create
it has become saturated.

When this occurs, the application writes a message to the log, noting
that the active feedback signal has become saturated, and that an
interlock has tripped. However, the message will not identify the
saturated signal as a calculated input, nor will it identify the specific
sensor signal component of the calculated input that is saturated.
Further, the mathematical function assigned to the saturated sensor
signal may make the calculated input signal appear to be operating
within its normal range when viewed with the scope or meters.

So, if your system has interlocked due to the saturation of the active
feedback signal, check to see if the active feedback signal is a
calculated input. If it is, you must identify and resolve the saturated
sensor component of the calculated input to bring the calculated input
within range.

Invalid active A feedback signal can also become invalid. An invalid signal is
feedback indicated as saturated.

An invalid active feedback error can occur under the following

conditions:

• If the current Manual Offset value for an active feedback signal

exceeds ±½ its current range.

• If the feedback is a calculated input and the calculation results in

an invalid number. For example—Your calculation attempts to
perform –1 .

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Manual offset example The Manual Offset control, on the Inputs panel’s Offset/Zero tab,
applies an offset to feedback signals.

A Manual Offset active feedback error typically occurs when you

switch from a large control range with a large Manual Offset to a
small control range without first reducing the Manual Offset.

For example—You apply a Manual Offset of +5 mm to your Range 1

displacement signal of ±60 mm. You disable hydraulics. You switch to
Range 2 with a displacement signal of ±6 mm. You forget to change
the Manual Offset of +5 mm. The Manual Offset of +5 exceeds ½ of
Range 2 (3 mm), generating an invalid active feedback interlock.

Error message If you have an invalid feedback, the following message displays when
you apply station power by overriding the interlock:

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Correcting invalid active This section describes how to correct an invalid feedback caused by a
feedback Manual Offset that is too large.

If an incorrect calculation causes an invalid active feedback, correct the

calculation.

1. In the Station Manager window’s Display menu, select Station

Setup.

2. In the Station Setup window’s navigation pane, locate and select

the signal producing the invalid active feedback.

3. In the Station Setup window, click .

4. In the Inputs panel’s Offset/Zero tab, reduce the Manual Offset

to less than half the current range.

The signal may still be saturated after reducing Manual Offset. For
information on applying hydraulics when the feedback is saturated,
see “How to Apply Hydraulics When a Channel’s Feedback is
Saturated” on page 190.

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How to Apply Hydraulics When a Channel’s Feedback is Saturated

Method 1 Use this method if the feedback is saturated because the current
Control Range is too small.

1. Change the Current Range:

A. In the Station Manager window’s Display menu, select

Station Setup.

B. In the Station Setup window’s navigation pane, locate and

select the saturated feedback signal.

C. In the Station Setup window, click .

D. In the Inputs panel, select a larger Current Range.

WARNING Applying hydraulics can result in sudden actuator motion.

A moving actuator can injure anyone in its path.

Always clear the actuator area before applying hydraulics.

2. In the Station Manager window’s Station Controls, reset the

interlock and apply station power:

A. Click Reset to remove the interlock.

B. Apply hydraulic pressure to the station.

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Method 2 Use this method if the feedback remains saturated after using Method
1 to change the Current Range.

1. In the Station Manager window’s Station Controls panel:

A. Click Reset/Override to provide enough time to override the

interlock.

Each click provides 10 seconds of override time.

B. Apply low hydraulic pressure.

Applying low station power displays the Control Channel

Saturation Warning window.

WARNING Applying hydraulics can result in sudden actuator motion.

A moving actuator can injure anyone in its path.

Always clear the actuator area before applying hydraulics.

2. Allow hydraulic pressure to be turned on.

In the Control Channel Saturation Warning window, click

Allow.

The software turns on low pressure hydraulics and moves the

actuator to the limit of its current range.

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How to Manually Position the Actuator

1. Set up the Scope window to display the actuator’s displacement
and force signals.

For more about setting up the Scope, see “About the Scope” on
page 159.

2. In the Station Manager window’s Station Controls panel

toolbar, click .

3. Set up the Manual Command window:

A. Select the Channel to be manually commanded.

B. Select the desired Control Mode.

C. Select Enable Manual Command.

WARNING Applying hydraulics can result in sudden actuator motion.

A moving actuator can injure anyone in its path.

Always clear the actuator area before applying hydraulics.

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4. In the Station Manager window’s Station Controls panel:

A. Click Reset to clear any interlocks.

B. As needed, click Reset/Override to override interlocks.

Each Reset/Override click adds 10 seconds of override time.

C. Apply station hydraulic power.

When possible, use low pressure.

As soon as power is applied, the Manual Command

window’s Manual Cmd shows the actual actuator position.

5. In the Manual Command window, use the Manual Cmd Slider

Bar to position the actuator.

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Working with Compensators

About Compensators
A compensator compares your command with the corresponding
sensor feedback to ensure that the command is fully applied to the
specimen. If the sensor feedback indicates that the specimen is not
reaching the commanded levels, the compensator alters the command
until the desired result is achieved.

For example, suppose while programming a sine wave for a ±10 cm

displacement, the LVDT feedback only achieves ±9 cm. A peak/valley
compensator will monitor the feedback and automatically boost the
initial command to ensure that the LVDT feedback reaches the
commanded ±10 cm. You can view the compensated command with
your Station Manager application’s scope and meters.

Compensator types Each type of compensator uses a different technique to achieve the
commanded levels. Certain compensators work more effectively than
others for specific applications.

Applying You configure compensators using the Station Setup window’s

compensation Compensators panel. When using the Function Generator, Basic
TestWare, and MultiPurpose TestWare applications, you use these
applications’ Compensator controls to apply a compensation method.

Additional See “Station Manager Controls and Displays” on page 273 for a
information complete description of this application’s controls and indicators.

For specifics about the controls referenced in this section, see:

• “Station Setup Window/Compensators Panel Tabs” on page 343.

• “Scope Window” on page 395.

• “Setup for Scope Window” on page 398.

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About Null Pacing
There are two types of null pacing:

• Static null pacing

• Dynamic null pacing

How static null If the error is too large, static null pacing holds the command at its
pacing works segment boundaries, allowing the sensor feedback more time to reach
its target peak. As the error comes within the user-specified Error
Tolerance, static null pacing resumes the command.

Amplitude Amplitude
SNP starts at end SNP SNP
of Segment #1 starts ends

Command Tolerance Command

Error

Feedback Feedback

Time Time
Segment #1 SNP Hold Segment #1 SNP Hold Segment #2

Static Null Pacing (SNP)

How dynamic null If the error is too large, dynamic null pacing reduces the command
pacing works frequency allowing the sensor feedback more time to track the
command.

The frequency decreases until either of the following occurs:

• The error comes within the user-specified Error Tolerance, at

which time the command frequency starts increasing towards the
command frequency.

• The frequency decreases to the minimum frequency value (20% of

the original frequency). The command is then held at this
frequency as long as the error remains out of tolerance. This
condition is also known as low cycle.

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How to Configure the Null Pacing Compensator

To use only Static Null Pacing, maximize the Error Tolerance values
for Dynamic Null Pacing. To use only Dynamic Null Pacing,
maximize the Error Tolerance values for Static Null Pacing.

For specifics about the controls referenced in this section, see: “Station
Setup Window/Compensators Panel Tabs” on page 343

1. In the Station Manager window’s toolbar, select an access level

of Tuning.

2. In the Station Manager window’s Display menu, select Station

Setup.

3. In the Station Setup window’s navigation pane, locate and select

the Channels control mode needing compensation.

4. In the Station Setup window, click .

5. In the Compensators panel, click the Null Pacing tab.

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WARNING Changes in compensation values made with hydraulic pressure on can
result in unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before changing values.

6. In the Null Pacing tab, define Static Null Pacing values:

A. Set the Error Tolerance.

B. Set the Timeout values.

C. Select a Timeout Action.

For more about time-out actions, see “About Detectors” on

page 223.

7. In the Null Pacing tab, define Dynamic Null Pacing values:

A. Set the Error Tolerance.

B. Set the Timeout values.

C. Select a Timeout Action.

8. To save the values, go to the Station Manager window’s File

menu and select Save Parameters.

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About PVC
Peak/Valley Compensation (PVC) monitors cyclic command feedback
for any amplitude roll-off or mean-level divergence.

• PVC boosts the command amplitude if roll-off is detected.

• PVC adjusts the commanded mean level if mean level divergence

is detected.
Note For best results when using PVC, set the I Gain as low as possible
on the control mode being compensated.

5
4
3
2
1
Mean Level
cm 0 Error
-1 Initial Feedback

-2
Test Command Amplitude
-3 Error
-4
-5

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How to Configure PVC
For specifics about the controls referenced in this section, see: “Station
Setup Window/Compensators Panel Tabs” on page 343

1. In the Station Manager window’s toolbar, select an access level

of Tuning.

2. In the Station Manager window’s Display menu, select Station

Setup.

3. In the Station Setup window’s navigation pane, locate and select

the Channels control mode needing compensation.

4. In the Station Setup window, click .

5. In the Compensators panel, click the PVC tab.

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WARNING Changes in compensation values made with hydraulic pressure on can

result in unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before changing values.

6. In the PVC tab, define PVC values:

A. Set the Convergence Rate.

B. Set the Sensitivity.

C. For Adaptation State, select Resume.

7. To save the values, go to the Station Manager window’s File

menu and select Save Parameters.

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About APC
The Amplitude and Phase Control (APC) compensator monitors
feedback from sine and sine tapered commands for amplitude roll-off
and phase lag.

• APC boosts the command amplitude if roll-off is detected.

• APC alters the command phase if phase lag is detected.

APC’s computational requirements may limit the sampling rate on

some older multichannel systems.

For best results when using APC, you may have to adjust the I Gain for
the control mode being compensated.

The Station Builder application must first enable APC before it can be
used as a compensation method. For more about enabling APC, see
“Enable optional compensators” on page 47.

Use guidelines APC works well when you need to control the amplitude of the
fundamental frequency component.

If you want to achieve peaks, particularly if the feedback is distorted,

using APC is not a good choice

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How to Configure APC

For specifics about the controls referenced in this section, see: “Station
Setup Window/Compensators Panel Tabs” on page 343

1. In the Station Manager window’s toolbar, select an access level

of Tuning.

2. In the Station Manager window’s Display menu, select Station

Setup.

3. In the Station Setup window’s navigation pane, locate and select

the Channels control mode needing compensation.

4. In the Station Setup window, click .

5. In the Compensators panel, click the APC tab.

WARNING Changes in compensation values made with hydraulic pressure on can

result in unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before changing values.

6. In the APC tab, define APC values:

A. Set the Convergence Rate.

B. For Adaptation State, select Resume.

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WARNING Changes in function generator frequency made with APC selected and
hydraulic pressure on can result in unexpected actuator movement.

A moving actuator can injure anyone in its path.

Avoid changing frequency values while running APC. If you must change
frequency, always clear the actuator area first.

7. To save the values, go to the Station Manager window’s File

menu and select Save Parameters.

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About AIC
Adaptive Inverse Control (AIC) is a linear compensation technique that
automatically adjusts a compensation filter that filters the command
signal to achieve the desired response signal. AIC is an effective digital
control technique for improving tracking accuracy in mainly linear
servohydraulic test systems.

• AIC works well on signals that have a wide frequency content.

• AIC adapts quickly and automatically to changes in system

dynamics.

• AIC works directly from test data created by the test.

The Station Builder application must first enable AIC before it can be
used as a compensation method. For more about enabling AIC, see
“Enable optional compensators” on page 47.

How AIC works The presence of dynamics in a test system can result in large tracking
errors, especially at higher frequencies. The AIC compensator identifies
these dynamics and actively adjusts an inverse-dynamics compensation
filter between the function generator and the test system. This active
adjustment precorrects the command signal for system dynamics,
resulting in optimal tracking.

While testing, compensation filter adaptation can be switched off once

the optimum filter has been determined, or left on to continue to
compensate and track changes in the specimen response.

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Test
System
Function
Generator Compensation
(or Drive File) Filter PID
-1( w )
Controller
T +
Desired Drive Actuator
å
–
LVDT

AIC consists of a
Compensation Filter and an Feedback
Inverse Test System identifier. (Actual)
Position

Inverse
System
Identifier Response

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How to Configure AIC

For specifics about the controls referenced in this section, see: “Station
Setup Window/Compensators Panel Tabs” on page 343

1. In the Station Manager window’s toolbar, select an access level

of Tuning.

2. In the Station Manager window’s Display menu, select Station

Setup.

3. In the Station Setup window’s navigation pane, locate and select

the Channels control mode that is to receive AIC compensation.

4. In the Station Setup window, click .

5. In the Compensators panel, click the AIC tab.

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WARNING Changes in compensation values made with hydraulic pressure on can
result in unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before changing values.

6. In the AIC tab, define AIC values:

A. Set the Convergence Rate.

B. Set the Anticipation.

C. Set the Impulse Response.

D. Set the Crossover Freq.

E. Select the required Pre-emphasis Filter.

Note Stroke control systems may require selection of an F or F2

pre-emphasis filter to allow the compensator to adapt to a wide
range of frequencies.

F. Set the Operating Band.

G. For the Adaptation State, select Resume.

H. For the AIC Coefficients Reference, select Update.

7. To save the tuning values, go to the Station Manager window’s

File menu and select Save Parameters.

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How to Tune AIC

Tuning an AIC compensator involves the following procedures:

• Find the initial Impulse Response for the displacement control

mode.

• Set up the Scope window to monitor frequency response.

• Set up an AIC tuning program.

• Run the AIC tuning program.

Find the initial Use the following procedure to determine the initial Impulse
Impulse Response Response setting for the displacement control mode.

Skip to “Set up the scope to monitor frequency response” on page 210

if you are using AIC only with the force control mode.

1. Remove any specimen.

2. In the Station Manager window’s toolbar, select an access level

of Tuning.

3. In the Station Manager window’s toolbar, click .

4. Set up the Scope window to display the command and

displacement feedback signals from the channel using AIC:

A. For Channel, select the channel whose command and

displacement signals are to be monitored.

B. For Signal, select the channel’s command and displacement

signals.

C. For Plot Mode, select Time.

D. For Trace Time, enter 1.0 Sec.

5. In the Station Manager window’s navigation pane, click .

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6. Set up a tuning program in the Function Generator panel:

A. For Channel, select the channel using AIC.

B. For Control Mode, select displacement.

C. For Command Type, select Cyclic.

D. For Target Setpoint, set 0 cm.

E. For Amplitude (±), select a value appropriate for the test

using the AIC compensation method.

F. For Frequency, set 1 Hz.

G. For Wave Shape, select Square.

H. For Compensator, select None.

7. Apply station hydraulic pressure.

8. Start the tuning program.

9. Observe the Scope window to determine the initial Impulse

Response setting.

The initial Impulse Response setting is the lag time between the
command and displacement signals.

This channel’s initial

Impulse Response setting
is 0.1 seconds

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10. In the Station Setup window, display the AIC tab for the selected
channel’s displacement control mode.

11. In the AIC tab, enter the initial Impulse Response setting for the
channel’s displacement control mode.

Set up the scope to Set up the Scope window to monitor the command and feedback
monitor frequency frequency response.
response
1. In the Scope window:

A. For Plot Mode, select Frequency.

B. In the toolbar, click .

2. In the Setup for Scope window, click the Frequency Mode tab.

3. In the Frequency Mode tab:

A. For Sampling Rate, select 1024 Hz.

B. For Buffer Size, select 1024.

C. In Calculations:

– For Averaging, select Linear.

– For Windowing, select None.

– Leave Show DC Value unchecked.

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D. In Vertical Axis:

– For Display, select ASD.

– For Scaling, select Linear.

Leave the Setup for Scope window open to make

adjustments while tuning is in progress.

Set up a tuning 1. Install a dummy specimen.

program
2. Set up and enable limits to protect yourself and your equipment.

3. In the Function Generator panel, set up an AIC tuning program:

A. Select the desired Channel.

B. Select the Control Mode whose AIC compensation is to be

tuned.

C. For Command Type, select Random.

D. For Target Setpoint, set a value appropriate for your

specimen.

E. For RMS Amplitude (±), set a value appropriate for the test
using the AIC compensator.

F. For Frequency Min/Max, set values appropriate for the test

using the AIC compensator.

G. For Wave Shape, select the desired Random function with

the correct spectral pre-emphasis function.

For displacement control modes, select Random - 1/F.

H. For Compensator, select AIC.

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Station Manager

Run the AIC tuning 1. In the Station Setup window, display the AIC tab for the selected
program channel’s control mode.

2. In the AIC tab, click Reset to reset the filter and coefficients.

WARNING Pressing the Station Controls panel’s Run button will put actuators in
motion.

A moving actuator can injure anyone in its path.

Always clear the actuator area before pressing the button.

3. In the Station Manager window’s Station Controls panel, click

to start the AIC tuning program.

4. In the Scope window, observe AIC tracking accuracy.

As needed, click to rescale the scope.

The signals should continue to converge as the compensator

builds coefficients.

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5. In the AIC tab, adjust the Impulse Response, Anticipation, and

Crossover Frequency as needed.

Adjusting the Anticipation or Impulse Response automatically

resets filter coefficients.

A. When optimum convergence is reached while in Adaptation

State, select Hold.

The controller will continue to compensate with the current

coefficients, but it will not continue adapting them.

B. Select Update to update the coefficient references.

6. To save the values, go to the Station Manager window’s File

menu and select Save Parameters.

Using the coefficients The AIC tab’s controls let you use the coefficients that were
determined through tuning as a starting position for your actual test.

• Select Restore or Restore All Channels to recall coefficients

from the parameter set.

• During testing, to track and compensate for changes in specimen

response:

– Set Convergence Rate to 10%.

– For Adaptation State, select Resume.

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About ALC
Arbitrary End-Level Compensation (ALC) is available only in
MultiPurpose TestWare application command processes. In addition,
frequency compensation can be enabled on single channel
configurations only.

ALC is an adaptive compensation technique that improves the tracking

accuracy of spectrum profiles played out with the MultiPurpose
TestWare application. This technique is also known as “from-to matrix
compensation.”

The advantages of this technique are:

• ALC works well on both linear and nonlinear specimens.

• ALC adapts quickly and automatically to changes in system

dynamics.

How ALC works ALC compensates for peak and valley errors by building and
continually updating a matrix of amplitude compensation factors.

The matrix is two-dimensional, with axes mapped to either plus or

minus full scale or a subrange of full scale. Each axis is divided into 16,
32, or 64 equal parts, with each part representing a fraction of the
defined range. The horizontal axis is labeled “From Level” and the
vertical axis is labeled “To Level.”

With each pass of the spectrum, the peak/valley errors are calculated,
and an estimated compensation factor is stored in the matrix. Before
the command generator generates a new segment, it notes the required
“From” and “To” levels, and refers to the matrix to determine how
much to over-program the segment.

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The following 5×5 sample matrix is for illustration only. The

MultiPurpose TestWare process defines actual matrixes as either 16×16,
32×32, or 64×64. An additional diagonal row (not shown here) is
added to the matrix to handle situations where the “From” and “To”
levels map to the same cell.

From Level

– FS 0 + FS

– FS x1 x2 x3 x4 x5

x6 x7 x8 x9 x10
To Level

0 x11 x12 x13 x14 x15 When going from O to + FS, ALC
uses this compensation factor.
x16 x17 x18 x19 x20

+ FS x21 x22 x23 x24 x25

Calculated Amplitude Compensation Factors

In order to run the test as fast as possible, ALC builds a second matrix
to store frequency compensation factors. The command generator uses
these factors to maintain the optimum spectrum play-out speed.
Frequency compensation can only be enabled on single-channel tests.

The matrix compensation factors are updated during each pass of the
spectrum. Depending on the convergence rate, it may take a number
of cycles before the feedback amplitude tracks the command to within
tolerance. To stop updating the compensation factors when the signals
converge, select Hold in the Station Setup window’s ALC tab. The
compensator will continue compensating with the current factors.

For more information on using the ALC compensator with your test,
refer to the Model 793.10 MultiPurpose TestWare manual.

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How to Configure ALC
1. In the Station Manager window’s toolbar, select an access level
of Tuning.

2. In the Station Manager window’s Display menu, select Station

Setup.

3. In the Station Setup window’s navigation pane, locate and select

the Channels control mode to receive ALC.

4. In the Station Setup window, click .

5. In the Compensators panel, click the ALC tab.

WARNING Changes in compensation values made with hydraulic pressure on can

result in unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before changing values.

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6. In the ALC tab, define ALC values:

A. Set the Ampl. Convergence.

B. Set the Amplitude Min/Max.

C. Set the Freq Convergence.

D. Set the Frequency Min/Max.

E. For Adaptive State, select Resume All.

7. To save the values, go to the Station Manager window’s File

menu and select Save Parameters.

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About PVP
The Peak/Valley Phase (PVP) compensator combines amplitude and
phase (APC) with Peak/Valley Compensation (PVC) algorithms to
improve the amplitude and phase tracking of the command and sensor
feedback.

The advantages of this technique are:

• PVP compensates for phase error, unlike PVC.

• PVP provides good amplitude tracking on nonlinear specimens,
unlike APC.

The PVP compensator’s computational requirements may limit the

sampling rate on multichannel systems.

Note The PVP compensator may have difficulty compensating command

waveforms below 0.5 Hz.

Basically, the PVP is a phase compensator cascading into a peak/valley

compensator. The phase algorithm is similar to the one used by APC.
The peak/valley algorithm is identical to the one used by PVC.

PVP Compensator Actuator

Segment Phase Peak/Valley

PIDF
Generator Compensator Compensator

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How to Configure PVP

1. In the Station Manager window’s toolbar, select an access level
of Tuning.

2. In the Station Manager window’s Display menu, select Station

Setup.

3. In the Station Setup window’s navigation pane, locate and select

the Channels control mode to receive PVP.

4. In the Station Setup window, click .

5. In the Compensators panel, click the PVP tab.

WARNING Changes in compensation values made with hydraulic pressure on can

result in unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before changing values.

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6. In the PVP tab, define PVP values:

A. Set the Convergence Rate.

B. Set the Sensitivity.

C. For Adaptation State, select Resume.

7. To save the values, go to the Station Manager window’s File

menu and select Save Parameters.

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Running Tests
The Station Manager application runs a variety of tests using:

• The Basic TestWare application

• The MultiPurpose TestWare application

• External programming sources

A typical test includes the following tasks:

1. Setting up error and limit detectors.

2. Performing a shunt cal if required

3. Configuring the outgoing program signal.

4. Configuring any digital inputs and outputs.

5. Running the test.

6. Adjusting the setpoint and span during a test.

Additional See “Station Manager Controls and Displays” on page 273 for a
information complete description of this application’s controls and indicators.

For specifics about the controls referenced in this section, see:

• “Station Setup Window/Inputs Panel Tabs” on page 310.

• “Station Setup Window/Drive Panel—Two Stage Valves” on page

327.

• “Station Setup Window/Drive Panel—Three Stage Valves” on page

329.

• “Station Setup Window/Detectors Panel Tabs” on page 373.

• “Station Setup Window/Digital Input/Outputs Panel Tabs” on page

367.

• “Linearization Data Window” on page 446.

• “Function Generator Control Panel” on page 485.

• “Setpoint and Span Window” on page 513.

• “Remote Setpoint Adjust Window” on page 515.

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About Detectors
Detectors monitor various system signals and perform specific actions
when user-specified conditions are met.

Limit detectors monitor sensor feedback signals. If the sensor signal

exceeds specified limits, the controller triggers a detector action.

Error detectors monitor the difference between the command signal

and the corresponding feedback signal. If the error exceeds specified
limits, the controller triggers a detector action.

Detector summaries The Station Manager window Station Controls panel’s Station
Limits, Interlock, and Program indicators summarize the detector
status and actions.

Detector status and

actions

The Station Setup window’s Detectors panel displays tabs that

summarize the Limit Detectors and Error Detectors status.

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A summary of settings, actions, and status for all detectors can also be
accessed by clicking on the Station Manager window’s Station
Controls panel toolbar. See “Detectors Window” on page 504 for
more detailed information.

Indicator colors The detector indicators use colors to show their status:

• Gray—The detector action is set to Disabled.

• White—The detector action is set to Indicate.

• Green—The detector action is set to Station Power Off,

Interlock, Program Interlock, Program Stop, Program Hold,
or Custom Actions.
• Red—The detector has tripped.

The Station Setup window displays Limit Detectors and Error

Detectors panels with tabs that define limit and error detectors’
actions.

The following actions can be selected:

Disabled—No action occurs. This setting grays out the indicator.

Indicate—Writes a message to the Message Log. This setting turns the
indicator white.

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Station Power Off—Writes a message to the Message Log, clamps
the servovalve (if enabled in the .hwi file), turns off pressure at the
hydraulic service manifold (HSM), and stops any program. This setting
turns the indicator green.
Interlock—Writes a message to the Message Log, turns off pressure
at both the HSM and hydraulic power unit (HPU), and stops any
program command. This setting turns the indicator green.
Program Interlock—Writes a message to the Message Log, stops any
program command, but does not turn off station hydraulic pressure.
This setting turns the indicator green. The Program Interlock needs
to be reset before the test can run again.
Program Stop—Writes a message to the Message Log and stops any
program command. Produces the same action as clicking the Program
Stop button on the Station Controls panel. This setting turns the
indicator green.
Program Hold—Writes a message to the Message Log and places a
hold on any program command. Produces the same action as clicking
the Program Hold button on the Station Controls panel. This setting
turns the indicator green.
Custom Action—Executes a user-defined action created in the
Event-Action Editor window. This setting turns the indicator green.
See “Event-Action Editor Window” on page 448 for more about using
this window.

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About Limit Detectors

Limit detectors monitor sensor feedback signals. If the sensor output
exceeds specified limits, the controller triggers a detector action.

Limit detectors can be used to:

• Reduce the risk of personal injury and equipment damage when

installing specimens.

• Indicate when defined sensor levels are detected.

• Automatically stop tests when defined sensor levels are detected.

Establish limits on at least one input signal to prevent damage if
closed-loop control is lost. Control can be lost if the specimen breaks
or a cable gets disconnected.

The following figure shows how a limit detector can automatically stop
a test. Here the limits have been set to remove station power when the
displacement feedback reaches either +1.1 cm or -1.1 cm. When the
specimen breaks, the +1.1 cm upper limit is reached. The limit detector
then trips, stops the test, and removes station power.

Upper Limit Detected

Specimen Breaks

1 cm Upper Limit= +1.1 cm

0 cm

–1 cm Lower Limit= –1.1 cm

Note If you do not know what the limit setting should be, you can run
your test and monitor the sensor signal with a Peak/Valley or a
Running Max/Min meter. While running the test, note the upper
and lower sensor values. Set the limits to slightly more than the
maximum and minimum values.

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How to Set Limit Detectors
Method 1 1. In the Station Manager window’s Display menu, select Station
Setup.

2. In the Station Setup window’s navigation pane, click Detectors

and then Limits.

3. In the Limit Detectors panel:

A. Click the Upper Limits tab and set Upper Limit and Upper
Action as required for each signal.

B. Click the Lower Limits tab and set Lower Limit and Lower
Action as required for each signal.

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Method 2 1. In the Station Manager window’s Display menu, select Station

Setup.

2. In the Station Setup window’s navigation pane, locate and select

the Channels feedback signal to be monitored for limits.

3. In the Station Setup window, click .

4. In the Inputs panel, click the Limits tab.

5. In the Limits tab, set the signal’s Upper Limit, Upper Action,
Lower Limit, and Lower Action.

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Method 3 1. In the Station Manager window’s Station Controls panel
toolbar, click .

2. In the Detectors window, click the Limit Detectors tab.

As needed,
type in new values

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How to Monitor Limit Detectors

Method 1 1. In the Station Manager window’s Display menu, select Station
Setup.

2. In the Station Setup window’s navigation pane, click Detectors

and then Limits.

3. In the Limit Detectors panel, click the Limits Summary tab.

Method 2 1. In the Station Manager window’s Station Controls panel

toolbar, click .

2. In the Detectors window, click the Limit Detectors tab.

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About Hardware Limit Detectors
For FlexTest IIm systems, a limit detector on each 497 conditioner
continuously compares its associated transducer output value to preset
upper and lower limit values set in the Hardware Limits tab.

Note Hardware limit detectors are supported as an option that must be

enabled.

When a conditioner’s upper or lower limit is exceeded its limit detector

is enabled, triggering an interlock.

Hardware limit detectors can be used to:

• Reduce the risk of personal injury and equipment damage when

installing specimens.

• Automatically stop tests when defined sensor levels are detected.

How to Set Hardware Limit Detectors

Method 1 1. In the Station Manager window’s Display menu, select Station
Setup.

2. In the Station Setup window’s navigation pane, click Detectors

and then Hardware Limits.

3. In the Hardware Limit Detectors panel:

A. Set the Upper Limits value as required for each signal.

B. Set the Lower Limits value as required for each signal.

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Method 2 1. In the Station Manager window’s Display menu, select Station

Setup.

2. In the Station Setup window’s navigation pane, locate and select

the Channels feedback signal to be monitored for limits.

3. In the Station Setup window, click .

4. In the Inputs panel, click the Hardware Limits tab.

5. In the Hardware Limits tab, set the conditioner’s Upper Limit,

and Lower Limit.

6. As required, enable or disable the hardware limits and excitation

interlocks by using the Enable Hardware Interlocks (Limits
and Excitation) checkbox.

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Method 3 1. In the Station Manager window’s Station Controls panel
toolbar, click .

2. In the Detectors window, click the Hardware Limit Detectors

tab.

As needed,
type in new values

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How to Monitor Hardware Limit Detectors

Method 1 1. In the Station Manager window’s Display menu, select Station
Setup.

2. In the Station Setup window’s navigation pane, click Detectors

and then Hardware Limits.

Method 2 1. In the Station Manager window’s Station Controls panel

toolbar, click .

2. In the Detectors window, click the Limit Detectors tab.

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About Error Detectors
Error detectors monitor the difference between a command signal and
its feedback signal. If the difference exceeds set limits, the controller
triggers a specified detector action.

Note Each defined control mode has an error detector, but only the error
detector for the active control mode of a channel is active

Error detectors can:

• Warn when a specimen is beginning to fail.

• Shut down the test before the specimen breaks.

When using error detectors, remember that:

• Effective error detection requires a properly tuned servoloop.

• Error limits should be set low on low frequency and static tests.

• Error limits should be set high on high frequency tests.

Error

Error

Feedback

Test Command

Feedback
Test Command
At lower frequencies the error level is At higher frequencies the error level is usually
usually smaller since the feedback can track larger since the phase lag creates a larger error.
the command more closely.

The Error Detectors tab has two limits:

• Inner Limit—Typically set to indicate the beginning of failure.

• Outer Limit—Typically set to stop the test.

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How to Set Error Detectors

Method 1 1. In the Station Manager window’s Display menu, select Station
Setup.

2. In the Station Setup window’s navigation pane, click Detectors

and then Errors.

3. In the Error Detectors panel:

A. Click the Outer Error tab and set the Outer Error and
Outer Action as required for each signal.

B. Click the Inner Error tab and set the Inner Error and
Inner Action as required for each signal.

Method 2 1. In the Station Manager window’s Station Controls panel

toolbar, click .

2. In the Detectors window, click the Error Detectors tab.

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As needed,
enter new values

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How to Monitor Error Detectors

Method 1 1. In the Station Manager window’s Display menu, select Station
Setup.

2. In the Station Setup window’s navigation pane, click Detectors

and then Errors.

3. In the Errors Detectors panel, click Error Summary tab.

As needed,
enter new values

Method 2 1. In the Station Manager window’s Station Controls panel

toolbar, click .

2. In the Detectors window, click the Error Detectors tab.

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About Sensor Ranges and Detectors
Sensor description Your system’s sensors convert measured mechanical values, such as
force, displacement, and pressure, into electrical signals that after
conditioning, are suitable for feedback for closed-loop control. Sensors
and sensor conditioners are calibrated together in pairs against a
standard to ensure their outputs accurately represent the physical
properties they are measuring.

Sensor ranges Every sensor has a full-scale capacity that defines its maximum
operating range. For example, an actuator that can extend its piston 6
cm from its fully retracted position is referred to as an actuator with a
“6-cm stroke.” The displacement sensor used with the actuator has a
full-scale capacity of 6 cm.

Full-range conditioners Some sensor conditioners, such as Model 493.25 Digital Universal
Conditioners, are full-range conditioners. They have only one range
that spans the sensor’s full-scale capacity.

Ranged conditioners Other sensor conditioners, such as Model 493.13 AC Conditioners and
Model 493.22 Dual DC Conditioners, may use two or more ranges.
Each range defines the electronic amplitude of the sensor’s feedback
signal for the purpose of providing better signal resolution. In other
words, it redefines the input channel to represent a portion of the
sensor's physical capacity.

With this type of sensor conditioner, you may create a range for any
portion of the sensor’s capacity. Typical ranges are: Range 1, 100%;
Range 2, 50%; Range 3, 20%; and Range 4, 10%.

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Range example Suppose a displacement sensor has a full-scale capacity of 10 mm. A

±5 mm range can operate across the full-scale range of the sensor (±5
mm). A ±2.5 mm range of the same sensor can operate across half the
capacity of the sensor (this redefines full scale to be ±2.5 mm).

Ranges represent a
portion of the sensor’s 10 mm
full-scale capacity 5 mm

Selecting ranges Be sure you select a range large enough to accommodate the
maximum sensor output expected during a test.

5 cm 2 cm

Select a full-scale range

to optimize the 2 cm
maximum sensor
output for a test 0 0

-2 cm

-5 cm -2 cm

For example, suppose your test requires a ±2.0 cm displacement. A ±6

cm or ±3 cm range functions properly, but a ±2 cm range provides the
best resolution.

When setting up a test, it is good practice to select a range slightly

larger than the largest value expected for the test. The smaller the
range, the better the resolution of the sensor’s signal.

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Initial limit detectors for When you select a range, the initial setting of the associated limit
each range detectors are ±130% of the range value. For example, suppose you
select Range 1 of your system’s force sensor, and that Range 1 is ±10
kN. In this case, the initial placement of the limit detectors will be ±13
kN.

Initial 13kN Limit

The application places 10 kN

the initial limit detectors
at ±130% of the
selected range (as
Range 1 0
shown).

-10 kN

Initial -13kN Limit

By default, limit detectors are initially disabled. So even if you enable a

limit detector at its initial setting (±130% of its range value), it still will
not work because the sensor conditioner’s hardware will saturate
before attaining ±130% of the current range.

Enabling limit detectors To allow a limit detector to work in a given range, you must:

• Change its limit value so that it falls within ±100% of its range, and

• Enable it (change its selected action from “Disable” to the desired

action)

9 kN Limit

To make a limit detector 10 kN

work, you must change its
initial setting so that it is
within ±100% of the
selected range Range 1 0
(as shown).

-10 kN

-7 kN Limit

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To set error and limit detectors, see “How to Set Limit Detectors” on
page 227, and “How to Set Error Detectors” on page 236.

Be aware of detector When you go from a larger range to a smaller range, limit detector do
settings when changing not automatically change, so they may not apply to your new range.
ranges When this occurs, the controller will display the following message:

“The range selected for signal ‘signal name’ has left one or
more of the signal's detectors outside of the new range.

Please verify that the detectors (limit and error) associated

with this signal are adjusted as necessary.”

For example, suppose you have a configuration in which Range 1

spans ±10 kN, with limits set at 9 kN and -5 kN, as shown below in the
figure to the left. Both limits are viable for Range 1.

Next, suppose you select Range 2, which spans ±6 kN, as shown

below in the figure to the right. In this case, the 9 kN limit would not
be applicable to Range 2, and the application would display the
message. However, the -5 kN limit still falls within the span of Range 2.

9 kN Limit 9 kN Limit

10 kN 10 kN

6 kN

Range 1 0 Range 1 Range 2 0

-6 kN

-10 kN -10 kN

-5 kN Limit -5 kN Limit

When you select a new range, review the limits you have defined for
the selected signal to ensure they are appropriate for your new range.

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About Digital Inputs/Outputs
Digital inputs are signals sent into the station controller from external
sources. Digital outputs are signals sent out from the station controller
to external devices. Input and output signals can be high, low, or
pulsed.

The Station Builder application must assign digital input and output
resources before the Station Manager application can use them. For
more about assigning digital input and output resources, see
“Allocating Controller Resources” on page 37.

About Digital Inputs

The Station Setup window’s Digital Inputs panel defines the
incoming signal’s trigger and its resulting action. Each digital input can
be assigned two different trigger/action sets.

Triggers The following input changes can trigger an action:

High/Low—Triggers when the input goes from a high state to a low

state.

Low/High—Triggers when the input goes from a low state to a high

state.

Either—Triggers when the input either goes from a high state to a low
state or from a high state to a low state.

Channel Low—Triggers when the channel goes low and stays

triggered as long as the channel remains low.

Channel High—Triggers when the channel goes high and stays

triggered as long as the channel remains high.

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Note Channel Low and Channel High trigger modes do not support the
following digital input actions: Program Stop, Program Hold, and
Custom Actions.

Actions Resulting actions include:

• Disabled—No action occurs.

• Indicate—Writes a message to the Message Low.

• Station Power Off—Writes a message to the Message Log,

clamps the servovalve, turns off pressure at the HSM, stops any
program command.

• Interlock—Writes a message to the Message Log, turns off

pressure at both the HSM and HPU, stops any program command,
and turns the Interlock indicator red.

• Program Interlock—Writes a message to the Message Log,

stops any program command, turns the Program indicator red,
but does not turn off station hydraulic pressure.

• Program Stop—Writes a message to the Message Log and stops

any program command. Produces the same action as clicking the
Program Stop button on the Station Controls panel. Channel
Low and Channel High trigger modes do not support this action.

• Program Hold—Writes a message to the Message Log and

places a hold on any program command. Produces the same
action as clicking the Program Hold button on the Station
Controls panel. Channel Low and Channel High trigger modes
do not support this action.

• Custom Action—Executes a user-defined action created in the

Event-Action Editor window. See “About the Event-Action Editor
Window” on page 246 for more about using this window.
Channel Low and Channel High trigger modes do not support
this action.

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How to Configure Responses to Digital Input Signals
1. In the Station Manager window’s Display menu, select Station
Setup.

2. In the Station Setup window’s navigation pane, double-click

Digital Inputs/Outputs and then click Inputs.

3. In the Digital Inputs panel:

A. Select the appropriate trigger(s) for each input.

B. Select the appropriate resulting action(s) for each input.

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About the Event-Action Editor Window

The Event-Action Editor window defines custom actions that can
occur in response to Limit Detector, Error Detector, Null Pacing
Timeout, and Digital Input events.

Important If you are using manual command, the defined actions Ramp
To and Stop At Level will not be triggered by a event (typically
a tripped limit). To trigger these actions you must be in “run”
mode when a limit is tripped; using either the function
generator, MultiPurpose TestWare, Basic TestWare, or any
other test application.

Custom action

For example, an action defined in the Event-Action Editor window

can be selected, in the Station Setup window’s Digital Input panel,
as an Action.

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How to Define a Custom Action
1. In the Station Manager window’s toolbar, select an access level
of Configuration.

2. In the Station Manager window’s Tools menu, select

Event-Action Editor.

3. In the Event-Action Editor window’s navigation pane, select

Actions by Type.

4. In the Event-Action Editor window:

A. Click Add.

B. Enter custom action Name, Message, and Severity.

C. Click Apply.

The defined action is now selectable, in the Station Setup

window’s Digital Inputs panel, as an Action that occurs in
response to a digital input Trigger.

This action can also be selected as a response to Limit

Detector, Error Detector, and Null Pacing Timeout events.

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How to Manually Control Digital Output Signals

Method 1 1. In the Station Manager window’s Display menu, select Station
Setup.

2. In the Station Setup window’s navigation pane, double-click

Digital Inputs/Outputs and then click Outputs.

3. In the Digital Outputs panel:

A. indicates that the output is on. If the output signal

resource is undefined, click this button to turn on the output
signal.

B. indicates that the output is off. If the output signal

resource is undefined, click this button to turn off the output
signal.

C. Use Assignment to assign a resource for each signal output

to external logic devices and switches.

D. Set signal polarity if required.

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Method 2 1. In the Station Manager window’s Station Controls panel
toolbar, click .

2. In the DI/Os window, click the Outputs tab.

3. In the Outputs tab:

A. Click to set the Output.

B. Click to clear the Output.

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About Shunt Calibration

Only DC conditioners require shunt calibration.

Shunt calibration verifies the calibration accuracy of a

sensor/conditioner pair.

How it works When you perform a shunt calibration, a precision resistor is placed
across the transducer bridge producing a known offset. This offset is
used to determine a “shunt cal voltage.”

By performing a shunt calibration immediately after calibrating your

sensor/conditioner pair, you can make the current shunt cal voltage
your Shunt Reference Value.

Whenever you start a new test or exchange a DC conditioner module,

you can perform another shunt calibration and compare the Current
Shunt Value to the saved Shunt Reference Value. Recalibrate the
sensor/conditioner pair if the two values differ by more than 20 mV.

Shunt Cal Sensor Feedback

Circuit Bridge

Excitation

Shunt Calibration Circuit

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How to Perform a Shunt Calibration
1. In the Station Manager window’s Display menu, select Station
Setup.

2. To apply a shunt calibration to a control mode:

A. In the Station Setup window’s navigation pane Channels,

locate and select the control mode needing a shunt
calibration.

B. In the Station Setup window, click .

To apply a shunt calibration to an auxiliary input:

In the navigation pane’s Auxiliary Inputs, click the input

signal needing shunt calibration.

3. In the Inputs panel, click the Shunt tab.

4. In the Shunt tab, perform the calibration.

A. As required, select the Current Range needing calibration.

B. In Select Shunt Type, select either (+) Shunt or (-) Shunt.

(FlexTest IIm systems only).

C. Click to apply the shunt.

5. Compare the Current Shunt Value to the Shunt Reference

Value.

A. In the Station Manager window’s toolbar, select an access

level of Calibration.

B. For the Shunt Reference Value units, select mv.

C. Recalibrate the sensor/conditioner pair if the values differ by

more than 20 mV.

D. To make the Current Shunt Value the new Shunt

Reference Value, click Update.

6. Click to remove the shunt.

Note Leaving the Shunt tab or choosing another item in the navigation
panel will automatically remove the shunt.

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About Program Outputs
Program output channels send analog program commands to external
controllers such as the Series 407 Controller and temperature
controllers.

External programmers can:

• Use the Station Manager application’s advanced programming

resources.

• Accommodate sensors that require special conditioning.

The Station Builder application must first create a Program Only,

Program with Feedback, or Command Plus Error program output
channel using an analog output before the Station Manager application
can output a program to an external programmer.

For more about using the Station Builder application to create program
output channels, see “Creating Program Channels” on page 40.

How to Adjust Program Output Signals

1. In the Station Manager window’s toolbar, select an access level
of Tuning.

2. In the Station Manager window’s Display menu, select Station

Setup.

3. In the Station Setup window’s navigation pane, locate and select

in Channels the drive needing adjustment.

4. In the Station Setup window, click .

5. In the Station Setup window navigation pane, select the channel

you want to adjust.

WARNING Changes in drive values made with hydraulic pressure on can result in
unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before changing values.

6. In the Drive panel:

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For Program and Control channels, set the Gain, Offset, and
Polarity.

For Program w/Feedback channels, set the Polarity.

For Program Only channels, set the Polarity and program output
Fullscale Min/Max values.

Fullscale Min/Max units and values may vary from what is

shown here, depending on the device being driven.

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How to Program with the Function Generator
The Station Manager window’s Function Generator can provide
simple programming for use when tuning the system and warming up
hydraulics.

Be sure to configure the compensator before starting your program.

See “Working with Compensators” on page 194.

The following steps give typical settings for setting up the Function
Generator to warm up a single-channel system that does not have an
installed specimen.

1. In the Station Manager window’s Application Controls panel,

click .

WARNING Changes in Function Generator values made with hydraulic pressure on

can result in unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before changing values.

2. In the Function Generator panel:

A. Select the Channel to be programmed.

B. Select a Control Mode of displacement.

C. Select a Command Type of Cyclic.

D. Set a Target Setpoint of midstroke.

Typically, the actuator should cycle around midpoint.

E. Set an Amplitude (±) that will move the actuator through

about 70% of its full displacement.

F. Set a Frequency of 0.25–0.5 Hz.

Note Displayed ranges for Target Setpoint, Amplitude, and Frequency are
saved and are restored when returning to a previously programmed
channel.

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G. Select a Wave Shape of Sine.

H. As needed, select a Compensator.

WARNING Pressing the Station Controls panel’s Run button will put actuators in
motion.

A moving actuator can injure anyone in its path.

Always clear the actuator area before pressing the button.

3. In the Station Manager window’s Station Controls panel:

A. Click Reset to clear interlocks.

B. Apply station power.

C. Click to start the program.

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How to Adjust Setpoint and Span During a Test
Reducing the Station Controls panel’s Master Span setting further
reduces an individual channel’s Span setting. For example: a Master
Span of 50% halves an individual channel’s Span of 50%, giving the
channel an effective 25% span.

The Setpoint controls can adjust the setpoint of both single channels
and multiple channels. Multiple channels are organized into a Master
Command Group, using the Channel Option window’s Master
Command tab, described on page 421.

When a Master Command Group becomes available, the Setpoint

and Span window displays a Channel button. Click this button to
choose between single channels and a Master Command Group.

WARNING Changes in Setpoint and Span values made with hydraulic pressure on
can result in unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before changing values.

1. In the Station Manager window Station Controls panel toolbar,

click .

2. In the Setpoint and Span window:

A. If the Channel button is available, click it to choose an
individual channel or a Master Command Group.
B. Set the Setpoint.
C. Set the Span.

Click to select a single channel

or a Master Command Group

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About the Optional Remote Setpoint Adjust

The optional Remote Setpoint Adjust (RSA) control box allows
remote adjustment of actuator setpoints, away from the computer
running the Station Manager application.

The Station Builder application must first allocate resources for the RSA
before the Station Manager can configure its control knobs. For more
about allocating resources, see “Setting Up Remote Setpoint Adjust” on
page 75.

How to Configure Remote Setpoint Adjust Controls

1. In the Station Manager window’s toolbar, select an access level
of Calibration.

2. In the Station Manager window’s Display menu, select Station

Setup.

3. In the Station Setup window’s navigation pane’s Remote

Setpoints, locate the knob to be configured.

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4. In the Remote Setpoint panel, configure the knob:

A. For Resolution, select Fine, Medium, or Coarse.

Knob movements with a Fine setting produce a small

actuator movement; equal knob movements with a Coarse
setting produce a large actuator movement.

B. Select a Polarity of Normal or Invert.

Typically, turning the knob clockwise with a Normal setting

increases the setpoint, extending the actuator.

About Channel Groups

Master Command and Master Span channel groups allow individual
actuators in a multichannel station to be controlled as a unit.

A Master Command channel group receives a common command

signal. The Channel Options window’s Master Command tab
defines Master Command groups.

Commands are applied to a Master Command group through:

• The Station Manager window’s Function Generator panel.

• The Manual Command window.

• The Setpoint and Span window.

A Master Span channel group has a common span. The Channel

Options window’s Master Span tab defines Master Span groups.

The span for a Master Span group is adjusted through the Station
Manager window Station Controls panel’s Master Span.

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A channel group allows these four actuators to be

controlled as a single unit

Additional ‘See “Station Manager Controls and Displays” on page 273 for a
information complete description of this application’s controls and indicators.

For specifics about the controls referenced in this section, see:

• “Master Span Tab” on page 418.

• “Master Command Tab” on page 421.

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How to Create a Master Command Group
1. In the Station Manager window’s toolbar, select an access level
of Tuning.

2. In the Station Manager window’s Tools menu, select Channel

Options.

3. In the Channel Options window, click the Master Command

tab.

4. In the Master Command tab, define a Master Command group:

A. Click Add Group and enter the new Group Name.

B. Select the Channel Dimension to be used by the group.

This selection determines the Available Channels/Modes.

C. Use the < > buttons to move highlighted selections between

Available Channels/Modes and Master Command
Channels.

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How to Select a Master Command Group

This section describes selecting a Master Command group for the
Function Generator panel.

1. In the Station Manager window’s Application Controls panel,

click .

2. In the Function Generator panel, select a Master Command

group.

A. Click Channel to change this button to Group.

The Group button will be unavailable if no Master

Command group has been defined.

B. As needed, select the right Master Command group.

The Setpoint and Span and Manual Command windows

use a similar method for selecting a Master Command
group.

Click

Select

The Control Mode switches to the mode(s) associated with

the Master Command group when the Station Controls
panel is clicked or when the Manual Command
window’s Enable Manual Command is selected.

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Defining a Master Span Group
1. In the Station Manager window’s toolbar, select an access level
of Tuning.

2. In the Station Manager window’s Tools menu, select Channel

Options.

3. In the Channel Options window, click the Master Span tab.

4. In the Master Span tab, define a Master Span group:

A. Click in Available Channels to select channels.

B. Use the < > buttons to move highlighted selections between

Available Channels and Master Span Channels.

By default, all channels start off as Master Span Channels.

The Station Controls panel’s Master Span becomes

unavailable if no Master Span Channels are selected.

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Using Rig Command (Park/Ride)

The Rig Commands tab on the Channel Options window defines Park
and Ride levels for vehicle testing. Park defines a level the enabled
channels can move to before hydraulic shut down. Ride defines a level
the enabled channels can move to before running any test.

Park and ride positioning, a system option, uses the Manual Command
window to move the actuators to their specified Park or Ride levels.
See “Using Manual Command Park/Ride” on page 512.

Setting Park/Ride There are two different ways to set park and ride values on the Rig
values Commands tab:

• Enter park and ride values in the Command 1/Command 2

columns.

• Click the Use Current button in the Command 1 (Park) or

Command 2 (Ride) box to use the current levels from all
non-disabled control modes for the corresponding Command 1
and Command 2 values.

See “Rig Commands Tab” on page 438 for more information.

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Setting Park/Ride If required, park or ride positioning values can be set concurrently for
channel groups a desired group of channels.

1. In the Station Manager window’s Station Controls panel

toolbar, click to open the Manual Command window.

2. Click the Channel button to toggle to Group.

3. Select the desired channel group for park or ride positioning. If an

appropriate channel group has not been created, see “How to
Create a Master Command Group” on page 261.

Low High
Value Value
Slider Slider

4. Click the Enable Manual Command box to activate manual

command.

5. Move the low value slider and/or the high value slider so that they
meet to form a “group value” slider.

6. Set the group value slider to the required Park or Ride position for
all actuators in the group.

7. Click the appropriate Use Current button on the Rig Commands

tab on the Channel Options window to use these new Park or
Ride position values for your actuator channel group.

See “About Channel Groups” on page 259 for more information on

grouping system channel.

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Station Manager

Working with Message Logs

About Message Logs
Message Logs record station and test events as they occur, including:

• File events

• Resource mismatches

• Hydraulic and station state changes

• Detector activity

• Over-temperature conditions

• Full-scale changes

When you open a new station configuration file, the Station Manager
application automatically creates a Message Log file to record events
that occur with the specific configuration.

The Station Manager application saves the Message Log file in your
config folder. The Station Manager application names the Message Log
file, using the station configuration name with a .log extension.

When the station configuration closes, the Station Manager application

saves the Message Log file. When the configuration reopens and
station activity resumes, new messages get appended to the old.

Auto-archive message

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Auto-archiving When the Message Logs window accumulates 1000 messages, it
automatically saves these messages to an archive file and then clears
them from its display.

The first archived file is named configuration file name000.log, the

second is named configuration file name001.log, and so on. This
continues until the last file is named configuration file name499.log.
The system then starts again with the oldest file, which is typically
configuration file name000.log

CAUTION Too many messages combined with the auto-archive feature can use up
all your disk space.

Running out of disk space can stop your test and result in lost data.

Use the Station Options window’s Station Log tab to filter messages sent
to the Message Logs window. For more information, see “Station Options
Window” on page 410.

Additional For specifics about the controls referenced in this section, see:
information
• “Message Logs Window” on page 403.

• “Station Log Tab” on page 410.

How to Open a Message Log

In the Station Manager window’s toolbar, click to display the

Message Logs window. Up to three Message Logs windows can be
opened.

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How to Print a Message Log

1. In the Station Manager window’s toolbar, click .

2. In the Message Logs window’s toolbar, click .

3. In the Message Log Print window:

A. As needed, click Print Range selections to define what is

printed.

B. As needed, click Print Filters to apply Severity and Source

filters to what prints.

C. Click OK to print the log.

How to Print the Message Log to File

1. In the Station Manager window’s toolbar, click .

2. In the Message Logs window’s toolbar, click .

3. In the Message Log Print to File window, specify the File Name
and its location. By default, the file is saved as a text (.txt) file.

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How to Add a User Entry to the Message Log

1. In the Station Manager window’s toolbar, click .

2. In the Message Logs window’s toolbar, click .

3. In the Message Log-Add Entry window:

A. Select a Message Severity level.

B. Select a Message Log source.

C. Enter a Message Text.

D. Click Add to enter the message.

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How to Delete a User Entry from the Message Log

Only user entries can be deleted.

1. In the Station Manager window’s toolbar, click .

2. In the Message Logs window, highlight the user entry to be

deleted.

3. In the Station Manager window’s toolbar, click .

4. In the Delete Confirmation window, click OK to delete the

selected entry.

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How to Define Which Messages Get Logged
1. In the Station Manager window’s Tools menu, select Station
Options.

2. In the Station Options window, click the Station Log tab.

3. In the Station Log tab’s Message Capture:

A. Select a Minimum Severity to set the least severe message

level to be logged.

B. Select a Source to log messages from just This Application

Only or All Applications.

4. As needed, click Delete Older Than to enable automatic deletion

and then enter the number of Days.

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How to Manually Archive a Message Log

1. In the Station Manager window’s toolbar, click .

2. Select a message in the Message Logs window, The highlighted

message and all earlier messages will be saved and cleared from
the log.

3. In the Message Logs window’s toolbar, click to archive the

file.

4. In the Archive Confirmation window, click Yes.

The Message Logs window displays a message showing when

the file was archived, and its name and location.

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Station Manager
Station Manager Controls and Displays

Access Level—see page 277

Menu Bar—see page 274

Toolbar—see page 275

Application Controls
Panel—see page 483

Station Controls
Panel—see page 498

Message Pane—see
page 278

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 Menu Bar
Station Manager

Menu Bar

Electronic
Open Station Station Options Documentation
Open Parameters Channel Options About
Save Parameters Station Setup Sensor File Editor
Save Parameters As Meters Event Action Editor
Delete Parameters Scope Calculation Editor
Save View Message Logs Unit Set Editor
Restore Saved View Minimize All
Restore Default View Show All Basic TestWare
Print Parameters MultiPurpose TestWare
Print Preview MultiPurpose TestWare (Edit Only)
Printer Setup Profile Editor
Print to File Station Builder
Exit Station Desktop Organizer
Station Manager

The Menu Bar has commands for managing the Station Manager
application. The toolbar has some of the more frequently used
commands.

• For more about the File menu, see “File Menu” on page 279.

• For more about the Display menu, see “Display Menu” on page
289.

• For more about the Applications menu, see “Applications Menu”

on page 408.

• For more about the Tools menu, see “Tools Menu” on page 409.

• For more about the Help menu, see “Help Menu” on page 482.

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 Station Manager Window Toolbar

Station Manager
Station Manager Window Toolbar

Print Preview Station Setup

Print Parameters Message Logs
User Level
Save Parameters Meters
Help
Open Station Scope

Create Station Setup Operator

Display Station Setup Tuning
Create Message Log Calibration
Display Message Log Configuration
Create Meters
Display Meters
Create Scope
Display Scope

Station Manager Window Toolbar (part 1 of 2)

ITEM DESCRIPTION

Displays the Open Station window. See “Open Station Window” on

page 281 for more information.

Saves station parameters to the currently selected parameter file.

Prints the current parameter set.

Displays the Print Preview window. See “Print Preview Window”

on page 286 for more information.

Create Station Setup—Displays the Station Setup window.

Display Station Setup—Restores a minimized Station Setup
window.
See “Station Setup Window” on page 290 for more information.

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Station Manager Window Toolbar (part 2 of 2)

ITEM DESCRIPTION

Create Message Log—Displays a Message Logs window.

Display Message Log—Restores minimized Message Logs
windows.
See “Message Logs Window” on page 403 for more information.

Create Meters—Displays a Meters window. Click a second time to

display a second Meters window.
Display Meters—Restores minimized Meters windows.
See “Meters Window” on page 392 for more information.

Create Scope—Displays a Scope window. Click a second time to

display a second Scope window.
Display Scope—Restores minimized Scope windows.
See “Scope Window” on page 395 for more information.

Sets User Access to restricted Tuning, Calibration, and

Configuration levels.
See “Access Level” on page 277 for more information.

Displays on-line help.

See “Help Menu” on page 482 for more information.

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Station Manager
Access Level

This control limits a user’s ability to access and change tuning,

calibration, and configuration settings. Access to Tuning, Calibration,
and Configuration levels require passwords that were created during
software installation.

See “Setting Access Levels” on page 129 for additional information.

Note Calibration and Configuration are at the same access level. Going
from Configuration to Calibration (or vice versa) requires a
password.

Note After making higher level changes, it is a good idea to always return
to the Operator level.

.
Access Level List
ITEM DESCRIPTION
access level Sets user access to tuning, calibration, and configuration controls.
Operator The default user level.
This level does not need a password and has the fewest privileges.
Tuning Enter this level to make tuning adjustments.
Calibration Enter this level to edit all Station Manager application windows except
the Event-Action Editor and Calculation Editor windows. This level
allows you to modify calibration parameters for both normal and
reconfigurable signals.
Configuration Enter this level to make changes in the Event-Action Editor and
Calculation Editor windows.
This level allows you to change the name, dimension, or calibration
parameters for reconfigurable signals. Calibration parameters for normal
signals can only be changed at the Calibration level.
Some applications may have to be closed to enter this level.

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Station Manager

Station Manager Window Message Pane

This panel, at the bottom of the Station Manager window, displays

Warning, Error, and Fatal Error messages from any application. Up
to 50 messages can be displayed. New messages replace old messages.

The Message Logs window provides a complete listing of station

events. See page 403 for more about this window.

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Station Manager
File Menu

This menu’s commands create, open, save, and print parameter sets.

File Menu (part 1 of 2)

ITEM DESCRIPTION
Open Station Displays the Open Station window.
See “Open Station Window” on page 281 for more information.
Open Parameters Displays the Open Parameter Set window.
See “Open Parameter Set Window” on page 283 for more
information.
Save Parameters Saves station parameters to the currently selected parameter file.
Save Parameters As Displays the Save Parameters As window.
See “Save Parameters As Window” on page 284 for more
information.
Delete Parameters Displays the Delete Parameters window.
See “Delete Parameter Set Window” on page 285 for more
information.

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File Menu (part 2 of 2)

ITEM DESCRIPTION
Save View Saves the current positions of Station Manager application windows.
Restore View Restores the Save View setting.
Restore Default View Restores windows to the positions that they had when the station
configuration was last loaded.
Print Parameters Prints the current parameter set.
Print Preview Displays the Print Preview window.
See “Print Preview Window” on page 286 for more information.
Printer Setup Displays a Print Setup window specific to your printer.
Print to File Displays the Print Parameters to File window.
See “Print Parameters to File Window” on page 288 for more
information.
Exit Quits the Station Manager application.
Note Before exiting Station Manager, station power must be off and
any ongoing test must be stopped. You may also need to shut
down some applications connected to the station before you can
shut down the station.

Note All 793.00 software applications connected to the station will shut
down upon exiting Station Manager.

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Open Station Window

Path File menu > Open Station

Station Manager window toolbar >

This window opens station configuration files.

Note Before opening Station Manager, station power must be off and any
ongoing test must be stopped. You may also need to shut down
some applications connected to the station before you can open the
station.

See “How to Open a Station Configuration File” on page 124 for more
information.

Open Station Window (part 1 of 2)

ITEM DESCRIPTION
Look In Selects drives and directories where configuration files are located.
Configuration Files Displays files in the selected directory.
File Name Displays the name of the selected configuration file.

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Open Station Window (part 2 of 2)

ITEM DESCRIPTION
Files of Type Selects the type of file displayed. The extension for application
configuration files is .cfg.
Parameter Sets Displays parameter sets that can be used with the selected
configuration.
Note Station Manager saves the last used interlock chain to the station
configuration, and will attempt to restore it if currently available.

Interlock Chain Specifies the interlock chain for the selected station configuration.
Note Station Manager saves the last used interlock chain to the station
configuration, and will attempt to restore it if currently available.

Enable Remote Station Enables the optional remote station control (RSC) on the selected
Control interlock chain.
For FlexTest™ series systems with multiple RSCs, the selected
Interlock Chain determines which RSC gets enabled.

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Open Parameter Set Window

Path File menu > Open Parameters

This window changes station configuration parameter sets.

Note Before opening any parameter sets, station power must be off and
any ongoing test must be stopped.

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 File Menu
Station Manager

Save Parameters As Window

Path File menu > Save Parameters As

This window saves a parameter set under a new name.

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Station Manager
Delete Parameter Set Window

Path File menu > Delete Parameters

This window deletes a parameter set.

The currently loaded parameter set cannot be deleted.

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Station Manager

Print Preview Window

Path File menu > Print Preview

Station Manager window toolbar >

This window displays a print preview of the parameter set. A toolbar

facilitates access and display of parameter set changes.

Asterisks (*) identify items that have been changed since the file was
opened. In addition, you can highlight these changes by selecting
Enable Change Highlighting on the Print Preview toolbar.

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 File Menu

Station Manager
Print Preview Toolbar

Enable/Disable Change Highlighting

Refresh Print
Previous Change
Next Change

Print Preview Toolbar

ITEM DESCRIPTION
Next Change Goes to the next change on the Print Preview window.
Previous Change Goes to the previous change on the Print Preview window.
Refresh Allows you to see current parameter set changes without closing and
reopening the Print Preview window. The current change(s) are
highlighted.
Enable/Disable Change Allows you to enable or disable highlighting of parameter set changes.
Highlighting

Print Prints the current parameter set.

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Print Parameters to File Window

Path File menu > Print to File

This window creates a text file that contains information about the
station configuration’s current parameter set.

Print Parameters to File Window

ITEM DESCRIPTION
Save In Selects the drive and directory where the text file (extension .txt) is
saved.
Using the default config directory ensures that all your files end up
in one place.
File Name Specifies the text file’s name.
Save as Type Automatically appends a .txt extension to the File Name.

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Station Manager
Display Menu

This menu’s commands display station setup and monitoring windows.

Display Menu
ITEM DESCRIPTION
Station Setup Displays the Station Setup window.
See “Station Setup Window” on page 290 for more information.
Meters Displays the Meters windows.
See “Meters Window” on page 392 for more information.
Scope Displays the Scope windows.
See “Scope Window” on page 395 for more information.
Message Logs Displays the Message Logs window.
See “Message Logs Window” on page 403 for more information.
Minimize All Minimizes, with the exception of the Station Manager window, all
open Station Manager application windows.
Show All Restores all minimized Station Manager application windows.

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 Station Setup Window
Station Manager

Station Setup Window

Path Display menu > Station Setup

Station Manager window toolbar >

Navigation Pane

Channel Buttons
Panel

Channel Buttons Detail

Channel Input Signals

Channel Drive

Channel Tuning

Channel Compensators

Sync Current Channel

This window defines the basic elements in the station configuration

parameter set. It combines tuning, setup, monitoring, and status
summary functions.

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Station Manager
Additional For information about using the controls described in this section, see:
information
• “Calibrating Sensors and Configuring Feedback” on page 131.

• “Tuning Your System” on page 540.

• “Working with Readout Devices” on page 158.

• “Working with Compensators” on page 194.

• “Running Tests” on page 222.

The station configuration loaded in the Station Manager application

determines the availability of some of the panels and buttons described
in the following table.

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Station Setup Window (part 1 of 2)

ITEM DESCRIPTION
navigation pane Displays a tree view of the station configuration, organized by
resource type, with control Channels at the top.
Selections within the navigation pane determine the Channel
buttons and right-hand pane displays.

Selections within the navigation pane determine what appears in the

Station Setup window’s right-hand panels. For example, a selection
within Channels displays Channels buttons and panels relevant for
configuring control channels; a Readouts selection displays panels
for defining readout signals.
Channels Displays the Channel Status panel which has tabs summarizing
control channel status and values.
Selecting a specific control channel within Channels displays these
Channel buttons:

Displays the Inputs panel tabs used to configure and calibrate

the selected channel’s sensor input signals. See “Station Setup
Window/Inputs Panel Tabs” on page 310 for more information.

Displays the Drive panel used to adjust the selected channel’s

drive signal. See “Station Setup Window/Drive Panel—Two Stage
Valves” on page 327 and “Station Setup Window/Drive Panel—Three
Stage Valves” on page 329 for more information.

Displays the Tuning panel tabs used to tune the selected

channel’s PIDF control modes. See “Station Setup Window/Tuning
Panel Tabs” on page 337 for more information.

Displays the Compensators panel tabs used to apply

compensation to the selected channel’s drive signal. See “Station
Setup Window/Compensators Panel Tabs” on page 343 for more
information.

Applies the current control channel and control mode (on

Station Setup) to the function generator channel/mode and the
scope. See “Station Setup Window/Sync Current Channel” on page
357.

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Station Setup Window (part 2 of 2)
ITEM DESCRIPTION
Readouts Displays the Readouts panels, which displays the values of all test
station readout signals and configures readout signals.
See “Station Setup Window/Readouts Panels” on page 358
Auxiliary Inputs Displays Auxiliary Inputs panels, which configure auxiliary sensor
input signals and display their values.
See “Station Setup Window/Auxiliary Inputs Panels” on page 360
Station Signals Displays the Station Signals panel, whose tabs display all station
signal values and other signal information.
See “Station Setup Window/Station Signals Panel Tabs” on page 363
Digital Displays Digital Inputs/Outputs panels, whose tabs display the
Inputs/Outputs status of digital inputs and outputs and configure the test station’s
response to digital inputs.

See “Station Setup Window/Digital Input/Outputs Panel Tabs” on

page 367
Detectors Displays Detectors panels, which summarize detector status and
configure error and limit detectors.

See “Station Setup Window/Detectors Panel Tabs” on page 373

Calculations Displays Calculations panels, which display calculated signals’
output values, their formulas, and hardware specific controls.

See “Station Setup Window/Calculations Panels” on page 384

Remote Setpoint Displays Remote Setpoint panels, which summarize Remote
Adjust Setpoint Adjust (RSA) knobs’ channel assignments and sensitivity.

See “Station Setup Window/Remote Setpoints Panels” on page 390

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Navigation pane The navigation pane shows a tree view of the station configuration,
starting with control Channels.

Use + and - to expand and contract the tree view.

Type
Channel Name
Control Modes

+ Expands View

– Contracts View

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Station Setup Window/Channel Status Panel Tabs

Channel Summary Tab

Path Station Setup window > navigation pane > Channels > Channels
Summary tab

This tab displays the status for each channel’s active control mode.

Use Channel List to select the channel(s) you want to display. You
can choose to display the status of all system channels (All Channels)
or a selected system channel.

You can select a group of channels for display in Channel List. See
“Channel Lists Tab” on page 440 for more information.

Channel Summary Tab (part 1 of 2)

ITEM DESCRIPTION
Active Mode Displays each channel’s active control mode.
Power Displays each channel’s power source.
Span Displays the current Span value for each channel’s active control mode.
These Span values are not editable.

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Channel Summary Tab (part 2 of 2)

ITEM DESCRIPTION
Setpoint Displays the current Setpoint value for each channel’s active control
mode. These Setpoint values are not editable.
Out of Range Displays the status of each channel’s feedback signal:
White—Within range.
Yellow—Out of Range.
Red—Saturated.

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Fullscale Tab
Path Station Setup window > navigation pane > Channels > Fullscale tab

This tab displays editable minimum and maximum sensor ranges for
each channel’s active control mode.

You can select a group of channels for display in Channel List. See
“Channel Lists Tab” on page 440 for more information.

Fullscale Tab
ITEM DESCRIPTION
Full scale Allows you to edit the displayed full-scale minimum and maximum range
for the sensor used in each channel’s active control mode.

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Tuning Tab
Path Station Setup window > navigation pane > Channels > Tuning tab

This tab allows you to set the displayed PIDF values and filter settings
for each channel’s active control mode. These parameters can also be
set on the Station Setup Tuning panel’s Adjustments and Filter tabs.

You can select a group of channels for display in Channel List. See
“Channel Lists Tab” on page 440 for more information.

Tuning Tab
ITEM DESCRIPTION
P Gain Sets the proportional gain (P Gain) value for each channel’s active
control mode.
I Gain Sets the integral gain (I Gain) value for each channel’s active control
mode.
D Gain Sets the derivative gain (D Gain) value for each channel’s active
control mode.
F Gain Sets the feed forward gain (F Gain) value for each channel’s active
control mode.
Filter Sets the Filter setting for each channel’s active control mode.

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Drive Tab
Path Station Setup window > navigation pane > Channels > Drive tab

This tab displays editable servovalve drive signal parameters for each
control channel based on the type of valve driver used by a channel.

You can select the channels displayed in the Channel List. See
“Channel Lists Tab” on page 440 for more information.

Dual Valve Driver For each channel that uses a dual valve driver, the following editable
parameters are displayed. These parameters can also be set on the
Station Setup Drive panel.

Drive Tab (Dual Valve)

ITEM DESCRIPTION
Polarity Sets the polarity for each dual valve control channel drive signal.
Valve Balance 1/Valve Sets the valve balance setting for each dual valve control channel.
Balance 2

Dither Amplitude Sets the amplitude of the dither signal for each dual valve control
channel.

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3-Stage Valve Driver For each channel that uses a 3-stage valve driver, the following
editable parameters are displayed. These parameters can also be set on
the Drive panel’s Valve, Inner Loop, and Conditioner tabs (for
3-stage valves).

Driver Tab (3-stage valve) (part 1 of 2)

ITEM DESCRIPTION
Valve Polarity Sets the polarity for each 3-stage valve control channel drive signal.
Valve Balance Sets the valve balance setting for each 3-stage valve control channel.
Dither Amplitude Sets the amplitude of the dither signal for each 3-stage valve control
channel.
Inner Loop Gain Sets the inner loop gain value for each 3-stage valve control channel.
Inner Loop Rate Sets the inner loop rate value for each 3-stage valve control channel.
Rate Input Selection Allows you to select the current rate input selection setting.
Spool Position—allows you to select the feedback from the
servovalve’s spool as the rate input. Most systems use this setting.
Inner Loop Error—allows you to select the inner loop error as the
rate input. This is the difference between spool position feedback
and spool position command.
Excitation Sets the AC excitation value that the conditioner is applying to the
servovalve for each 3-stage valve control channel.
Phase Sets the phase for the conditioner’s demodulation circuitry that
receives the sensor’s output.

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Driver Tab (3-stage valve) (part 2 of 2)
ITEM DESCRIPTION
Offset Sets the offset applied by the conditioner to the sensor’s output
signal.
Gain Sets the amount of gain applied by the conditioner to the sensor’s
output signal.
Gain values affect tuning settings and the noise sensitivity of the
valve command.
Conditioner Polarity Sets polarity setting of the spool output or inner loop output signal.
Monitor Mux Output Allows you to select an inner loop signal for monitoring.

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Compensators Tab
Path Station Setup window > navigation pane > Channels >
Compensators tab

This tab displays editable compensator parameters for each channel’s

active control mode based on the type of compensation method being
used.

You can select a group of channels for display in Channel List. See
“Channel Lists Tab” on page 440 for more information.

Null Pacing For channels using the null pacing method, the following active
control mode parameters can be set.

Compensators Tab (Null Pacing)

ITEM DESCRIPTION
Static Error Sets the maximum error setting as a percentage of the command
Tolerance signal. Exceeding this error setting activates Static Null Pacing
which holds the command.
Static Timeout Sets the time allowed for feedback to come within tolerance.

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Compensators Tab (Null Pacing)
ITEM DESCRIPTION
Timeout Action Sets the test station’s action when the Timeout is exceeded.
(Static)

Dynamic Error Sets the maximum error setting as a percentage of the command
Tolerance signal. Exceeding this error setting activates Dynamic Null Pacing
which slows the command.
Dynamic Timeout Sets the time allowed for feedback to come within tolerance.
Timeout Action Sets the test station’s action when the Timeout is exceeded.
(Dynamic)

PVC For channels using the Peak/Valley Compensation (PVC) method, the
following active control mode parameters are displayed.

Compensators Tab (PVC)

ITEM DESCRIPTION
Convergence Rate This setting determines how quickly compensation values are
applied to converge the feedback and command signals.
Sensitivity This setting determines how much the feedback signal must change,
as a percentage of its peak-to-peak value, before a peak or valley is
detected.
Adaptation State Allows you to select one of the following two adaptation states:
Hold—Continues to use current values but stops adapting new
values.
Resume—Adapts and continuously updates compensation values.

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APC For channels using the amplitude and phase control (APC)
compensation method, the following active control mode parameters
are displayed.

Compensators Tab (APC)

ITEM DESCRIPTION
Convergence Rate This setting determines how quickly compensation values are
applied to converge the feedback and command signals.
Adaptation State Allows you to select one of the following two adaptation states:
Hold—Continues to use current values but stops adapting new
values.
Resume—Adapts and continuously updates compensation values.

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AIC For channels using the adaptive inverse control (AIC) compensation
method, the following active control mode parameters are displayed.

Compensators Tab (AIC)

ITEM DESCRIPTION
Convergence Rate Determines how quickly compensation values are applied to
converge the feedback and command signals.
Anticipation Sets the time delay between the desired and response signals.
Impulse Response Sets the length of the adaptive filter, which influences how
completely the dynamics of the controller/actuator/specimen
combination are cancelled.
Crossover Freq. Sets the crossover frequency.
When applying AIC to a dual compensation mode configured in the
Station Builder application for Amplitude Control Only, set this
control to 0.
Operating Band Sets the range in which AIC operates. Frequencies outside this range
are considered noise.
Adaptation State Allows you to select one of the following two adaptation states:
Hold—Continues to use current values but stops adapting new
values.
Resume—Adapts and continuously updates compensation values.

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ALC For channels using the Arbitrary End-Level Compensation (ALC)

method, the following active control mode parameters are displayed.

Compensators Tab (ALC)

ITEM DESCRIPTION
Ampl. Convergence This setting determines how quickly compensation values get
applied to converge the feedback and command signal amplitudes.
Amplitude MIN/MAX Allows you to set amplitude MIN/MAX values as follows:
Min—Fixed at 0.
Max—Displays the factor by which the compensated command’s
amplitude can exceed the original command’s amplitude.
Freq Convergence This setting determines how quickly compensation values get
applied to converge the feedback and command signal frequencies.
Frequency MIN/MAX Allow you to set frequency MIN/MAX values as follows:
Min—Displays the minimum factor by which the compensated
command’s frequency can exceed the original command’s frequency.
Max—Displays the maximum factor by which the compensated
command’s frequency can exceed the original command’s frequency.

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PVP For channels using the Peak/Valley Phase (PVP) method, the following
active control mode parameters are displayed.

Compensators Tab (PVP)

ITEM DESCRIPTION
Convergence Rate This setting determines how quickly compensation values are
applied to converge the feedback and command signals.
Sensitivity This setting determines how much the feedback signal must change,
as a percentage of its peak-to-peak value, before a peak or valley is
detected.
Adaptation State Allows you to select one of the following two adaptation states:
Hold—Continues to use current values but stops adapting new
values.
Resume—Adapts and continuously updates compensation values.

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Calibration Tab
Path Station Setup window > navigation pane > Channels > Calibration
tab

This tab displays editable calibration parameters for the active control
mode of each channel. Displayed calibration parameters depend on
the conditioner type and the active control mode selected.

You can select a group of channels for display in Channel List. See
“Channel Lists Tab” on page 440 for more information.

Calibration Tab (part 1 of 2)

ITEM DESCRIPTION
Polarity Sets the polarity of the feedback signal to change how the actuator
responds to commands:
Normal—A positive command can extend or retract the actuator,
depending on system conventions.
Invert—Reverses the actuator’s Normal response.
Pre-Amp Sets the coarse gain applied. Pre-Amp gain cannot be adjusted with
hydraulics on.
Gain Sets the gain applied to the sensor’s output signal.
Total gain cannot be adjusted with hydraulics on.

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Calibration Tab (part 2 of 2)
ITEM DESCRIPTION
Post Amp Sets the fine gain applied. This control’s range is user adjustable.
Note For DUC B conditioners in AC mode the Post Amp gain slider has a
maximum limit of 52.

Excitation Sets the excitation applied to the sensor. The proper excitation is usually
specified by the sensor manufacturer.
Typically AC sensors require a 10 V AC excitation signal and DC sensors
require a 10 V DC signal.
DeltaK Specifies the amount of delta K applied to the sensor’s output signal.
Equally negative and positive inputs cause asymmetry in the sensor’s
output signal. Delta K compensates for this asymmetry.
Zero Adjusts the offset applied by the conditioner to the sensor’s output signal
to set this signal’s zero point.
Fine Zero Applies a fine zero offset to the sensor’s output signal.
(if available)

Zero/Balance For 497.22 DC Conditioners—Provides either pre-amp offset (coarse

zero) or bridge balance control, depending 497.22 DC jumpering.
(DC Conditioners only)
See the Model 497.22 Dual DC Conditioner manual for more information
about the required jumpering.

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Station Setup Window/Inputs Panel Tabs

Sensor Tab
Path Station Setup window > navigation pane > Channels control mode >

> Sensor tab.

This tab assigns sensor calibration files to the internally conditioned

input signals used in control modes. It also assigns Transducer IDs,
used with 493 hardware, to these control mode signals.

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Sensor Tab (part 1 of 2)
ITEM DESCRIPTION
Current Range Displays the current range.
Full scale Displays the full-scale minimum and maximum values for the current
range.
Sensor File Selects available sensor calibration files.
(Transducer ID) appears when Transducer ID modules are selected.
Assign Assigns the selected Sensor File or Transducer ID to the current signal.
File Name Displays the sensor calibration file name.
Dimension Displays the dimension used in the conditioner output.
Conditioner Type Displays the compatible conditioner type for the selected Sensor File.
Sensor Name Names the sensor. Names can have up to 30 characters.
Sensor Serial # Enters the sensor serial number.
Conditioner Serial # Enters the conditioner serial number.
Last Calibration Date Enters the calibration date for the sensor/conditioner pair.
Hardware Resource Enters the sensor signal’s hardware resource. The Station Builder
application assigns this resource.
General Information Enters additional information as needed.
Ranges Displays the ranges available in the assigned sensor calibration file.
Range Name Names the selected range. Names can have up to 30 characters.
Note You may only change the name of the currently loaded range. Ensure
that the Current Range selection matches the Range Name, before
renaming a range.

Add Adds sensor ranges. After adding a new range, use the Calibration tab
to set the range’s Fullscale Min/Max range.
Delete Deletes the highlighted sensor range.
Save To Displays the Save Sensor File As window. Use this window to create a
sensor calibration file, containing settings from the Sensor, Calibration,
and Shunt tabs or to save to a Transducer ID.

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Sensor Tab (part 2 of 2)

ITEM DESCRIPTION
Save Saves settings from the Sensor, Calibration, and Shunt tabs to the
current sensor calibration file. Displays the Save Sensor File As window
if no file has been created.
Show TransID For Series 493 Conditioners with Transducer IDs—Displays Transducer
ID information. Use this information to verify that you are assigning the
correct Transducer ID.

Restore Restores the values on the Sensor, Calibration, and Shunt tabs from
the sensor calibration file or Transducer ID.
Note Restore is disabled if the input signal does not have a sensor file
assigned or the input signal control mode is the active feedback with
the system hydraulics on.

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Calibration Tab
Path Station Setup window > navigation pane > Channels control mode >

> Calibration tab

This tab defines the calibration values that a conditioner applies to its
sensor. This tab’s controls vary with the type of conditioner used.

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Calibration Tab (part 1 of 4)

ITEM DESCRIPTION
Fullscale Min/Max Sets the Current Range minimum and maximum values and the
feedback signal’s display units.
Ranges can be asymmetrical if the Max is greater than or equal to zero
and the Min is less than or equal to zero.
Polarity Sets the polarity of the feedback signal to change how the actuator
responds to commands:
Normal—A positive command can extend or retract the actuator,
depending on system conventions.
Invert—Reverses the actuator’s Normal response.
Resolution Sets the encoder or temposonics resolution value, typically the value
specified in documentation supplied with the sensor.
(Temposonics/Encoders
only) Note If want to use units different than those supplied in the sensor
documentation, enter the full scale and resolution in the supplied units
first, and then switch to the desired full-scale units. The units
conversion will be calculated automatically.

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Calibration Tab (part 2 of 4)
ITEM DESCRIPTION
Cal Type Sets the type of calibration used for the feedback signal.
The calibration types displayed in this list depend on the conditioner
type selected.
Gain/Delta-K—Select to use delta K for calibration of sensors. Allows
you to specify the amount of delta K applied to the sensor’s output
signal.
Equally negative and positive inputs cause asymmetry in the sensor’s
output signal. Delta K compensates for this asymmetry.
Gain/Linearization—Select to use linearization data for calibration of
sensors with full-range conditioners. This type of calibration allows use
of the Linearization Data window to precisely edit range data points.
mV/V Pos Tension—Select when a sensor has been calibrated so that a
positive output represents actuator retraction (tension).
mV/V Pos Comp—Select when a sensor has been calibrated so that a
positive output represents actuator extension (compression).
Gain Sets the gain applied to the sensor’s output signal.
Pre-Amp and Total gain cannot be adjusted with hydraulics on.
Note For mV/V Pos Tension and mV/V Pos Comp calibration types, Gain is a
read-only display.

Pre-Amp Set the coarse gain applied.

Post-Amp Sets the fine gain applied. This control’s range is user adjustable.
Total Displays the total gain applied. This value is a function of Pre-Amp and
Post-Amp values.
Entering a total gain value here causes the Station Manager application to
enter the Pre-Amp and Post-Amp values required to achieve this value.
Neg. Compression Adjust for the required -mV/V compression sensitivity value.
(mV/V Pos Tension only)

Pos. Tension Adjust for the required +mV/V tension sensitivity value.
(mV/V Pos Tension only)

Neg. Tension Adjust for required -mV/V tension sensitivity value.

(mV/V Pos Compression
only)

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Calibration Tab (part 3 of 4)

ITEM DESCRIPTION
Pos. Compression Adjust for required +mV/V compression value.
(mV/V Pos Compression
only)

Excitation Sets the excitation applied to the sensor. The proper excitation is usually
specified by the sensor manufacturer.
Typically AC sensors require a 10 V AC excitation signal and DC sensors
require a 10 V DC signal.
Phase Adjusts the phase of the feedback signal based on the excitation signal.
(AC only)
Optimal phase adjustments produce the maximum output signal from the
sensor. Phase values are usually between 30º–45º.
Delta K Specifies the amount of delta K applied to the sensor’s output signal.
Equally negative and positive inputs cause asymmetry in the sensor’s
output signal. Delta K compensates for this asymmetry.
Note For mV/V Pos Tension and mV/V Pos Comp calibration types, Delta K
is a read-only display.

Zero Adjusts the offset applied by the conditioner to the sensor’s output signal
to set this signal’s zero point.
Zero controls vary by conditioner type.
Auto Zero Zeroes the sensor signal to make the current output the new zero point.
(DC only)

Fine Zero Applies a fine zero offset to the sensor’s output signal.
(if available)

Zero/Balance For 497.22 DC Conditioners—Provides either pre-amp offset (coarse

(DC only) zero) or bridge balance control, depending on 497.22 DC jumpering.
See the Model 497.22 Dual DC Conditioner manual for more information
about the required jumpering.

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Calibration Tab (part 4 of 4)
ITEM DESCRIPTION
Save Saves settings from the Sensor, Calibration, and Shunt tabs to the
current sensor calibration file.
Displays the Save Sensor File As window if no file has been created.
Restore Restores the values on the Sensor, Calibration, and Shunt tabs from
the sensor calibration file or Transducer ID.
Note Restore is disabled if the input signal does not have a sensor file
assigned or the input signal control mode is the active feedback with
the system hydraulics on.

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Calibration Tab for a Calculated Input

Path Station Setup window > navigation pane > Channels control mode

using calculated input > > Calibration tab

This tab displays the expression used in the selected control mode that
uses a calculated input.

For more about defining calculations, see “Calculation Editor Window”

on page 459.

Calculation Tab for a Calculated Input

ITEM DESCRIPTION
Fullscale Min/Max Specifies the selected inputs full-scale minimum and maximum
values. The result of this calculation gets clipped to these values.
Expression Displays the formula used to produce the input.
Use the Calculation Editor window to define the formula.
Uses Displays a list of the parameters and signals that are used within this
expression.

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Shunt Tab
Path Station Setup window > navigation pane > Channels force control

mode > > Shunt tab

This tab performs shunt calibrations of DC conditioner/sensor pairs.

Shunt calibration verifies the current calibration accuracy of the
sensor/conditioner pair.

This tab’s controls vary slightly depending on the type of DC

conditioner used.

For more information about using this tab, see “About Shunt
Calibration” on page 250.

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Shunt Tab
ITEM DESCRIPTION
Gain Sets the gain applied to the sensor’s output signal.
Total and Pre-amp Gain cannot be adjusted with hydraulics on.
Pre-Amp Set the coarse gain applied.
Post-Amp Sets the fine gain applied. This control’s range is user adjustable.
Total Displays the total gain applied. This value is a function of Pre-Amp and
Post-Amp values.
Entering a Total value causes the Station Manager application to enter
the Pre-Amp and Post-Amp values required to achieve this value.
Excitation Sets the excitation applied to the sensor. The proper excitation is usually
specified by the sensor manufacturer.
Typically DC sensors require a 10 V DC excitation signal.
Select Shunt Type (+) Shunt—Connects the shunt resistor to a positive arm of the sensor’s
resistive bridge circuit.
(Available for FlexTest
IIm only) (–) Shunt—Connects the shunt resistor to a negative arm of the sensor’s
resistive bridge circuit.
Shunt Reference Value Displays the saved shunt reference value.
Update Makes the Current Shunt Value the new Shunt Reference Value.
Current Shunt Value Displays the current shunt value.
On/Off These buttons apply and remove the shunt.
Save Saves settings from the Sensor, Calibration, and Shunt tabs to the
current sensor calibration file.
Displays the Save Sensor File As window if no file has been created.
Restore Restores the values on the Sensor, Calibration, and Shunt tabs from
the sensor calibration file or Transducer ID.
Note Restore is disabled if the input signal does not have a sensor file
assigned or the input signal control mode is the active feedback with
the system hydraulics on.

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Station Manager
Offset/Zero Tab
Path Station Setup window > navigation pane > Channels control mode >

>Offset/Zero tab

This tab applies a zeroing offset to feedback signals and shifts the
conditioners’ zero references.

For additional information on using this tab, see “About Offset” on

page 149.

Offset/Zero Tab
ITEM DESCRIPTION
Offset Applies an offset to zero the selected conditioner’s feedback signal.
Auto Offset Lock Select to disable Auto Offset for the Tuning and Operator user levels.
Available at the Calibration user level.

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Offset/Zero Tab
ITEM DESCRIPTION
Auto Offset Automatically applies a zeroing offset to the selected conditioner’s
feedback signal.
Manual Offset Manually applies a zeroing offset to the selected conditioner’s feedback
signal.
If station power is on, this control cannot be used to offset active control
modes.
Electrical Zero Applies an offset to make the selected conditioner’s sensor signal zero.
If station power is on, Auto Zero and Manual Zero cannot be used on
active control modes.
Electrical Zero Lock Select to disable Auto Zero for the Tuning and Operator user levels.
Available at the Calibration user level.
Auto Zero Automatically applies an offset to zero the selected conditioner’s sensor
signal.
Manual Zero Manually applies an offset to make the selected conditioner’s sensor
signal zero.
Current Value Displays the current output of the selected signal.

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Limits Tab
Path Station Setup window > navigation pane > Channels control mode >

> Limits tab

.

This tab sets feedback signals’ limit values and the test station’s
response if these limits are exceeded.

For additional information, see “About Limit Detectors” on page 226.

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Limits Tab
ITEM DESCRIPTION
Upper Limit Sets the upper limit that the feedback signal must cross to trigger the
Upper Action.
The adjustment range equals 130% of the selected range’s full scale.
Lower Limit Sets the lower limit that the feedback signal must cross to trigger the
Lower Action.
The adjustment range equals 130% of the selected range’s full scale.
Upper Action/ Adjusts the test station’s response when a Limit trips.
Lower Action
Actions include:
Disabled—No action occurs. This setting grays out the Limit indicator.
Indicate—Writes a message to the Message Log. This setting turns the
Limit indicator white.
Station Power Off—Writes a message to the Message Log, clamps the
servovalve, turns off pressure at the hydraulic service manifold (HSM),
and stops any program. This setting turns the Limit indicator green.
Interlock—Writes a message to the Message Log, turns off pressure at
both the HSM and hydraulic power unit (HPU), and stops any program
command. This setting turns the Limit indicator green.
Program Interlock—Writes a message to the Message Log, stops any
program command, but does not turn off station hydraulic pressure. This
setting turns the Limit indicator green.
Program Stop—Writes a message to the Message Log and stops any
program command. Produces the same action as clicking the Program
Stop button on the Station Controls panel. This setting turns the Limit
indicator green.
Program Hold—Writes a message to the Message Log and places a
hold on any program command. Produces the same action as clicking
the Program Hold button on the Station Controls panel. This setting
turns the Limit indicator green.
Custom Action—Executes a user-defined action created in the
Event-Action Editor window. This setting turns the Limit indicator
green. See “Event-Action Editor Window” on page 448 for more about
using this window.
A tripped limit turns an enabled detector’s Limit indicator red.

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Station Manager
Hardware Limits Tab
Path Station Setup window > navigation pane > Channels control mode >

> Hardware Limits tab

This tab, provided on FlexTest IIm systems only, allows you to set
hardware limits for individual 497 conditioners in your system.

Hardware limits A limit detector on each 497 conditioner continuously compares its
associated transducer output value to preset upper and lower limit
values that you set in the Hardware Limits tab.

When a conditioner limit is exceeded, the limit detector is enabled.

The system responds by sending a digital request to the control system
for an emergency stop.

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Hardware Limits Tab

ITEM DESCRIPTION
Enable Hardware Select to enable hardware interlocks when previously set conditioner
Interlocks (Limits and limits or excitation values are exceeded.
Excitation)
Note If hardware interlocks are not enabled, interlock indicators will be gray
and the interlock will not occur.

Upper Limit Sets the upper limit that the conditioner’s feedback signal voltage must
exceed to trigger a hardware interlock.
Exceeding an upper limit writes a message to the Message Log, turns off
pressure at both the HSM and hydraulic power unit (HPU), and stops any
program command. The Upper Limit indicator turns green.
Lower Limit Sets the lower limit that the conditioner’s feedback signal voltage must
exceed to trigger a hardware interlock.
Exceeding an upper limit writes a message to the Message Log, turns off
pressure at both the HSM and hydraulic power unit (HPU), and stops any
program command. The Lower Limit indicator turns green.

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Station Manager
Station Setup Window/Drive Panel—Two Stage Valves

Path Station Setup window > navigation pane > Channels > Control

Channel n >

This panel configures control channel drive signals for two-stage valve
drivers.

The panels controls vary with the type of valve driver used.

For more information about using this panel, see “About Valve
Balance” on page 557 and “About Dither” on page 563.

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Drive Panel for Two-Stage Valve Drivers

ITEM DESCRIPTION
Fullscale Min/Max Displays the valve driver’s full minimum and maximum output
values.
Polarity Sets the polarity of the valve drive signal to Normal or Invert.
The Polarity cannot be changed when station pressure is on.
Valve Balance Compensates for minor mechanical imbalances in the servovalve.
A second Valve Balance displays if you have dual valves. See “How
to Balance Dual Valves” on page 559
Dither Amplitude Adjusts the amplitude of the dither signal.
Dither Frequency For Model 493.14 Valve Drivers—Adjusts the dither signal frequency.

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Station Setup Window/Drive Panel—Three Stage Valves
For additional information on using the tabs described in this section,
see “How to Tune the Inner Loop of Three-Stage Valves” on page 549.

Valve Tab for Three Stage Valve Drivers

Path Station Setup window > navigation pane > Channels > Control

Channel n > > Valve tab

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This tab configures the drive signal output of three-stage valve drivers.

Valve Tab for Three-Stage Valve Drivers (part 1 of 3)

ITEM DESCRIPTION
Fullscale Min/Max Displays the valve driver’s full minimum and maximum output values.
Polarity Sets the polarity of the valve drive signal to Normal or Invert.
Polarity cannot be changed with station pressure on.
Valve Balance Compensates for minor mechanical imbalances in the servovalve.
Dither Amplitude Adjusts the amplitude of the dither signal.
Dither Frequency For Model 493.15 3-Stage Valve Drivers—Adjusts the dither signal
frequency.

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Valve Tab for Three-Stage Valve Drivers (part 2 of 3)
ITEM DESCRIPTION
Service Port Output Select an inner loop signal to monitor:
(TestStar IIs, TestStar
IIm, FlexTest GT Valve Current—Final output to the servovalve expressed in voltage. The
Controllers) current-to-voltage relationship is 10 V DC = 50 mA (or 25 mA, depending
on the .hwi file setting.
Inner Loop Command—Input signal to the three-stage valve driver.
Demod Filter Output—The analog output of the demodulator prior to
gain.
Spool Offset—Signal is summed with spool position to remove any DC
offset. ±10 V represents ±4 V of zero summing.
Spool Position—The Conditioner Out signal summed with the Spool
Zero signal.
Preamp Output—The raw AC input from the spool LVDT.
Conditioner Out—Conditioned feedback signal from the servovalve’s
inner loop displacement sensor.
Voltage Reference (5V) —Internal board reference test only.
On TestStar™ IIs controllers, monitor signals through the J48 Service
connector.
On TestStar™ IIm and FlexTest™ GT controllers, monitor signals through
the 493.40 I/O carrier card’s J3 Service Connector.

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Valve Tab for Three-Stage Valve Drivers (part 3 of 3)

ITEM DESCRIPTION
Monitor Mux Output Select an inner loop signal to monitor:
(FlexTest IIm and
FlexTest CTC controllers) Valve Current—Final output to the servovalve expressed in voltage. The
relationship of current-to-voltage is 10 V DC = 50 mA.
Valve Balance—Amount of valve balance command applied by the
Valve tab’s Valve Balance control.
Inner Loop Command—Input signal to the three-stage valve driver.
Inner Loop Error—Inner Loop Command summed with the
Conditioner Out signal.
Spool Position—Conditioner Out signal summed with the Spool Zero
signal.
Conditioner Out—Conditioned feedback signal from the servovalve’s
inner loop displacement sensor.
Spool Zero—Amount of offset introduced by the Conditioner tab’s
Offset control.
Ground—Signal common.
On FlexTest™ series controllers, monitor signals through the 497.15’s
front panel tip jacks.

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Inner Loop Tab for Three Stage Valve Drivers
Path Station Setup window > navigation pane > Channels > Control

Channel n > > Inner Loop tab

This tab defines inner loop tuning values.

Inner Loop Tab for Three-Stage Valve Drivers

ITEM DESCRIPTION
Inner Loop Gain Sets the inner loop’s proportional gain, which affects the inner loop
response of the pilot valve.
Inner Loop Rate Sets the inner loop’s derivative gain, which affects the servovalve’s
stability at higher inner loop gain settings.
Rate Input Selection Spool Position—Sets the feedback from the servovalve’s spool as
the rate input. Most systems use this setting.
Inner Loop Error—Sets the inner loop error as the rate input. This
is the difference between spool position feedback and spool position
command.

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Conditioner Tab for Three-Stage Valve Drivers

Path Station Setup window > navigation pane > Channels > Control

Channel n > > Conditioner tab

This tab defines the inner loop conditioner values.

Conditioner Tab for Three-Stage Valve Drivers (part 1 of 2)

ITEM DESCRIPTION
Excitation Sets amount of AC excitation that the conditioner applies to the
servovalve’s sensor spool.
Phase Sets the phase for the demodulation circuitry that receives the
sensor’s output.
The sensor’s output rides on the conditioner’s excitation signal,
which is an AC signal. An optimal phase shift yields the maximum
DC output from the conditioner.
Offset Sets the offset applied by the conditioner to the sensor’s output
signal.

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Conditioner Tab for Three-Stage Valve Drivers (part 2 of 2)
ITEM DESCRIPTION
Gain Sets the amount of gain applied by the conditioner to the sensor’s
output signal.
Gain values affect tuning settings and the noise sensitivity of the
valve command.
Polarity Sets the polarity of the spool output or inner loop output signal to
Normal or Invert.
Polarity cannot be changed when the station pressure is on.

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Calculated Drive Signals Not Assigned Hardware

Path Station Setup window > navigation pane > Channels > Control

Channel n (with calculated output) > > Calculated

Calculated Drive Signals Not Assigned Hardware

ITEM DESCRIPTION
Calculated Specifies the calculated resource(s) that use the drive signal output
of the selected channel.

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Station Setup Window/Tuning Panel Tabs

Adjustments Tab—PIDF Control Modes

Path Station Setup window > navigation pane > Channels PIDF control

mode > > Adjustments tab

This tab tunes selected PIDF control modes for stability and accurate
response to commands.

This tab’s controls vary with the type of control mode being tuned.

For additional information, see “About Manual Tuning” on page 575.

Adjustments Tab—PIDF Control Modes (part 1 of 2)

ITEM DESCRIPTION
P Gain Adjusts the proportional gain applied to the selected control mode.
I Gain Adjusts the integral gain applied to the selected control mode.
D Gain Adjusts the derivative gain applied to the selected control mode.

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Adjustments Tab—PIDF Control Modes (part 2 of 2)

ITEM DESCRIPTION
F Gain Adjusts the feed forward gain applied to the selected control mode.
S Gain Sets the stabilization gain applied to the selected control mode.
S Gain enhances stability for systems that move large masses at high
speeds.
For S Gain to be available, the Station Builder application must have
added a stabilization resource to the channel when it defined the
configuration.
FL Filter Adjusts the forward loop filter applied to the selected control mode.
Show References Select to display the Refs column.
Refs Displays tuning reference values.
Refs values are saved in the parameter set. To save current PIDF values
for reference, copy them to Refs, and then save the parameter set.
> copies all PIDF values to Refs.
< copies all Refs values to the current PIDF values.
< > swaps all PIDF values with a Refs values.

— replaces the current PIDF values with saved parameter set

values.

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Adjustments Tab—CLC Control Modes
Path Station Setup window > navigation pane > Channels CLC control

mode > > Adjustments tab

This tab tunes channel limited channel control modes (CLC).

The Station Builder application creates CLC control modes. They are
used in specimen installation. For more information, see “Creating
Control Modes” on page 60.

See “About Channel Limited Channel (CLC) Control Modes” on page

590 for more information.

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Adjustments Tab—CLC Control Modes

ITEM DESCRIPTION
Active P Gain Adjusts the gain of the feedback signal used in the active control mode.
The active control mode controls the actuator movement. It is typically
displacement.
Limiting P Gain Adjusts the gain of the feedback signal used in the limiting control mode.
The limiting control mode puts limits on the actuator movement. It is
typically force.
Upper Limit/ Sets the limiting control mode’s upper and lower limits. The actuator, in
Lower Limit its movements, cannot exceed these limits.

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Filter Tab
Path Station Setup window > navigation pane > Channels PIDF control

mode > > Filter tab

This tab applies filtering to the selected control mode. Filtering reduces
the system’s resonance responses, allowing increased gain settings for
better system response.

See “About Tuning Filters” on page 600 for more information.

Filter Tab (part 1 of 2)

ITEM DESCRIPTION
Forward Loop Selects filter types:
Filter No Filter—Applies no filtering.
Low-pass—Attenuates signals above a specified Frequency.
Band-stop—Attenuates signals within a Bandwidth at a specified
Frequency.
Frequency For a Low-pass filter, attenuation occurs above this value.
For a Band-stop filter, attenuation occurs in a Bandwidth around this
value.

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Filter Tab (part 2 of 2)

ITEM DESCRIPTION
Bandwidth For Band-stop filters only—Sets the band around the Frequency in
which attenuation occurs.
For example, setting the Frequency to 400 Hz and the Bandwidth to
100 Hz attenuates signals that have frequencies between 350 - 450 Hz.
Stabilization Filter Note This control is available only for control modes that are equipped with
stabilization. For more information, see “Stabilization” on page 101.

Selects filter types:

1 Hz High-pass—Attenuates signals below 1 Hz. This filter is the default
Stabilization filter selection. It is compatible with configurations created
prior to Version 3.1 of MTS Series 793 software.
Band-pass—Attenuates signals outside of the band defined by the
Frequency Limits control. This selection provides additional tuning
capability for systems with complex tuning characteristics.
Frequency For Band-pass filters only—Sets the upper and lower frequency limits of
Limits the band outside of which signal attenuation occurs.
For example, setting the lower frequency to 10 Hz and the upper
frequency to 200 Hz creates a 190 Hz band in which signals can pass
without attenuation.

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Station Setup Window/Compensators Panel Tabs
For more about the compensation methods described in this section,
see “About Compensators” on page 194.

Null Pacing Tab

Path Station Setup window > navigation pane > Channels PIDF control

mode > > Null Pacing tab

This tab defines the null pacing compensation that can be applied
through the selected control mode to the command signal.

If the error becomes too large:

• Static null pacing holds the command at a steady state at the

peak/valley until the feedback reaches its target peak/valley.

• Dynamic null pacing slows the command frequency to allow the

feedback more time to track the command.

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See “About Null Pacing” on page 195 for more about this
compensation method.

Null Pacing Tab (part 1 of 2)

ITEM DESCRIPTION
Static Null Pacing Sets Static Null Pacing values.
Error Sets the maximum error, as a percentage of the command signal, allowed
Tolerance before Static Null Pacing holds the command.
Timeout Sets the time allowed for feedback to come within tolerance.
Timeout Sets the test station’s action when the Timeout is exceeded.
Action

Dynamic Null Pacing Sets Dynamic Null Pacing values.

Error Sets the maximum error, as a percentage of the command signal, allowed
Tolerance before Dynamic Null Pacing slows the command.

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Null Pacing Tab (part 2 of 2)
ITEM DESCRIPTION
Timeout Sets the time allowed for feedback to come within tolerance.
Timeout Sets the test station’s action when the Timeout is exceeded.
Action
Timeout Actions for Static Null Pacing and Dynamic Null Pacing
include:
Disabled—No action occurs. This setting grays out the Timeout
indicator.
Indicate—Writes a message to the Message Log. This setting turns the
Timeout indicator white.
Station Power Off—Writes a message to the Message Log, clamps the
servovalve, turns off pressure at the hydraulic service manifold (HSM),
and stops any program. This setting turns the Timeout indicator green.
Interlock—Writes a message to the Message Log, turns off pressure at
both the HSM and hydraulic power unit (HPU), and stops any program
command. This setting turns the Timeout indicator green.
Program Interlock—Writes a message to the Message Log, stops any
program command, but does not turn off station hydraulic pressure. This
setting turns the Timeout indicator green.
Program Stop—Writes a message to the Message Log and stops any
program command. Produces the same action as clicking the Program
Stop button on the Station Controls panel. This setting turns the
Timeout indicator green.
Program Hold—Writes a message to the Message Log and places a
hold on any program command. Produces the same action as clicking
the Program Hold button on the Station Controls panel. This setting
turns the Timeout indicator green.
Custom Action—Executes a user-defined action created in the
Event-Action Editor window. Turns Timeout indicator green. See
“Event-Action Editor Window” on page 448 for more about using this
window.
A Timeout turns an enabled Timeout indicator red.

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PVC Tab
Path Station Setup window > navigation pane > Channels PIDF control

mode > > PVC tab

This tab defines the peak/valley compensation (PVC) that can be

applied through the selected control mode to the command signal.

• PVC increases the command amplitude if it detects amplitude

roll-off in the feedback signal.

• PVC adjusts the mean command level if it detects mean-level

divergence in the feedback signal.

See “About PVC” on page 198 for more about this compensation
method.

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PVC Tab
ITEM DESCRIPTION
Convergence Rate Sets how quickly compensation values are applied to converge the
feedback and command signals.
Sensitivity Determines how much the feedback signal must change, as a percentage
of its peak-to-peak value, before a peak or valley is detected.
Adaptation State Hold—Continues to use current values but stops adapting new values.
Resume—Adapts and continuously updates compensation values.
Reset Clears acquired compensation values and restarts the adaptation process.
Clicking Reset with compensation applied may produce a spike in the
feedback signal. Read the Warning that follows this table.

WARNING Clicking Reset in this tab with hydraulic pressure on can result in
unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before clicking reset.

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APC Tab
Path Station Setup window > navigation pane > Channels PIDF control

mode > > APC tab

This tab defines the amplitude and phase control (APC) compensation
that can be applied through the selected control mode to the
command signal.

• APC increases the command amplitude if it detects roll-off in the

feedback signal.

• APC alters the command phase if it detects phase lag in the

feedback signal.

• The Station Builder application must enable APC to make it

available in the Station Manager application. For more
information, see “Enable optional compensators” on page 47.

See “About APC” on page 201 for more about this compensation
method.

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APC Tab
ITEM DESCRIPTION
Convergence Rate Sets how quickly compensation values are applied to converge the
feedback and command signals.
Adaptation State Hold—Continues to use current values but stops adapting new values.
Resume—Adapts and continuously updates compensation values.
Reset Clears acquired compensation values and restarts the adaptation process.
Clicking Reset with compensation applied may produce a spike in the
feedback signal. Read the Warning that follows this table.

WARNING Clicking Reset in this tab with hydraulic pressure on can result in
unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before clicking reset.

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AIC Tab
Path Station Setup window > navigation pane > Channels PIDF control

mode > > AIC tab

This tab defines the adaptive inverse control (AIC) compensation that
can be applied through the selected control mode to the command
signal.

• AIC is a linear compensation technique that senses the frequency

content of the drive signal, automatically generates an inverse
filter, and then filters the command to achieve the desired
response.

• The Station Builder application must enable AIC to make it

available in the Station Manager application. For more
information, see “Enable optional compensators” on page 47.

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See “About AIC” on page 204 for more about this compensation
method.

AIC Tab (part 1 of 2)

ITEM DESCRIPTION
Convergence Rate Sets how quickly compensation values are applied to converge the
feedback and command signals.
Anticipation Sets a time delay between the desired and response signals.
Impulse Response Sets the length of the adaptive filter, which influences how completely
the dynamics of the controller/actuator/specimen combination are
cancelled.
Crossover Freq Sets the crossover frequency.
When applying AIC to a dual compensation mode configured in the
Station Builder application for Amplitude Control Only, set this control
to 0.
Pre-emphasis Filter Allows selection of required type of pre-emphasis filter.
A pre-emphasis filter is used to make the convergence rate constant over
all frequencies, by boosting high frequencies and suppressing low
frequencies.
Operating Band Sets the range in which the AIC operates. Frequencies outside this range
are considered noise.
Adaptation State Hold—Continues to use current values but stops adapting new values.
Resume—Adapts and continuously updates compensation values.
Reset Clears acquired compensation values and restarts the adaptation process.
Changing Anticipation or Impulse Response when the filter is
adapting automatically resets all filter coefficients.
Clicking Reset with compensation applied may produce a spike in the
feedback signal. See the Warning that follows this table.
AIC Coefficients Manages coefficients used in the compensation filter and saved in the
Reference parameter set.
Coefficients do not display and do not change AIC tab values.
Restore Restores the saved AIC filter coefficients for the selected channel.

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AIC Tab (part 2 of 2)

ITEM DESCRIPTION
Restore All Restores the saved AIC filter coefficients for all channels.
Channels

Update Updates the coefficient references for the active channel.

To save the coefficient references, click Update and then save the
parameter set.
Reset All Clears acquired compensation values and restarts the adaptation process
Channels on all channels.
Clicking Reset All Channels with compensation applied may produce a
spike in the feedback signals. Read the Warning that follows this table.

WARNING Clicking Reset or Reset All Channels in this tab with hydraulic pressure
on can result in unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before clicking reset.

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Station Manager
ALC Tab
Path Station Setup window > navigation pane > Channels PIDF control

mode > > ALC tab

This tab defines the arbitrary end-level (ALC) compensation that can be
applied by the selected control mode to the command signal.

• ALC is available only in MultiPurpose TestWare application

processes.

• ALC uses a continuously updated matrix which stores

compensation factors developed from peak/valley errors to
improve the tracking accuracy of spectrum profiles.

See “About ALC” on page 215 for more about this compensation
method.

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ALC Tab
ITEM DESCRIPTION
Ampl. Convergence Sets how quickly compensation values get applied to converge the
feedback and command signal amplitudes.
Amplitude MIN/MAX Min—Fixed at 0.
Max—Sets the factor by which the compensated command’s amplitude
can exceed the original command’s amplitude.
Freq Convergence Sets how quickly compensation values get applied to converge the
feedback and command signal frequencies.
Frequency MIN/MAX Min—Sets the minimum factor by which the compensated command’s
frequency can exceed the original command’s frequency.
Max—Sets the maximum factor by which the compensated command’s
frequency can exceed the original command’s frequency.
Adaptive State Hold All—Continues to use current values but stops adapting new
values.
Resume All—Adapts and continuously updates compensation values.
Reset All Clears acquired compensation values and restarts the adaptation process.
Clicking Reset All with compensation applied may produce a spike in
the feedback signal. Read the Warning that follows this table.

WARNING Clicking Reset All in this tab with hydraulic pressure on can result in
unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before clicking reset.

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Station Manager
PVP Tab
Path Station Setup window > navigation pane > Channels PIDF control

mode > > PVP tab

This tab defines the peak/valley phase (PVP) compensation that can be
applied by the selected control mode to the command signal.

• PVP compensation alters the command phase to correct for phase

lag.

• PVP compensation increases the command amplitude to correct

for amplitude roll-off.

• PVP adjusts the mean command level if it detects mean-level

divergence in the feedback signal.
Note The PVP compensator may have difficulty compensating command
waveforms below 0.5 Hz.

See “About PVP” on page 219 for more about this compensation
method.

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PVP Tab
ITEM DESCRIPTION
Convergence Rate Sets how quickly compensation values get applied to converge the
feedback and command signal amplitudes.
Sensitivity Sets how much the feedback signal must change, as a percentage of its
peak-to-peak value, before a peak or valley is detected.
Adaptation State Hold—Continues to use current values but stops adapting new values.
Resume—Adapts and continuously updates compensation values.
Reset Clears acquired compensation values and restarts the adaptation process.
Clicking Reset with compensation applied may produce a spike in the
feedback signal. Read the Warning that follows this table.

WARNING Clicking Reset in this tab with hydraulic pressure on can result in
unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before clicking reset.

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Station Manager
Station Setup Window/Sync Current Channel

Clicking the Station Setup Sync Current Channel button applies

the current channel and control mode selections on the Station Setup
to the function generator. The Function Generator slider settings will
be updated to reflect this selection.

If the function generator is running or is in group mode, clicking the

Sync Current Channel button will not make any changes to the
function generator.

The Station Setup Sync Current Channel button can also apply the
current Station Setup channel selection to both Channel selections on
a scope display. First, click the two-state Sync Station Channel
button on the Scope Toolbar to set the “sync” state, and then click
on the Station Setup window. Control mode setting will remain the
same.

The Sync Current Channel feature effectively “synchronizes” channel

selection for the function generator and scope. This feature facilitates
the set up and tuning of systems with a large number of channels.

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Station Setup Window/Readouts Panels

Readouts Summary Panel

Path Station Setup window > navigation pane > Readouts

This panel displays the current values of readout signals.

The Station Builder application allocates the resources used to output

these readout signals. For more information, “Creating Readouts” on
page 69.

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Readout Adjust Panel
Path Station Setup window > navigation pane > Readouts > Readout n

This panel defines the output of the selected Readout, displayed in the
Readouts Summary panel shown on “Readouts Summary Panel” on
page 358.

Note With Gain = 1 and Offset = 0 V (default values): a positive full-scale

signal = +10 volts and a negative full-scale signal = -10 volts.

Readout Adjust Panel

ITEM DESCRIPTION
Signal Selects the signal to be displayed.
Gain Sets the amplification applied to the readout signal.
Offset Sets the offset applied to the readout signal.

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Station Setup Window/Auxiliary Inputs Panels

Auxiliary Inputs Summary Panel

Path Station Setup window > navigation pane > Auxiliary Inputs

This panel displays the current values of auxiliary input signals.

The Station Builder application allocates the resources used to input

these signals, typically used for data acquisition. See “Creating
Auxiliary Inputs” on page 72 for more information.

If the Station Builder application has created a control mode with

stabilization, the Auxiliary Inputs panels displays values and controls
for this mode’s stabilization signal. See “How to Create a Control Mode
Stabilization Signal” on page 65 for more information.

Auxiliary Inputs also displays external command signals.

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Station Manager
Auxiliary Inputs Panel Tabs
Path Station Setup window > navigation pane > Auxiliary Inputs > Aux
Input

This panel’s tabs configure the auxiliary input signals.

The Auxiliary Inputs panel tabs have the same controls as the Inputs
panel tabs used to adjust control mode inputs.

Although not used in control modes, auxiliary inputs require the same
setup as control mode inputs to accurately acquire data and perform
limit functions.

For more about Inputs panel tabs, see “Station Setup Window/Inputs
Panel Tabs” on page 310.

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Reconfigurable signals As an option, you can define certain auxiliary inputs as reconfigurable.
If you check the Reconfigurable checkbox for an auxiliary input in
Station Builder, the signal name and dimension can be changed in
Station Manager, without returning to Station Builder. You must be at
the Configuration access level in Station Manager to make these
signal configuration changes.

You can use the Calibration tab to make signal name and dimension
changes for a reconfigurable signal.

Note When you change a signal name, an information message will be

logged (e.g., “The Display Name for Aux Input 2 has been
changed”).

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Station Manager
Station Setup Window/Station Signals Panel Tabs

Values Tab
Path Station Setup window > navigation pane > Station Signals > Values
tab

This tab displays current values for signals in the selected Signal List.

The Station Manager application’s Channel Options window’s Signal

Lists tab edits the signals included in a Signal list. For more
information, see “Signal Lists Tab” on page 432.

For more about displaying and editing signals, see “About the Station
Signals Panel” on page 176.

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Hardware Tab
Path Station Setup window > navigation pane > Station Signals >
Hardware tab

This tab displays Resource and Connector information for the signals
in the selected Signal List.

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Fullscale Tab
Path Station Setup window > navigation pane > Station Signals >
Fullscale tab

This tab displays the Fullscale Min and Max ranges for each signal in
the selected Signal list.

Note The values and dimensions on this tab are editable at the
Calibration access level.

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Calibration Tab
Path Station Setup window > navigation pane > Station Signals >
Calibration tab

This tab displays conditioner values for each selected Conditioner

Type in the Signal list.

Note The values and dimensions on this tab are editable at the
Calibration access level.

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Station Manager
Station Setup Window/Digital Input/Outputs Panel Tabs

Inputs Summary Tab

Station Setup window > navigation pane > Digital Inputs/Outputs >
Inputs tab

This tab summarizes digital input status. When an input triggers, its
State indicator turns green.

The Station Builder application allocates the resources used for digital
inputs. For more information. see “Creating Digital Inputs” on page 70.

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Outputs Summary Tab

Station Setup window > navigation pane > Digital Inputs/Outputs >
Outputs tab

This tab displays digital output status and provides a way to test these
outputs:

• turns green if a Digital Output is set.

• To set a Digital Output, press its .

The Station Builder application allocates the resources used for digital
outputs. For more information, see “Creating Digital Outputs” on page
71.

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Digital Inputs Panel
Station Setup window > navigation pane > Digital Inputs/Outputs >
Inputs

This panel defines each digital input’s trigger(s) (Trigger and/or

Trigger 2) and their resulting actions.

Note Channel Low and Channel High trigger modes do not support the
following digital input actions: Program Stop, Program Hold, and
all custom actions.

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Digital Inputs Panel (part 1 of 2)

ITEM DESCRIPTION
State This indicator is green if the digital input is high and white if the
digital input is low.
Trigger or Trigger 2 Sets the change in the digital input signal’s state needed to trigger
Action or Action 2.
High/Low—Triggers when the input goes from a high state to a low
state.

Low/High—Triggers when the input goes from a low state to a high

state.

Either—Triggers when the input either goes from a low state to a

high state or from a high state to a low state.

Channel Low—Triggers when the channel goes low and remains

triggered as long as the channel stays low.

Channel High—Triggers when the channel goes high and remains

triggered as long as the channel stays high.

None—Disables the Action.

370 Model 793.00 System Software

 Station Setup Window

Station Manager
Digital Inputs Panel (part 2 of 2)
ITEM DESCRIPTION
Action or Action 2 Sets a response to Trigger or Trigger 2:
Disabled—No action occurs.
Station Power Off—Writes a message to the Message Log, clamps
the servovalve, turns off pressure at the hydraulic service manifold
(HSM), and stops any program.
Interlock—Writes a message to the Message Log, turns off pressure
at both the HSM and hydraulic power unit (HPU), and stops any
program command.
Program Interlock—Writes a message to the Message Log, stops
any program command, but does not turn off station hydraulic
pressure.
Program Stop—Writes a message to the Message Log and stops
any program command. Produces the same action as clicking the
Program Stop button on the Station Controls panel. Channel Low
and Channel High trigger modes do not support this action.
Program Hold—Writes a message to the Message Log and places a
hold on any program command. Produces the same action as
clicking the Program Hold button on the Station Controls panel.
Channel Low and Channel High trigger modes do not support this
action.
Custom Action—Executes an action defined by you in the
Event-Action Editor window. See “Event-Action Editor Window” on
page 448 for more about this window. Channel Low and Channel
High trigger modes do not support this action.

Model 793.00 System Software 371

 Station Setup Window
Station Manager

Digital Outputs Panel

Station Setup window > navigation pane > Digital Inputs/Outputs >
Outputs

Digital Outputs Panel

ITEM DESCRIPTION
Assignment Displays and allows you to assign a resource for each signal output to
external logic devices and switches.
Indicator/Button
Red indicates that the output is off. If the output signal resource is
undefined, click this button to turn off the output signal.

Green indicates that the output is on. If the output signal resource
is undefined, click this button to turn on the output signal.
Polarity Displays and allows you to set the polarity of the output signal.

372 Model 793.00 System Software

 Station Setup Window

Station Manager
Station Setup Window/Detectors Panel Tabs

Detectors Summary Tabs

Path Station Setup window > navigation pane > Detectors > Limit
Detectors tab or Error Detectors tab

These tabs summarize limit and error detector status.

• Limit detectors monitor input feedback signals. Actions can be set

to occur when signals exceed user-defined limits.

• Error detectors monitor the difference (error) between command

and feedback signals. Actions can be set to occur when errors
exceed user-defined limits.

• Hardware limit detectors (FlexTest IIm systems only) monitor the

difference between an associated transducer output value and
preset upper/lower limit values

For more information, see the following pages and “About Detectors”
on page 223.

The Limit Detectors and Hardware Limit Detectors tabs have

Upper and Lower indicators. The Error Detectors tab has Inner and
Outer indicators.

Model 793.00 System Software 373

 Station Setup Window
Station Manager

Use List to select the detectors you want to display. You can choose to
display the status of all system detectors (All Detectors) or detectors
on a selected system channel.

Detectors Summary Tabs

ITEM DESCRIPTION
Upper/Lower Colors indicate the detector’s status.
or Inner/Outer Gray—The detector’s Action is set to Disabled.
White—The detector’s Action is set to Indicate.
Green—The detector’s Action is set to Station Power Off, Interlock,
Program Interlock, Program Stop, Program Hold or a user-defined
Custom Action.
Red—A signal tripped the detector’s limit.

374 Model 793.00 System Software

 Station Setup Window

Station Manager
Limits Summary Tab
Path Station Setup window > navigation pane > Detectors > Limits >
Limits Summary tab

This tab summarizes the values and status of the selected limit
detectors.

Use List to select the limit detectors you want to display. You can
choose to display the status of all system limit detectors (All
Detectors) or limit detectors on a selected system channel.

Note The All Detectors list cannot be edited and is only updated when
the station configuration changes.

Limits Summary Tab

ITEM DESCRIPTION
Upper Limit Displays the input signal’s most positive limit. A detector action can
occur if the signal exceeds this limit.
Indicator colors show the detector’s status. For more about the
colors, see “Detectors Summary Tabs” on page 373.
New values can be entered in the display boxes.
Lower Limit Displays the input signal’s most negative limit. A detector action can
occur if the signal exceeds this limit.
Indicator colors show the detector’s status. For more about the
colors, see “Detectors Summary Tabs” on page 373.
New values can be entered in the display boxes.

Model 793.00 System Software 375

 Station Setup Window
Station Manager

Upper Limits /Lower Limits Tabs

Path Station Setup window > navigation pane > Detectors > Limits >
Upper Limits tab or Lower Limits tab

These two tabs set detector Upper Limits and Lower and also define
the resulting Action when an input signal exceeds a limit.

These two tabs are similar so only the Upper Limits tab is shown.

Use List to select the upper or lower limits you want to display. You
can choose to display upper or lower limits for all system detectors
(All Detectors) or for a selected system channel.

376 Model 793.00 System Software

 Station Setup Window

Station Manager
Upper Limits/Lower Limits Tab
ITEM DESCRIPTION
Limits Upper Limit—Sets the input signal’s most positive limit. An Action
can occur if the signal exceeds this limit.
Lower Limit—Sets the input signal’s most negative limit. An Action
can occur if the signal exceeds this limit.
Action Sets the test station’s Action when an input signal exceeds a limit:
Disabled—No action occurs. This setting grays out the Limit
indicator.
Indicate—Writes a message to the Message Log. This setting turns
the Limit indicator white.
Station Power Off—Writes a message to the Message Log, clamps
the servovalve, turns off pressure at the hydraulic service manifold
(HSM), and stops any program. This setting turns the Limit indicator
green.
Interlock—Writes a message to the Message Log, turns off pressure
at both the HSM and hydraulic power unit (HPU), and stops any
program command. This setting turns the Limit indicator green.
Program Interlock—Writes a message to the Message Log, stops
any program command, but does not turn off station hydraulic
pressure. This setting turns the Limit indicator green.
Program Stop—Writes a message to the Message Log and stops
any program command. Produces the same action as clicking the
Program Stop button on the Station Controls panel. This setting
turns the Limit indicator green.
Program Hold—Writes a message to the Message Log and places a
hold on any program command. Produces the same action as
clicking the Program Hold button on the Station Controls panel.
This setting turns the Limit indicator green.
Custom Action—Executes a user-defined action created in the
Event-Action Editor window. This setting turns the Limit indicator
green. See “Event-Action Editor Window” on page 448 for more
about using this window.
A tripped limit turns an enabled detector’s Limit indicator red.

Model 793.00 System Software 377

 Station Setup Window
Station Manager

Error Summary Tab

Path Station Setup window > navigation pane > Detectors > Errors >
Error Summary tab

This tab summarizes the values and status of all error detectors.

Error detection uses Absolute Error signals. These signal values are in
engineering units and are all positive.

Use List to select the error detectors you want to display. You can
choose to display the status of all system error detectors (All
Detectors) or error detectors on a selected system channel.

378 Model 793.00 System Software

 Station Setup Window

Station Manager
Error Summary Tab
ITEM DESCRIPTION
Outer Error Displays the error signal’s outer limit. A detector action can occur if
the signal exceeds this limit.
Indicator colors show the detector’s status. For more about the
colors, see “Detectors Summary Tabs” on page 373.
New values can be entered in the display boxes.
Inner Error Displays the error signal’s inner limit. A detector action can occur if
the signal exceeds this limit.
Indicator colors show the detector’s status. For more about the
colors, see “Detectors Summary Tabs” on page 373.
New values can be entered in the display boxes.

Model 793.00 System Software 379

 Station Setup Window
Station Manager

Outer Error/Inner Error Tabs

Path Station Setup window > navigation pane > Detectors > Errors >
Outer Error tab or Inner Error tab

These two tabs set detector Outer Error and Inner Error limits and
also define the resulting Action when an error signal exceeds a limit.

These two tabs are similar so only the Outer Error tab is shown.

Use List to select the outer or inner error limits you want to display.
You can choose to display outer or inner error limits for all system
detectors (All Detectors) or for a selected system channel.

380 Model 793.00 System Software

 Station Setup Window

Station Manager
Outer Error/Inner Error Tabs
ITEM DESCRIPTION
Limits Outer Error—Sets the error signal’s outer limit. An Action can
occur if the signal exceeds this limit.
Inner Error—Sets the error signal’s most inner limit. An Action can
occur if the signal exceeds this limit.
Error detection uses the Abs. Error signal. This signal’s values are in
engineering units and all values are positive.
Action Sets the test station’s Action when an input signal exceeds a limit:
Disabled—No action occurs. This setting grays out the Limit
indicator.
Indicate—Writes a message to the Message Log. This setting turns
the Limit indicator white.
Station Power Off—Writes a message to the Message Log, clamps
the servovalve, turns off pressure at the hydraulic service manifold
(HSM), and stops any program. This setting turns the Limit indicator
green.
Interlock—Writes a message to the Message Log, turns off pressure
at both the HSM and hydraulic power unit (HPU), and stops any
program command. This setting turns the Limit indicator green.
Program Interlock—Writes a message to the Message Log, stops
any program command, but does not turn off station hydraulic
pressure. This setting turns the Limit indicator green.
Program Stop—Writes a message to the Message Log and stops
any program command. Produces the same action as clicking the
Program Stop button on the Station Controls panel. This setting
turns the Limit indicator green.
Program Hold—Writes a message to the Message Log and places a
hold on any program command. Produces the same action as
clicking the Program Hold button on the Station Controls
panel.This setting turns the Limit indicator green.
Custom Action—Executes a user-defined action created in the
Event-Action Editor window. This setting turns the Limit indicator
green. See “Event-Action Editor Window” on page 448 for more
about using this window.
A tripped limit turns an enabled detector’s Limit indicator red.

Model 793.00 System Software 381

 Station Setup Window
Station Manager

Hardware Limits Tab

Path Station Setup window > navigation pane > Detectors > Hardware
Limits tab

This tab, provided on FlexTest IIm systems only, displays and allow
you to set the upper and lower limit values of selected hardware limit
detectors. The status of each limit detector value is also displayed here.
See “About Hardware Limit Detectors” on page 231 for more
information.

Use List to select the hardware limit detectors you want to display.
You can choose to display values for all system hardware limit
detectors (All Detectors) or hardware limit detector values on a
selected system channel.

Hardware limits A limit detector on each 497 conditioner continuously compares its
associated transducer output value to preset upper and lower limit
values.

When a conditioner limit is exceeded, the limit detector is enabled.

The system responds by sending a digital request to the control system
for an emergency stop.

382 Model 793.00 System Software

 Station Setup Window

Station Manager
.

Hardware Limits Tab

ITEM DESCRIPTION
Upper Limit Displays the input signal’s most positive limit. A detector action can
occur if the signal exceeds this limit.
Indicator colors show the detector’s status. For more about the
colors, see “Detectors Summary Tabs” on page 373.
New values can be entered in the display boxes.
Lower Limit Displays the input signal’s most negative limit. A detector action can
occur if the signal exceeds this limit.
Indicator colors show the detector’s status. For more about the
colors, see “Detectors Summary Tabs” on page 373.
New values can be entered in the display boxes.

Model 793.00 System Software 383

 Station Setup Window
Station Manager

Station Setup Window/Calculations Panels

Calculated Outputs Panel/Values Tab

Path Display menu > Station Setup > Station Setup window > navigation
pane > Calculations >Calculated Outputs > Values tab

This panel displays the current values of all calculated output signals.

For more about defining calculations, see “Calculation Editor Window”

on page 459.

WARNING For systems with calculated outputs and multiple independent HSMs,
turning on only one HSM can result in unexpected or exaggerated
actuator motion.

Unexpected or exaggerated actuator motion can injure anyone in its

path.

For these systems, always use the All Off, All Low, and All High buttons on
the Station Controls panel for hydraulic control.

384 Model 793.00 System Software

 Station Setup Window

Station Manager
Calculated Outputs Panel/Fullscale Tab
Path Display menu > Station Setup > Station Setup window > navigation
pane > Calculations > Calculated Outputs > Fullscale tab

This tab displays the Fullscale Min and Max ranges for each
calculated output signal.

Note The Fullscale Min/Max values on this tab only editable at the
Calibration and Configuration access level.

Model 793.00 System Software 385

 Station Setup Window
Station Manager

Calculated Outputs Panel/Drive Tab

Path Display menu > Station Setup > Station Setup window > navigation
pane > Calculations >Calculated Outputs > Drive tab

This tab displays drive signal output parameters for the selected
calculated output signal(s).

Note Drive parameter values are not editable at the Operator access
level.

Drive Tab
ITEM DESCRIPTION
Polarity Sets the polarity of the valve drive signal to Normal or Invert.
Polarity cannot be changed with station pressure on.
Valve Balance Compensates for minor mechanical imbalances in the servovalve.
Dither Amplitude Adjusts the amplitude of the dither signal, a small high frequency
signal that keeps the servovalve from sticking.

386 Model 793.00 System Software

 Station Setup Window

Station Manager
Calculated Output/Calculation Tab
Path Display menu > Station Setup > Station Setup window > navigation
pane > Calculations >Calculated Outputs > Calculated Output n >
Calculation tab

This tab displays the expression used to produce the selected

calculated output’s drive signal.

For more about defining calculations, see “Calculation Editor Window”

on page 459.

Calculation Tab
ITEM DESCRIPTION
Fullscale Min/Max Specifies the selected output’s full-scale minimum and maximum
values. The result of this calculation gets clipped to these values.
Expression Displays the formula used to produce the output.
Use the Calculation Editor window to define the formula.
Uses Displays a list of the parameters and signals that are used within this
expression.

Model 793.00 System Software 387

 Station Setup Window
Station Manager

Calculated Output/Drive Tab

Path Display menu > Station Setup > Station Setup window > navigation
pane > Calculations >Calculated Outputs > Calculated Output n >
Drive tab

This tab configures the drive signals of a calculated output channel.

This tab’s contents vary with the type of hardware used. See page 327
through page 329 for additional information.

Drive Tab
ITEM DESCRIPTION
Fullscale Min/Max Displays the valve driver’s full minimum and maximum output
values.
Polarity Sets the polarity of the valve drive signal to Normal or Invert.
Polarity cannot be changed with station pressure on.
Valve Balance Compensates for minor mechanical imbalances in the servovalve.
Dither Amplitude Adjusts the amplitude of the dither signal, a small high frequency
signal that keeps the servovalve from sticking.

388 Model 793.00 System Software

 Station Setup Window

Station Manager
Calculation Parameters Panel
Path Display menu > Station Setup > Station Setup window > navigation
pane > Calculations > Calculation Parameters

This panel summarizes the current values used in calculated

parameters.

The Calculation Editor window’s access level setting determines a

user’s ability to change these values.

WARNING Small parameter changes can produce large control loop changes,
resulting in violent actuator actions.

Violent actuator movement can result in injury and equipment damage.

Use care in changing parameters.

For more about defining parameters, see “Parameters Definition Panel”

on page 477.

Model 793.00 System Software 389

 Station Setup Window
Station Manager

Station Setup Window/Remote Setpoints Panels

Path Station Setup window > navigation pane > Remote Setpoints

This tab summarizes the Control Channel or Group Setting

assignment of knobs on the Remote Setpoint Adjust (RSA) box.

For more information, see “About the Optional Remote Setpoint

Adjust” on page 258.

• An RSA box allows actuator setpoints to be remotely adjusted,

away from the Test Station’s computer screen.

• The Station Manager application’s Remote Setpoint Adjust

window assigns channel and control modes to each knob. For
more about this window, see “Remote Setpoint Adjust Window”
on page 515.

• The Station Builder application assigns the resources used by the

RSA. See “Setting Up Remote Setpoint Adjust” on page 75.

390 Model 793.00 System Software

 Station Setup Window

Station Manager
Remote Setpoint Knob Panel
Path Station Setup window > navigation pane > Remote Setpoints >
Knob n

This panel sets knobs’ Resolution and Polarity.

Remote Setpoint Knob Panel

ITEM DESCRIPTION
Resolution Fine—Knob movements produce small actuator movements.
Medium—Knob movements produce moderate actuator
movements.
Coarse—Knob movements produce large actuator movements.
Polarity Normal—A clockwise knob movement typically extends the
actuator.
Invert—A counterclockwise knob movement typically retracts the
actuator.

Model 793.00 System Software 391

 Meters Window
Station Manager

Meters Window
Path Display menu > Meters

Station Manager window toolbar >

Toolbar Detail
Reset Align
Run Stop Add

Run
Program Control

Meter Setup button

Meter Type

Meter Types

Timed Mean/Amplitude

Peak/Valley Running Maximum/Minimum

This window provides digital voltmeter displays of station signals. You

can create up to 16 meters by successively clicking on the Add button
on the Meters window toolbar. If a second Meters window is
displayed, the total number of meters added between the two Meters
windows is limited to 16. See “About Meters” on page 172 for more
about using meters.

392 Model 793.00 System Software

 Meters Window

Station Manager
Meters Window
ITEM DESCRIPTION
Meter toolbar Controls the operation of all displayed meters.

Run—Starts all meters.

Program Control—The Station Manager window’s Station Controls
panel Run and Stop buttons start and stop the meters. Starting a
program resets all meters.

Stops updating all meters.

Resets all meters.

Switches meter alignment in the Meters window between various

formats.

Adds a meter to the Meters window. Up to 16 meters can be displayed

in a Meters window. Very large individual meters will limit the total
meters that can be displayed.
Meter Setup button Displays the Meter Setup window. The button’s legend identifies the
signal being monitored.
Meter Types Identifies the meter type selected.

Displays signal’s current value.

Displays the highest peak value and the lowest valley value for each
cycle monitored.

Displays the midpoint value and the difference between the peak
and valley values for each cycle monitored.

Displays the highest and lowest values reached while the meter is
running.

Model 793.00 System Software 393

 Meters Window
Station Manager

Meter Setup Window

Path Meters window > Meter Setup button

This window defines the meters displayed in the Meters window.

Meters Setup Window

ITEM DESCRIPTION
Meter Type Specifies a meter type of Timed, Peak/Valley, Mean/Amplitude, or
Running Max/Min.
Delete Deletes the current meter. This button is disabled when only one meter is
left.
Signal Selection Selects the signal monitored by the meter.
Channel Specifies the channel whose signals can be selected for monitoring.
Signal Specifies the channel signal selected for monitoring.
Display Mode Selects a meter readout in Engineering Units or Volts.
When Engineering Units is selected, the meter’s display units changes
to match the type of signal selected.
Display Resolution Sets the number of digits the meter displays, from one to fifteen.
Sensitivity Peak/Valley and Mean/Amplitude meters only—Sets the amount that the
signal must change before the meter updates.

394 Model 793.00 System Software

 Scope Window

Station Manager
Scope Window
Path Display menu > Scope

Station Manager window toolbar >

Toolbar Detail

Auto-Scale Rescale
Same Scale
Setup
Stop Sync Station Channel
Run Print Change View

Print
Continuous Sweep
Printer Setup
Program Control
Print to File
Single Sweep

Use this window to plot signals against time, frequency, and signals
against each other. You can create another scope by clicking Create
Scope on the Scope icon pull-down menu. Scope 1 identifies the first
scope window; Scope 2 identifies the second scope window.

Model 793.00 System Software 395

 Scope Window
Station Manager

For information about using the controls described in this section, see
“About the Scope” on page 159.

Scope Window (part 1 of 2)

ITEM DESCRIPTION
toolbar Controls scope operation.

Starts the scope trace.

Continuous Sweep—The scope traces the signals continuously. This
is the scope’s default setting.
Program Control—The Station Manager window’s Station
Controls panel Run and Stop buttons start and stop the scope.
Single Sweep—The scope traces signals for a single pass and stops.

Stops the scope trace.

Displays the Setup for Scope window.

See “Setup for Scope Window” on page 398 for more information.

Continuously adjusts the scope to accommodate increasing signal

amplitudes. indicates auto-scaling has been applied.

Adjusts the scope to accommodate increased or decreased signal

amplitudes.

Applies the first Y axis Units/Div to the second Y axis’ Units/Div

when the Plot Mode is Time. indicates same scale has been
applied.

Setting this two-state button to “sync” allows you to assign the

control channel currently selected on Station Setup to both scope
Channel selections. To assign this channel, you must click the Sync
Current Channel button on the Station Setup window
The control mode Signal selections will remain as currently selected. If
the scope is in A/B plot mode, this button will not work. See “Station
Setup Window/Sync Current Channel” on page 357 for more
information.

396 Model 793.00 System Software

 Scope Window

Station Manager
Scope Window (part 2 of 2)
ITEM DESCRIPTION

Stopping the scope makes the print options available.

Print—Prints a copy of the scope trace.
Printer Setup—Displays a Print Setup window specific to your
printer.
Print to File—Prints the scope trace to a Windows Enhanced Metafile
file (extension .emf) which can be imported into word processing and
spreadsheet applications (typically Word or Excel) by selecting
Insert-Picture-From File from the application

Progressively removes controls from the Scope window before

restoring a full view with complete controls.
Channel Selects channels with signals that can be displayed.
Signal Selects the signals to be displayed.
Units/Div Plot Mode of Time or X/Y Plot—Specifies the grid line values.
Units Plot Mode of Time or X/Y Plot—Specifies the display units.
Y Maximum Specifies the highest peak amplitude displayed during a Frequency
plot.
Offset Specifies how much the Y axis grid’s zero references shift from the
center of the display.
In a Frequency plot, this displays the minimum value for the vertical
axis.
Plot Mode Specifies the type of plot displayed:
Time—Plots the specified signals against time.
Frequency—Plots the specified signals against frequency.
X/Y Plot—Plots the specified signals against each other.
Sampling Rate Plot Mode of Frequency—Specifies how frequently the scope
acquires data. The default is 1024 Hz.
This change takes affect immediately.
Trace Time Plot Mode of Time or X/Y Plot—Specifies the length of time for a
signal trace to cross the scope.
Plot Mode of Time—Sets the grid’s x-axis scale.

Model 793.00 System Software 397

 Scope Window
Station Manager

Setup for Scope Window

Graph Settings Tab

Path Scope window toolbar > > Graph Settings tab

This tab sets up the Scope window’s graph. The window title Setup
for Scope 1 identifies the setup window for Scope 1. Setup for
Scope 2 identifies the setup window for Scope 2.

Graph Settings Tab (part 1 of 2)

ITEM DESCRIPTION
Graph Options Defines the Scope window’s graphing functions.
Show Grid Select to display grid lines.
Enable Auto-Sizing Select to automatically hide and display controls as you resize the Scope
window.
Auto-Scale Mode Specifies how Auto-Scale and Rescale affect Units/Div and Offset.
Sensitivity & Offset—Auto-Scale and Rescale can change both
Units/Div and Offset.
Sensitivity—Auto-Scale and Rescale can only change the Units/Div.

398 Model 793.00 System Software

 Scope Window

Station Manager
Graph Settings Tab (part 2 of 2)
ITEM DESCRIPTION
Color Selections Selects the grid line and background colors.
Grid Color Specifies the color of the grid lines.
Background Color Specifies the grid’s background color.

Model 793.00 System Software 399

 Scope Window
Station Manager

Trace Settings Tab

Path Scope window toolbar > > Trace Settings tab

This tab defines the display of grid Trace and Limit Lines.

Trace Settings Tab

ITEM DESCRIPTION
Trace Options Define the display of Trace and Limit Lines in the grid.
Trace Select Trace 1 to define the first Y axis trace. Select Trace 2 to define the
other trace.
Line Style Select to make the Trace and Limit Lines solid or dotted.
Line Color Displays the Color window, used to set Trace and grid label colors.
Limit Lines Sets the display of limit lines for the selected Trace:
None—The grid displays no limit lines.
Detector Limits—The grid displays detector limits. For more about
setting limits, see “Upper Limits /Lower Limits Tabs” on page 376.
User Specified—The grid displays the Upper Limit and the Lower
Limit.

400 Model 793.00 System Software

 Scope Window

Station Manager
Frequency Mode Tab
Path Scope window toolbar > > Frequency Mode tab

This tab defines the display of data when the Scope window’s Plot
Mode selection is Frequency.

Frequency Mode Tab (part 1 of 2)

ITEM DESCRIPTION
Sampling Rate Specifies how frequently the scope acquires data. The default rate is
1024 Hz.
Buffer Size Specifies the number of data elements used for calculating
autospectral density (ASD). The default size is 512.

Model 793.00 System Software 401

 Scope Window
Station Manager

Frequency Mode Tab (part 2 of 2)

ITEM DESCRIPTION
Calculations Determines the calculation and display methods applied to data.
Averaging Sets the averaging method applied after the calculation of ASD
values:
None—No averaging is applied to the ASD values.
Peak Hold—Selects the largest value between the current and new
buffer of data for each of the ASD values.
Linear—Takes previous data into account.
Exponential—Takes previous data into account. The factor used in
calculating exponential averaging is obtained from other sources and
“hard-coded” in the calculations.
Windowing Specifies the way data displays. The selections are None or
Hanning.
Show DC Value Select this if your waveform has an offset or some other bias.
Vertical Axis Defines the display of data on the vertical axis.
Display Selects either an ASD or Amplitude display of data.
Scaling Specifies vertical scaling:
Logarithmic—Plots the log of ASD or Amplitude values.
Linear—Plots ASD or Amplitude values on a linear scale.
Decades Sets the vertical divisions when Scaling is set to Logarithmic.

402 Model 793.00 System Software

 Message Logs Window

Station Manager
Message Logs Window
Path Display menu > Message Logs

Station Manager window > toolbar >

Print to File
Print Add Entry
Close Delete Entry
Save Copy
Open Display Options

Toolbar Detail

Date/Time
Enable All Display Options
Severity
Source

This window records station and test events as they occur, including:

• Power status changes

• Station state changes

• Detector activity

• Over-temperature conditions

• Full-scale changes

Model 793.00 System Software 403

 Message Logs Window
Station Manager

The default location for station log files is C:\ftiim\config,

C:\tsiis\config, or C:\ftgt\config.

See “Working with Message Logs” on page 266 for more information.

For quick reference during testing, the Station Manager window’s

Message Pane displays Warning, Error, and Fatal Error messages
from all applications. See page 278 for more information.

Message Logs Window (part 1 of 2)

ITEM DESCRIPTION
toolbar Controls Message Log operation.

Displays the Open Message Log File window. Use this window to open
archived message log files (extension .log).

Saves all messages to a new message log file and clears all messages
from the Message Log window.
To clear only some messages, highlight a message before saving.
Messages that follow the highlighted message will remain in the window.
The first message log saved is named configuration_file_name001.log,
the second is named configuration_file_name002.log, and so on.

Closes the current archived message log and displays the Station Log for
the active station configuration.

Displays the Message Log Print window, which specifies what

messages get printed.

Displays the Message Log Print To File window, which is used to save
message logs as text files (extension .txt).

Displays the Add Entry window, which is used to insert user-defined

entries into the message log.

Deletes the highlighted user entry from the log. Only user-defined entries
can be deleted.

Copies the highlighted entries to the clipboard.

404 Model 793.00 System Software

 Message Logs Window

Station Manager
Message Logs Window (part 2 of 2)
ITEM DESCRIPTION

Enables all message log display options. Control the message log’s detail
level by unchecking display options that are not needed
Date/Time—Allows date and time information display when checked.
Severity—Allows severity information display when checked.
Source—Allows source information display when checked.
Log Selects the message log displayed.
Select Station Log to display the log for the station configuration. Select
MPT Specimen Log or Basic TestWare Log to view logs for
MultiPurpose TestWare and Basic TestWare tests. Opened archive may
also be displayed.
Scroll to New Entry Keeps the window scrolling to the last logged entry.

Model 793.00 System Software 405

 Message Logs Window
Station Manager

Message Log Add Entry Window

Path Message Log window > toolbar >

This window adds user-defined messages to the message log.

Message Log Add Entry Window

ITEM DESCRIPTION
Message Severity Sets a message level of Diagnostic, Information, Warning, or Error.
Message Log Identifies the source of the log message.
Stmgr—Sets a message source of Stgmr User.
MPT—Sets a message source of MPT User.
Basic TestWare—Sets a message source of Basic TestWare User.
Message Text Type here the message that you want to add.
Add Adds the message to the log.
Clear Clears the Message Text.
Close Closes the window.

406 Model 793.00 System Software

 Message Logs Window

Station Manager
Message Log Print Window

Path Message Logs window > toolbar >

This window specifies the message log entries that are printed.

Message Log Print Window

ITEM DESCRIPTION
Print Range All—Print all the message log entries.
Selection—Print the highlighted message log entries.
View—Print just the visible message log entries.
Setup Displays the Print Setup window specific to your printer.
Severity Sets the lowest message severity level to be printed.
Source Specifies the source of the messages to be printed.

Model 793.00 System Software 407

 Applications Menu
Station Manager

Applications Menu

This menu’s commands open applications that are used with the
Station Manager application.

Operating at an access level of Configuration makes this menu’s

Basic TestWare, MultiPurpose TestWare, and MultiPurpose
TestWare (Edit Only) selections unavailable.

Applications Menu
ITEM DESCRIPTION
Basic TestWare Opens the Basic TestWare application and displays its controls in the
Station Manager window’s Application Controls panel. See Chapter
4, “Basic TestWare” for more about this application.
MultiPurpose TestWare Opens the optional MultiPurpose (MPT) application and displays its
controls in the Station Manager window’s Application Controls
panel. See the Model 793.10 MultiPurpose TestWare manual for more
information.
MultiPurpose TestWare Opens an edit-only version of MPT, leaving the Station Manager
(Edit Only) application free to run other tests and functions.
Profile Editor Opens the optional Profile Editor application. See the Model 793.11
Profile Editor manual for more information.
Station Builder Opens the Station Builder application. See Chapter 2, “Station
Builder” for more information.
Station Manager Opens another instance of the Station Manager application.
Station Desktop Organizer Opens the Station Desktop Organizer application. See Chapter 6,
“Station Desktop Organizer” for more information.

408 Model 793.00 System Software

 Tools Menu

Station Manager
Tools Menu

This menu’s commands display windows that increase the Station

Manager application’s effectiveness.

Tools Menu
ITEM DESCRIPTION
Station Options Displays the Station Options window, used to set viewing and file
options. See “Station Options Window” on page 410 for more
information.
Channel Options Displays the Channel Options window, used to set channel
options. See “Channel Options Window” on page 418 for more
information.
Sensor File Editor Displays the Sensor File Editor window, used to create and edit
sensor calibration files. See “Sensor File Editor Window” on page 442
for more information.
Event-Action Editor Displays the Event-Action Editor window, used to define custom
actions that can occur in response to system events. See
“Event-Action Editor Window” on page 448 for more information.
Calculation Editor Displays the Calculation Editor window. See “Calculation Editor
Window” on page 459 for more information.
Unit Set Editor Displays the Unit Set Editor window. See “Unit Assignment Set
Editor Window” on page 479 for more information.

Model 793.00 System Software 409

 Station Options Window
Station Manager

Station Options Window

This section describes the Station Option window’s tabs.

Station Log Tab

Path Tools menu > Station Options > Station Options window > Station
Log tab

This tab specifies the messages written to the Message Logs window
described on page 403.

Station Log Tab (part 1 of 2)

ITEM DESCRIPTION
Message Capture Sets the severity level and sources for messages written to the Message
Logs window.
Minimum Sets the minimum threshold severity level for logged messages.
Severity
Only messages with the selected severity level or a higher severity level
get logged.

410 Model 793.00 System Software

 Station Options Window

Station Manager
Station Log Tab (part 2 of 2)
ITEM DESCRIPTION
Source This Application Only—Only Station Manager messages get logged.
All Applications—Station Manager and other applications’ messages get
logged.
Archive Auto Deletion Sets the date when archived files are automatically deleted.

Model 793.00 System Software 411

 Station Options Window
Station Manager

Unit Selection Tab

Path Tools menu > Station Options > Station Options window > Unit
Selection tab

This tab specifies the units of measure used in test data files.

The Directories tab, described on page 414, specifies where unit

assignment sets (UAS) are stored.

412 Model 793.00 System Software

 Station Options Window

Station Manager
Unit Selection Tab
ITEM DESCRIPTION
UAS Comment Displays a brief description of the selected unit assignment set.
Unit Assignment Sets Select from the following MTS supplied sets:

CGSSET - Centimeters-Grams-Seconds—Units are based on

centimeters, grams, and seconds.

ENGSET - U.S. Engineering Units—Units are based on Customary U.S.

engineering units with force related units in kips.

ENGSETSM - U.S. Engineering Units (small)—Units are based on

Customary U.S. engineering units with force related units in lbfs.

SISET - SI (Systeme International d’Unites)—Units are based on

Customary International (metric) units with force related units in kNs.

SISETSM - SI (Systeme International d’Unites) - small—Units are

based on Customary International (metric) units with force related units
in Ns.

SYSDEF - System Units Definition—Contains units used by the

hardware.

Additional user-defined sets can be selected here.

Set Default Makes the selected unit assignment the default set for the system.
Open applications such as Basic TestWare must be reopened before they
adopt the new default set.
Edit Displays the Unit Assignment Set Editor window, used to edit and
create unit assignment sets. See “Unit Assignment Set Editor Window” on
page 479 for more information.

Model 793.00 System Software 413

 Station Options Window
Station Manager

Directories Tab
Path Tools menu > Station Options > Station Options window >
Directories tab

This tab sets the default directory locations for station configuration
and unit assignment set files.

For additional information, see “How to Open a Station Configuration

File” on page 124 and “Unit Selection Tab” on page 412.

Directories Tab (part 1 of 2)

ITEM DESCRIPTION
File Type Select Station Configuration Files to display station configuration files
in the Station Configuration Files list that are available through the
Directory Path.
Select Unit Assignment Set Files to display unit assignment set files in
the Unit Assignment Set Files list that are available through the
Directory Path.
Files of Type Displays the .cfg or .uas extensions used by the station configuration and
unit assignment set files in the selected directory.

414 Model 793.00 System Software

 Station Options Window

Station Manager
Directories Tab (part 2 of 2)
ITEM DESCRIPTION
Set Default Updates the directory for Station Configuration Files or Unit
Assignment Set Files.
The selected path is used immediately by all station configurations.
Paths must be created using Windows before they can be assigned in this
window.
Directory Path Click to select the directory path for the selected file type.

Model 793.00 System Software 415

 Station Options Window
Station Manager

Station View Options Tab

Path Tools menu > Station Options > Station Options window > Station
View Options tab

This tab controls the Station Manager window’s display of its Master
Span control and Station Limits indicators.

Station View Options Tab (part 1 of 2)

ITEM DESCRIPTION
Display Station Limits Select to display Station Limits status indicators on the Station
on Main Window Manager window’s Control panel. See “Station Controls Panel” on page
498 for more information.
Display Master Span Select to display the Master Span controls on the Station Manager
on Main Window window’s Control panel. See “Station Controls Panel” on page 498 for
more information.
Main Window Always Select to always display the Station Manager Main window at the “on
On Top top” display level.

416 Model 793.00 System Software

 Station Options Window

Station Manager
Station View Options Tab (part 2 of 2)
ITEM DESCRIPTION
Display Rig Command Select to display Rig Command Park and Ride buttons on the Station
on Main Window Manager window’s Station Controls panel.
The Park and Ride buttons are also displayed on the Station Manager
Manual Command window.
Rig command display and control is an optional feature.
Setpoint enable on Select to enable setpoint control on the Remote Station Controller. You
RSC must be at the Configuration access level to change this control.
When Manual Control is enabled on the RSC, this check box is disabled.
You must disable manual control on the RSC to change this check box.

Model 793.00 System Software 417

 Channel Options Window
Station Manager

Channel Options Window

This section describes the Channel Option window’s tabs.

Master Span Tab

Path Tools menu > Channel Options > Channel Options window >
Master Span tab

This tab defines the channels whose spans are adjusted through the
Station Controls panel’s Master Span control. These channels also
have an individually adjustable Span whose setting is affected by the
Master Span control. For example, a Master Span of 50% halves an
individual channel’s Span of 50%, giving the channel an effective span
of 25%.

This tab’s controls are unavailable for single channel systems.

For more information, see “Station Controls Panel” on page 498.

418 Model 793.00 System Software

 Channel Options Window

Station Manager
Master Span Tab
ITEM DESCRIPTION
Available Channels Lists the channels whose spans are not adjusted using the Station
Manager window’s Master Span control.

Moves the selected Available Channels item to Master Span

Channels.
Master Span Channels Lists the group of channels whose spans are adjusted using the Station
Manager window’s Master Span control.
By default, new configurations place all control channels into Master
Span Channels.
These channels also have an individually adjustable Span whose setting
is affected by the Master Span control. For example, a Master Span of
50% halves an individual channel’s Span of 50%, giving the channel an
effective span of 25%.

Moves the selected Master Span Channels item to Available

Channels.

Model 793.00 System Software 419

 Channel Options Window
Station Manager

External Command Tab

Path Tools menu > Channel Options > Channel Options window >
External Command tab

This tab defines channels that are programmed as a group through an

external program source.

This tab’s controls are unavailable on single channel systems.

Channels must be configured in the Station Builder application to

accept external program signals. For more information, see “Enabling
External Command Inputs” on page 74.

External Command Tab

ITEM DESCRIPTION
Available Lists the channels that can be added to the External Command
Channels/Modes Channel group.
Channels appear with the control mode dimension used by the external
program signal.

Moves the selected Available Channels/Modes item to External

Command Channels.
External Command Lists the channels controlled as group through an external program
Channels source.
By default, new configurations place all control channels with external
inputs into External Command Channels.

Moves External Command Channels item to Available

Channels/Modes.

420 Model 793.00 System Software

 Channel Options Window

Station Manager
Master Command Tab
Path Tools menu > Channel Options > Channel Options window >
Master Command tab

This tab defines channels that are programmed as a group through

internal test station signals.

This tab’s controls are unavailable for single channel systems.

The Function Generator panel, Setpoint and Span window, and

Manual Command window provide the program signals for master
command groups.

For information about using the Master Command controls, see

“How to Create a Master Command Group” on page 261.

Master Command Tab (part 1 of 2)

ITEM DESCRIPTION
Group Name Enter a name for the master command group selected below.
Master Command Lists master command groups.
Groups

Model 793.00 System Software 421

 Channel Options Window
Station Manager

Master Command Tab (part 2 of 2)

ITEM DESCRIPTION
Add Group Adds a new Group Name to the Master Command Groups.
Delete Group Deletes the selected master command group from the Master Command
Groups.
Channel Dimension Selects the dimension to be used by the master command group. Only
channels with the selected dimension will display in Available
Channels/Modes.
Available Lists the available channels with the control modes that can be selected
Channels/Modes as Master Command Channels.
If more than one control mode/range match exists, both display but only
one can be added to the Master Command Channels.

Moves the selected Available Channels/Modes item to Master

Command Channels.
Master Command Lists the channels included in the selected master command group.
Channels
These channels must have common control modes and must have ranges
within 5% of each other.

Moves selected Master Command Channels item to Available

Channels/Modes.

422 Model 793.00 System Software

 Channel Options Window

Station Manager
Command Options Tab
Path Tools menu > Channel Options > Channel Options window >
Command Options tab

This tab sets transition times for commands. The initial default setting
for all times is 2.0 seconds.

Command Options Tab (part 1 of 3)

ITEM DESCRIPTION
Taper Times Set the transition time, where tapers are used, between run, hold, and
stop states.
Taper times have different effects depending on the application.
Start Function Generator—Not used.
Basic TestWare (BTW)—Not used.
MultiPurpose TestWare (MPT)—Sets the transition time from stop to run
states. Applies in procedures where the MPT application’s Option
Editor window Command Stop Behavior selection is either Taper to
Mean or Taper to Level.

Model 793.00 System Software 423

 Channel Options Window
Station Manager

Command Options Tab (part 2 of 3)

ITEM DESCRIPTION
Stop Function Generator—Sets the transition time for tapered wave shapes to
go from run to stop states.
BTW—Sets the transition time for tapered wave shapes to go from run to
stop states.
MPT—Sets the transition time from run to stop states. Applies to
procedures where the MPT application’s Option Editor window
Command Stop Behavior selection is either Taper to Zero or Taper
to Mean.
Hold Function Generator—Not used.
BTW—Sets the transition time for tapered wave shapes to go from run to
hold states.
MPT—Sets the transition time from run to hold states. Applies to
procedures where the MPT application’s Option Editor window
Command Hold Behavior selection is either Taper to Zero or Taper
to Mean.
Resume Function Generator—Not used.
BTW—Sets the transition time for tapered wave shapes to go from hold
to run states.
MPT—Sets the transition time from hold to run states. Applies to
procedures where the MPT application’s Option Editor window
Command Hold Behavior selection is either Taper to Zero or Taper
to Mean.
Ramp Times Sets ramp times between run, hold, and stop states in MPT application
procedures.
Start Sets the ramp time from stop to run states. Applies in procedures where
the MPT application’s Option Editor window Command Stop
Behavior selection is either Ramp to Zero or Ramp to Mean.
Stop Sets the ramp time from run to stop states. Applies in procedures where
the MPT application’s Option Editor window Command Stop
Behavior selection is either Ramp to Mean or Ramp to Zero.
Hold Sets the ramp time from run to hold states. Applies to procedures where
the MPT application’s Option Editor window Command Hold
Behavior selection is either Ramp to Mean or Ramp to Zero.

424 Model 793.00 System Software

 Channel Options Window

Station Manager
Command Options Tab (part 3 of 3)
ITEM DESCRIPTION
Resume Sets the ramp time from hold to run states. Applies in procedures where
the MPT application’s Option Editor window Command Hold
Behavior selection is either Ramp to Mean or Ramp to Zero.
Begin/End Times Sets starting and ending times for tapered wave shapes.
These values also apply to the beginning and ending times of external
command signals applied to controllers with a soft start/stop feature.
Begin Function Generator—Sets the transition time for tapered wave shapes to
go from stop to run.
BTW—Sets the beginning taper time for tapered wave shapes.
MPT—Sets the beginning taper time for tapered wave shapes.
End Function Generator—Not used.
BTW—Sets the ending taper time for tapered wave shapes as they reach
the end of their counts.
MPT—Sets the ending taper time for tapered wave shapes as they reach
the end of their counts.
Setpoint/Span Times

Setpoint Sets the ramp time for commands applied with the Setpoint (Setpoint
and Span window), Target Setpoint (Function Generator or BTW), or
Manual Command (Manual Command window) controls.
Span Sets the taper time for changes applied with the Span (Setpoint and Span
window) or Master Span (Station Controls panel) controls.
Reset Restores all Times to the values saved when Set Default was last
clicked.
Set Default Applies the Times to the system default settings.

Model 793.00 System Software 425

 Channel Options Window
Station Manager

Taper and The Command Options tab’s Taper Times and Ramp Times values
Ramp Times set transition times between run, hold, and stop states.

Transitions between run, hold, and stop states can be initiated from
many sources, including:

• The Station Manager window’s Program Stop, Program Hold,

and Program Run buttons

• User-defined actions

• The Remote Station Control (RSC) panel

• BTW applications

• MPT applications

When using the Station Manager’s Program Stop, Program Hold,

and Program Run buttons, the following applies:

• Clicking Program Run initiates the transition to the run state.

• Clicking Program Stop initiates the transition to the stop state.

• Clicking Program Hold initiates the transition to the hold state.

• Clicking Program Run after Program Hold initiates the

transition to the run state.

For more information, see “Station Controls Panel” on page 498.

426 Model 793.00 System Software

 Channel Options Window

Station Manager
Taper times Taper Times specify the time it takes command waveforms to go from
zero amplitude to peak amplitude or from peak amplitude to zero
amplitude.

Command Target
Amplitude Setpoint

Start/Resume
Taper Time

Tapered waveform starting or resuming from the mean level

Target
Command Setpoint
Amplitude

Stop/Hold
Taper Time

Tapered waveform stopping or holding from the command amplitude to the mean level

Model 793.00 System Software 427

 Channel Options Window
Station Manager

Ramp Times Ramp Times set the time for MPT processes to ramp to commanded
levels.

Start/Resume
Ramp Time

Target
Command Setpoint
Amplitude

Current Setpoint
Waveform ramping from the current setpoint to the target setpoint

Stop/Hold
Ramp Time

Target
Command Setpoint
Amplitude

Zero Setpoint
Waveform ramping from target setpoint to zero setpoint

428 Model 793.00 System Software

 Channel Options Window

Station Manager
Begin/End times Begin Times values set the taper time at the beginning of MPT, BTW,
and Function Generator blocks using tapered wave shapes.

End Times values set the taper time for MPT and BTW blocks using
tapered wave shapes as these blocks reach the end of a predefined
count.

Begin/End Times also apply to incoming external commands applied

to controllers with a soft start/stop feature.

Target
Command Setpoint
Amplitude

Waveform without soft start/stop—The waveform immediately begins

oscillating at the full command amplitude from the target setpoint.

Begin End
Time Time

Target
Command Setpoint
Amplitude

Tapered Waveform —The waveform tapers up to the full command amplitude and down to the
target setpoint.

Model 793.00 System Software 429

 Channel Options Window
Station Manager

Begin/End times with a For MultiPurpose TestWare blocks employing a tapered segment
command process shape, Begin and End Times define the time it takes to taper the
command at the beginning and end of each process.

The following figure shows an MPT block using a tapered segment

shape that is interrupted with a hold and subsequently restarted.

Hold Resume
Begin Taper Taper End
Time Time Time Time

Command Target
Amplitude Setpoint

Start of Process End of Process

MPT Process with Interrupt and Restart

430 Model 793.00 System Software

 Channel Options Window

Station Manager
Setpoint/Span Times The Setpoint/Span Times values set the time it takes to change to a
new setpoint or span.

These times specify how long it takes to change the Setpoint from
zero to full scale or the Span to change from 0 to 100%. If the value
has less distance to travel, the time will be correspondingly less.

Initial New
Command Command
Amplitude Amplitude

Specified
Span Time

The Station Manager Channel Span or Master

Span control reduces the waveform span.

Specified
Setpoint Time

Specified
Begin Time New
Setpoint

Initial
Target
Setpoint

The Station Manager Setpoint control

changes the waveform setpoint.

Model 793.00 System Software 431

 Channel Options Window
Station Manager

Signal Lists Tab

Path Tools menu > Channel Options > Channel Options window >
Signal Lists tab

This tab defines the signals displayed in the Station Setup window’s
Station Signals tab, in the Auto Offset window, and in the optional
Remote Station Control (RSC) panel.

See “How to Edit the Signal Lists” on page 178 for more information
about using this tab’s controls.

Signal Lists Tab (part 1 of 2)

ITEM DESCRIPTION
Name Displays the name of the selected signal list. Predefined default signal
lists are grayed out. You can name user-defined lists here.
Signal List Displays all signal lists. Select a name to edit the signals included in its
list.
Add Creates a new signal list.

432 Model 793.00 System Software

 Channel Options Window

Station Manager
Signal Lists Tab (part 2 of 2)
ITEM DESCRIPTION
Delete Deletes the selected signal list.
Predefined signal lists cannot be deleted.
Reset Restores signals to predefined signal lists.
This control does not work for user-defined signal lists.
List Filter Applies a filter to predefined signal lists, displaying only Available
Signals that are likely to be used with the list.
Enter text that describes the signal(s) you want to display. For example,
enter force to display all force signals.
You can also enter part of a signal description to display a signal type.
For example, enter disp to display all displacement signals.
Available Signals Lists signals that can be Included in a signal list.

Moves selected signals from Available Signals to Included.

Moves all signals from Available Signals to Included.

Included Lists the signals in the selected signal list.

Moves selected signals from Included to Available Signals.

Moves all selected signals from Included to Available Signals.

Moves the selected Included signal one place up in the list.

Moves the selected Included signal one place down in the list.

Model 793.00 System Software 433

 Channel Options Window
Station Manager

RSC Tab
Path Tools menu > Channel Options > Channel Options window > RSC
tab

This tab defines custom Remote Station Control (RSC) signal pages that
display only specified signals. RSC is an option.

RSC Tab (part 1 of 2)

ITEM DESCRIPTION
Additional Pages Displays the name of the selected signal page. Rename pages here.
Pages Lists signal pages.
Add Creates a new signal page.
Delete Deletes the selected signal page.
Hide Application Select to not display controlling application names on the signal page.
Hide Channel Select to not display channel information on the signal page.
Information

434 Model 793.00 System Software

 Channel Options Window

Station Manager
RSC Tab (part 2 of 2)
ITEM DESCRIPTION
Current Signal List Specifies the signal list displayed on the selected signal page.
Apply Applies the changes to the RSC immediately. The setting is saved with
the current view set.

Model 793.00 System Software 435

 Channel Options Window
Station Manager

Detector Lists Tab

Path Tools menu > Channel Options > Channel Options window
>Detector Lists tab

This tab defines the signals displayed in the Station Setup window’s
Detectors tab, in the Detectors window.

Detector Lists Tab (part 1 of 2)

ITEM DESCRIPTION
Name Displays the name of the selected detector list. Predefined default
detector lists are grayed out. You can name user-defined lists here.
Detector List Displays all detector lists. Select a name to edit the detectors included in
its list.
Note The All Detectors list cannot be edited.

Add Creates a new detector list.

Delete Deletes the selected detector list.
Predefined detector lists cannot be deleted.

436 Model 793.00 System Software

 Channel Options Window

Station Manager
Detector Lists Tab (part 2 of 2)
ITEM DESCRIPTION
Reset Restores signals to predefined detector lists.
This control does not work for user-defined detector lists.
List Filter Applies a filter to predefined detector lists, displaying only Available
Detectors that are likely to be used with the list.
Enter text that describes the signals you want to display. For example, to
display all force signals, enter force.
You can also enter part of a signal description to display a signal type.
For example, enter disp to display all displacement signals.
Available Detectors Lists signals that can be Included in a detector list.

Moves selected detectors from Available Detectors to Included.

Moves all detectors from Available Detectors to Included.

Included Lists the detectors in the selected detector list.

Moves selected detectors from Included to Available Detectors.

Moves all selected detectors from Included to Available Detectors.

Moves the selected Included detector one place up in the list.

Moves the selected Included detector one place down in the list.

Model 793.00 System Software 437

 Channel Options Window
Station Manager

Rig Commands Tab

Path Tools menu > Channel Options > Channel Options window > Rig
Commands tab

The Rig Commands tab defines Park and Ride levels for vehicle testing.
Park defines a level the enabled channels can move to before
hydraulic shut down. Ride defines a level the enabled channels can
move to before running any test.

Use the Manual Command window to move the enabled channel(s) to

its Park or Ride position. Enabled channels can be moved individually
or as a group.

See “Using Rig Command (Park/Ride)” on page 264 and “Using

Manual Command Park/Ride” on page 512 for more information about
using this tab’s controls.

438 Model 793.00 System Software

 Channel Options Window

Station Manager
Rig Commands Tab
ITEM DESCRIPTION
Command 1 (Park)

Name Defines the name of the Command 1 (Park) position.

Ramp Time Sets the time required for the enabled channels to ramp to the Command
1 (Park) position.
Define Levels Click Use Current to use the currently defined component feedback
values for the corresponding Command 1 values.
Command 2 (Ride)

Name Define the name of the Command 2 (Ride) position.

Ramp Time Sets the time required for the enabled channels to ramp to the Command
2 (Ride) position.
Define Levels Click Use Current to use the currently defined component feedback
values for the corresponding Command 2 values.
Channel Displays active channels.
Control Mode Displays the active control mode for each channel.
Command 1 Displays the current Command 1 (Park) value for the corresponding
channel.
Command 2 Displays the current Command 2 (Ride) value for the corresponding
channel.

Model 793.00 System Software 439

 Channel Options Window
Station Manager

Channel Lists Tab

Path Tools menu > Channel Options > Channel Options window >
Channel Lists tab

This tab defines channels that can be selected from the Channel List
on the Channel Status Panel. See “Station Setup Window/Channel
Status Panel Tabs” on page 295 for more information.

Note The All Channels list cannot be edited and is only updated when
the station configuration changes

Channel Lists Tab (part 1 of 2)

ITEM DESCRIPTION
Group Name Enter a name for the channel list selected below.
Channel Lists Displays channel lists.
Add Group Adds a new Group Name to the Channel Lists Groups.
Delete Group Deletes the selected channel list from the Channel Lists Groups.
Available Channels Lists the available channels that can be selected for Channel Lists.

440 Model 793.00 System Software

 Channel Options Window

Station Manager
Channel Lists Tab (part 2 of 2)
ITEM DESCRIPTION

Moves the selected Available Channels item to Selected Channels list.

Selected Channels Lists the channels included in the selected Channel Lists group.

Moves Selected Channels item to Available Channels.

Model 793.00 System Software 441

 Sensor File Editor Window
Station Manager

Sensor File Editor Window

Path Tools menu > Sensor File Editor

Open Print
Save

Toolbar Detail

Open Print
New Print to File
Save
Save As

This window creates and edits sensor calibration files.

Valid sensor files require Conditioner Type, Dimension, and at least

one Range Definition.

See “Calibrating Sensors and Configuring Feedback” on page 131 for

more about using this window’s controls.

442 Model 793.00 System Software

 Sensor File Editor Window

Station Manager
Sensor File Editor Window (part 1 of 3)
ITEM DESCRIPTION

toolbar Manages sensor files.

Open—Displays the Open Sensor File window. Use this box to open
existing sensor calibration files (extensions .scf and .clb).
New—Displays a Sensor File Editor window with default values
displayed. Use this window to define new sensor files.

Save—Saves the sensor file. Displays the Save Sensor File As window if
a new sensor file is being saved.
Save As—Displays the Save Sensor File As window. Use this window
to name new sensor files and rename old sensor files.

Print—Prints out the sensor file information.

Print to File—Displays the Print to File window. Use this window to
print the sensor file to a text file (extension .txt).
File Definition Defines sensor calibration information. Information entered here also
appears in the Station Setup window’s Sensor tab.
Sensor File Displays the sensor calibration file name.
Name

Sensor Name Names the sensor. Enter any name up to 30 characters.

Sensor Serial Specifies the sensor serial number.
#

Conditioner Selects the compatible conditioner type for this sensor calibration file.
Type

Conditioner Specifies the conditioner serial number.

Serial #

Dimension Selects the conditioner output’s dimension.

Last Enter the most recent calibration date for the sensor/conditioner pair.
Calibration
Date

Hardware Enter the hardware resource allocated in the Station Builder application
Resource for this sensor signal.
General Enter additional useful information.
Information

Model 793.00 System Software 443

 Sensor File Editor Window
Station Manager

Sensor File Editor Window (part 2 of 3)

ITEM DESCRIPTION
Sensor Polarity Select a Normal or Invert polarity for the sensor signal.
Range Definition Defines the sensor’s ranges.
Ranges Lists sensor ranges.
This list is available only when a multi-range conditioner is selected in
Conditioner Type.
Add Adds a new range to the sensor calibration file. Each file can have up to
four ranges.
This button is available only when a multi-range conditioner is selected
in Conditioner Type.
Delete Deletes the selected range.
This button is available only when a multi-range conditioner is selected
in Conditioner Type.
Name Displays the name of the selected range (multi-range conditioners) or a
single range (full-range conditioners). Enter new range name(s) here.
Fullscale Specifies the selected range’s full-scale minimum and maximum values.
Min/Max
Ranges can be asymmetrical as long as Min is less than zero and Max is
greater than zero.
Linearization This button is available only when a full-range conditioner is selected in
Data Conditioner Type.
Click this button to display the Linearization Data window. See
“Linearization Data Window” on page 446
Use the Linearization Data window to precisely edit range data points.

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Sensor File Editor Window (part 3 of 3)
ITEM DESCRIPTION
Calibration Values The Conditioner Type selected determines these controls. Values
entered here appear in the Station Setup window’s Calibration tab.
See “Calibration Tab” on page 313 for more information.
Cal Type Sets the type of calibration used for the feedback signal.
The calibration types displayed in this list depend on the conditioner
type selected.
Gain/Delta-K—Select to use delta K for calibration of sensors. Allows
you to specify the amount of delta K applied to the sensor’s output
signal.
Equally negative and positive inputs cause asymmetry in the sensor’s
output signal. Delta K compensates for this asymmetry.
Gain/Linearization—Select to use linearization data for calibration of
sensors with full-range conditioners. This type of calibration allows use
of the Linearization Data window to precisely edit range data points.
mV/V Pos Tension—Select when a sensor has been calibrated so that a
positive output represents actuator retraction (tension).
mV/V Pos Comp—Select when a sensor has been calibrated so that a
positive output represents actuator extension (compression).

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Linearization Data Window

Path Tools menu > Sensor File Editor > Sensor File Editor window >
Linearization Data button

The test system uses the difference between this window’s Standard
and Conditioner values to compensate for transducer non-linearity.

Linearization Data Window (part 1 of 2)

ITEM DESCRIPTION
Fullscale Min/Max Displays the full scale value for the selected transducer.
Data Range Sets the operating range over which linearization data values apply.
Range is expressed as a percentage of the transducer’s Fullscale value.
Reset Resets all Standard and Conditioner values to their default values.

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Linearization Data Window (part 2 of 2)
ITEM DESCRIPTION
Standard Displays the actual force or displacement values applied during
calibration as measured by a standard such as a dial indicator gage or
calibrated force sensor.
Conditioner Displays the conditioner’s output feedback in response to the applied
force or displacement value as measured by the standard.

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Event-Action Editor Window

Define Actions Tab
Path Tools menu > Event-Action Editor > Event-Action Editor window >
Define Actions tab

navigation pane

Panel

This tab defines custom responses to Limit Detector, Error Detector,

Null Pacing Timeout, and Digital Input events.

Actions must be defined in this tab before they can be selected in the
Action Lists tab, described on page 457.

See “How to Define a Custom Action” on page 247 for more about
using this tab’s controls.

Important If you are using manual command, the defined actions Ramp
To and Stop At Level will not be triggered by a event (typically
a tripped limit). To trigger these actions you must be in “run”
mode when a limit is tripped; using either the function
generator, MultiPurpose TestWare, or Basic TestWare.

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Define Actions Tab
ITEM DESCRIPTION
navigation pane Displays a tree view of actions, organized by type.
Selections within the navigation pane determine the tab’s right-hand
panel controls. For example, selecting Message displays panel controls
for logging a message in response to an event.
Click – to contract the tree view; click + to expand the tree view.
Add Adds a new action of the type selected in the tree view.
Delete Deletes the selected action.
Apply Commits any changes that have been made to the current action. The
changes are not effective until they have been applied.
Note If you have made changes to the current action, you cannot switch the
editor to a different action without clicking Apply or Reset.

Reset Resets the action entries to the values set when the action was loaded or
when Apply was last clicked.

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Message Panel

Select Message in the navigation pane to display controls to define

messages written to the Message Logs window, described on page
403.

Message Panel
ITEM DESCRIPTION
Name Enter the action’s name. This name appears in the navigation pane and
in the Action Lists tab’s Included list.
Message Type the message text that will be written to the Message Logs window.
Severity Select a severity level associated with the message.

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Ramp To Panel

Select Ramp To in the navigation pane to define a controlled ramp to

a specific level. The program stops at the end of the ramp.

You can have a total of seven Ramp To and Stop At Level actions.

For more about ramps, see “Command Options Tab” on page 423.

Ramp To Panel
ITEM DESCRIPTION
Name Enter the action’s name. This name appears the navigation pane and in
the Action Lists tab’s Included list.
Ramp Time Sets the ramp time.
Channel Identifies the channels where the ramp occurs.
Control Mode Sets each ramp’s control mode.
Level Sets each ramp’s ending level.

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Stop At Level Panel

Select Stop At Level in the navigation pane to display controls for

defining program stop actions.

You can have a total of seven Stop At Level and Ramp To actions.

Stop At Level Panel

ITEM DESCRIPTION
Name Enter the action’s name. This name appears in the navigation pane and
in the Action Lists tab’s Included list.
Channel Identifies the channels where the stop occurs.
Control Mode Sets each stop’s control mode.

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Hydraulics/Powers
Panel

Select Hydraulics/Powers in the navigation pane to display controls

for defining station hydraulic and power actions.

Hydraulics/Powers Panel
ITEM DESCRIPTION
Name Enter the action’s name. This name appears in the navigation pane and
in the Action Lists tab’s Included list.
Power Identifies the power source affected by the action.
Options Defines what each action does. For hydraulic service manifolds (HSMs),
the choices are Disabled and Power Off.

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Digital Output Panel

Select Digital Output in the navigation pane to display controls for

defining digital output actions.

Digital Output Panel

ITEM DESCRIPTION
Name Enter the action’s name. This name appears in the navigation pane and
in the Action Lists tab’s Included list.
Pulse Width Sets the pulse duration time for digital outputs with a pulse option.
Signal Identifies the digital output.
Options Defines the digital output signal’s behavior:
Disabled—No signal.
Set—The signal goes high.
Clear—The signal goes low.
Toggle—The signal changes state.
Pulse—The signal changes state for the Pulse Width time and then
returns to its initial state.

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Delay Panel

Select Delay in the navigation pane to display controls to define a

delaying action. Delay actions are only useful in an Action Group, so
they must be added to a group.

Delay Panel
ITEM DESCRIPTION
Name Type the action name in this field. This name appears in the navigation
pane and in the Action Lists tab’s Included list.
Time Sets the delay time.

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Action Group Panel

Select Action Group in the navigation pane to display controls to

create a single action that combines individual actions.

An Action Group can include the standard Indicate, Station Power

Off, Interlock, Program Interlock, Program Stop, and Program
Hold actions.

The timing of actions in a group is set by the order in which they

appear in Included. It is not necessary for one action to complete
before the following action starts. Use Delay to sequence actions in a
group.

Action Group Panel

ITEM DESCRIPTION
Name Type the action name in this field. This name appears in the navigation
pane and in the Action Lists tab’s Included list.
Available Lists the user-defined and standard actions that can be combined into an
Action Group.
Included Lists the actions that have been added to the Action Group.

Moves the selected Included action up one place in the list.

Moves the selected Included action down one place in the list.

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Action Lists Tab
Path Tools menu > Event-Action Editor > Event-Action Editor window >
Action Lists tab

This tab’s selections determines if custom actions can be selected as

Action responses to Limit Detector, Error Detector, Null Pacing
Timeout, or Digital Input events.

See “About Detectors” on page 223, “About Null Pacing” on page 195,
and “About Digital Inputs” on page 243 for more information.

Action Lists Tab (part 1 of 2)

ITEM DESCRIPTION
Event Type Limit Detector—An Included action can be selected as the Action
triggered by a limit detection event.
Error Detector—An Included action can be selected as the Action
triggered by an error detection event.
Null Pacing Timeout—An Included action can be selected as the
Action triggered by a static or dynamic null pacing timeout.
Digital Input—An Included action can be selected as the Action
triggered by a digital input.
All Actions List—An Included action can be selected as the Action
triggered by any of the above events.
Available Lists actions that can be Included as an Action in response to the
selected Event Type.

Moves selected actions from Available to Included.

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Action Lists Tab (part 2 of 2)

ITEM DESCRIPTION

Moves all actions from Available to Included.

Included Lists the actions available for the selected Event Type.
By default, all new custom actions go here.

Moves selected actions from Included to Available.

Moves all actions from Included to Available.

Moves the selected Included action up one place in the list.

Moves the selected Included action down one place in the list.

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Station Manager
Calculation Editor Window
Path Tools menu > Calculation Editor

Navigation
Pane

Panel

This window defines the formulas used to produce a calculated signal.

Signals resulting from these formulas can be output as drive signals,
input for use in control modes, and saved as data.

The Station Builder application assigns resources for actual station

signals and creates calculated resources. The formulas defined in this
window tie together actual signals with calculated resources to
produce usable inputs and outputs. For more information, see Use care
when applying the results of an expression.

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Calculation Editor Window

ITEM DESCRIPTION
navigation pane Displays a tree view of calculated signals, organized by type.
Selections within the navigation pane determine the tab’s right-hand
Panel controls. For example, selecting Calculation Parameters displays
the Parameter panel, with controls to define parameters used in
formulas. The following pages describe these controls.
Click – to contract the tree view; click + to expand the tree view.

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Calculation Definition Panels

Path Tools menu > Calculation Editor > Calculation Editor window >
navigation pane > Calculated Input Signals or Calculated Output
Signals

Expression Toolbar—Detail Copy Paste

Cut Undo

Print

Expression

Results

Arithmetic Operators Toolbar—Detail

Division Left Parenthesis
Multiplication Right Parenthesis
Subtraction Left Square-bracket
Addition Right Square-bracket

These panels define the formulas used to produce calculated inputs

and outputs. The panels that define inputs and outputs are identical.

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WARNING
WARNING Small formula changes can produce large control loop changes,
resulting in violent actuator actions.

Violent actuator movement can result in injury and equipment damage.

Use care when changing formulas.

WARNING
WARNING Expressions use SI (Systeme International d’Unites) units, such
millimeters and Newtons. The Station Manager can be calibrated and
programmed using U.S. Customary units, such as inches and pounds.
Applying the results of an SI based expression in a control loop using
U.S. Customary Units can produce violent actuator movement.

Violent actuator movement can result in injury and equipment damage.

Use care when applying the results of an expression.

Calculation Definition Panels (part 1 of 2)

ITEM DESCRIPTION
Expression toolbar Use to edit the formula in the Expression box.

Cuts selected text.

Copies selected text to the clipboard.

Pastes in the clipboard contents at the cursor position.

Undo the last typed change.

Prints the expression.

Expression Create and edit formulas here for Calculated Input Signals and
Calculated Output Signals selected in the navigation pane.
Create and edit expressions using the Expression toolbar and
Arithmetic Operator buttons, as well as by direct typing.

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Calculation Definition Panels (part 2 of 2)
ITEM DESCRIPTION
Results Displays the results of clicking Apply to compile the formula.
Success indicates a successful compilation.
Error messages identify errors by row and column, which may not
always be accurate. Undefined variable errors produce messages that
point to the end of the formula.
Insert Use to insert common Operators, Functions, and Signals into the
Expression box’s formula.
Arithmetic Use this toolbar’s buttons to insert common operators into the
Operators toolbar Expression box’s formula.
Functions Select and then double-click to insert these common functions into
the Expression box’s formula.
Signals Displays a tree view of signals that can be used in formulas.
Note Signals designated as “reconfigurable” are removed from this
lost of available signals.

Double-click to insert signals into the Expression box’s formula.

The following signal types are available:
Real Signals—These are actual station signals, such as Command.
Integer Signals—These signals use an integer representation, such
as Count.
Calculation Parameters—Parameters defined using the
Calculation Editor window’s Parameter Definition panel,
described on page 477.
Apply Compiles and saves the formula.
The Results box shows the success or failure of a compilation.
Note You must Apply or Cancel edits before switching to a different
calculation.

Cancel Cancels any changes made in the formula and returns formula values
to where they were when Apply was last clicked or the calculation
initially loaded.
Clear Removes the formula from the Expression box.

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Functions The following Functions are available:

int abs(int x) real cosh(real x) real sin(real x)

real acos(real x) real exp(real x) real sinh(real x)

real asin(real x) real fabs(real x) real sqrt(real x)

real atan(real xy) real ln(real x) real tan(real x)

real atan2(real x, real y) real log10(real x) real tanh(real x)

real cos(real x) real pow(real x, real y) real pi ( )

real rate ( ) int size(real x[ ]) int isize(int x[ ])

real avg(real x[ ], int y) real shift(real x[ ], real y) int ishift(int x[ ], int y)

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Calculation Grammar
Simple Expression The simplest form of an expression for a calculated signal is an
equation that assigns the signal to some equation of other signals and
calculation parameters.

For example:

“Axial Stress” = “Axial Force” / “Area”;

If the names contain spaces or other special characters, they must be

enclosed in quotation marks. In the preceding example, the quotation
marks could have been left off of Area. However, it is typical to always
put them in.

Names are case sensitive in the Calculation Editor window.

The expression can span multiple lines, and spaces or tabs can be
inserted to improve readability. However, the names in quotation
marks must not contain extra spaces or line terminators.

Comments C-style comment delimiters can be used to insert comments in the

expression, or temporarily comment out portions of the code. There
are two types of comments—bracketing comments and end-of-line
comments.

Bracketing comments are delimited by character sequences /* and */

that can span multiple lines. For example:

/* …
...my comment...
...*/

End of line comments start with a double-slash, and end at the end of
the line. For example:

“Axial Stress” = “Axial Force” / “Area”; //my comment

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Data types In simple situations, the calculation designer can think of all the data in
calculations as being numbers. However, the calculation engine
actually handles different kinds of data. A value is an IEEE 32-bit
floating point, an IEEE 64-bit floating point, or a 32-bit integer.

• All calculation parameters are stored in IEEE 32-bit floating-point

format.

• All floating point signals are 32-bit floating points.

• All integer signals are 32-bit integers.

• Floating point data within the calculation engine are 64-bit floating
points.

• Integer data within the calculation engine are 32-bit integers.

Data values are converted as necessary, so you generally do not need

to be concerned with them.

Literal numbers and Expressions are evaluated in system units. System units are based on
dimensions millimeters, kilo newtons, and seconds. The Calculation Editor
window displays the System Units used by all selected Signals. Look
in the file SYSDEF.UAS for a full list of the system units. The values that
the expression reads from signals and calculation parameters will be in
these units. The value assigned to the result signal must be in the
appropriate signal unit.

If literal values are put into the expression, they must be interpreted in
system units.

The calculation engine does not do any unit conversion or dimensional

analysis.

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Operators The language understands the normal plus, minus, multiply, and
divide operators. The default precedence of these operators matches
most programming and mathematical languages. It evaluates all
multiplication and division (left to right) and then all addition and
subtraction (left to right). To change the order of evaluation, you use
parenthesis operators.

For example:

“Axial Force” = (“Axial Force 1” + “Axial Force 2”) / 2;

The following table shows all the recognized operators organized by

group and listed in order of precedence. Within a group, all operators
have the same precedence.

Calculation Editor Window Operators (part 1 of 2)

PRECEDENCE OPERATOR FUNCTION OPERAND TYPE RESULT TYPE DIRECTION

1 [] Array index Int Int or real Left-to-right

() Function call Int or real (same as

operand)

2 ! Logical NOT Int or real (same as Right-to-left

operand)

3 – Unary minus Int or real (same as Right-to-left

operand)

4 * Multiply Int or real (same as Left-to-right

operands)

/ Divide

5 + Addition Int or real (same as Left-to-right

operands)

– Subtraction

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Calculation Editor Window Operators (part 2 of 2)

PRECEDENCE OPERATOR FUNCTION OPERAND TYPE RESULT TYPE DIRECTION

6 < Less than Int or real Int Left-to-right

<= Less than or

equal

> Greater than

>= Greater than

or equal

== Is equal

!= Not equal

7 || Logical OR Int Int Left-to-right

&& Logical AND Left-to-right

The compiler will automatically provide conversions to get to the

proper types. For example, if you add a real number and an integer
number, the code will convert the integer number to a real number
before doing the addition.

Built-in arithmetic The language understands the following built-in arithmetic functions:
functions
int abs(int x) real cosh(real x) real sin(real x)

real acos(real x) real exp(real x) real sinh(real x)

real asin(real x) real fabs(real x) real sqrt(real x)

real atan(real x) real ln(real x) real tan(real x)

real atan2(real x, real y) real log10(real x) real tanh(real x)

real cos(real x) real pow(real x, real y) real sin(real x)

real rate() real pi( )

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Multiple statements There is only so much that you can do in a single equation. It can be
and variables convenient or necessary to break the calculation equation into multiple
statements. This requires variables to store intermediate results.
Variables can also be used to remember data from one clock tick to the
next.

Using variables for You can declare variables by specifying the data type, and following it
intermediate results with a comma-separated list of variable names. For example, the
following defines three floating-point variables (x, y, and z) and an
integer variable (count):

real x, y, z;
int count;

The names of variables follow the same rules as other names. If they
contain spaces or other special characters, they must be put in quotes.

By using variables, intermediate results can be evaluated and used in

the main equation. For example:

real x;
x = “Axial Force 1” * Area;
“Axial Stress” = p0 + (p1 + (p2 + p3 * x)* x) * x;

The variables p0, p1, p2, p3 and Area are calculated parameters.

While this could have been done in a single expression, it would have
required that the multiplication x to be done three times and that
would have been much less readable.

Variables are local to a particular signal’s expression. Multiple signals

can use the same name in their expressions without any conflict.

Using variables to Variables that are defined as shown in the preceding example
remember history remember their value from one pass to the next. The following
expression does a two-point running average:

real oldValue;
“My Average Signal” = (“My Signal” + oldValue)/2;
oldValue = “My Signal”; //Remember the previous value.

When an expression is loaded into the machine (either when the

configuration is loaded, or when a new expression is applied), the
values of all variables are set to zero. Thereafter, they keep the last
value that was set into them.

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Arrays An array is a variable that holds multiple values of the same data type.
Arrays are declared in much the same way as normal variables. The
only difference is that a size is specified.

For example, the following declares an array “A” of 10 elements:

real A[10];

The elements of an array are indexed from zero.

The array in the preceding example contains elements:

A[0], A[1], A[2], A[3], A[4], A[5], A[6], A[7], A[8], and A[9]

One declaration statement can declare multiple array and non-array

variables. For example:

real A[100], a, B[20], x;

int counts[10], i;

The elements of an array can be individually referenced or assigned.

Arrays can be used to conveniently store more history.

For example, here is a four-point running average:

real old[4];
old[3] = old[2];
old[2] = old[1];
old[1] = old[0];
old[0] = “My Signal”; //Remember the previous value.
“My Average Signal” = (old[0] + old[1] + old[2] + old[3])/4;

The language supports the following built-in array functions:

int size(real x[ ]) int ishift(int x[ ], int y)

int isize(int x[ ]) real avg(real x[ ], int y)

real shift(real x[ ], real y)

The function shift (Array, value) performs the same operation as

shown in the preceding example (the function ishift(iarray, value)
works the same for integer arrays). The shift function shifts every
element up to the next higher index and puts the specified value into
element zero. It returns the value that shifted out of the last element in
the array.

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With this function, the preceding four-point running average can be
written as:

real old[4];
shift(old, “My Signal”); //just discard oldest value.
“My Average Signal” = avg (old, 4);

The shift function does not really have to move all the values. It is as
efficient on large arrays as it is on small ones.

The other useful function is size(array). It returns the allocated size of

a real array (isize(array) works with integer arrays). This is useful
when writing loops, which is the next topic. Here is a more general
implementation of the running average expression:

real oldValues[50]; //keeps the last 50 values.

real currentSum; //assume all values start out 0.
real discardedValue; //temporary
discardedValue = shift(oldValues, “My Signal”);
current Sum = currentSum + “My Signal” – discardedValue;
“My Average Signal” = currentSum/size(oldValues);

Indexing outside the bounds of an array is an error. The signal will be

set to invalid. See “Error handling” on page 475 for more information.

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Control structures Expressions support two control structures—The if statement, and the
(if, while) while statement.

if if statements work similar to their equivalents in the C language:

if (expression) if (expression) if (expression)

trueStatement; trueStatement;
else {
falseStatement; statements;
}

The expression is something that evaluates to an integer. Zero means

false, and non-zero means true. Most often, this expression will involve
relational operators, and logical operators.

For example, the following code, where Maximum and Minimum are
calculation parameters, clips the data on “My Signal” and puts the
result on “My clipped signal”

if (“My Signal” > Maximum)

“My clipped signal” = Maximum;
else if (“My Signal” < Minimum)
“My clipped signal” = Minimum;
else
“My clipped signal” = “My Signal”

To put more than one statement into the true or false conditional, you
can use a compound statement. A compound statement is a series of
statements enclosed with { } (called curly brackets or braces).

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while The while loop has a similar form:

while (expression) while (expression)

statement {
statements;
}

The following example implements a 50-tick delay. It also contains

logic that will initialize the array the first time it is called. After the first
time, the variable “i” will contain 50, so the logic will not be repeated.

real oldValues[50];
int i;
while (i < 50)
{
oldValues[i] = “My Signal”;
i = i + 1;
}
“Delayed Signal” = shift(oldValues, “My Signal”);

When using while loops, it is very easy to implement a loop that will
run forever. If this happens, the system will start missing interrupts.
This will cause a watchdog timer to fire, causing an interlock. The
expression evaluator will detect this, and stop executing the
expression. The signal will be set to invalid, and will remain that way
until Interlock Reset is pressed. See “Error handling” on page 475 for
more information.

User-defined Within the expression of a calculated signal, the user can define new
functions functions. These are only available in that particular expression.

The syntax is:

function returnType fcnName ( arguments )

{
variable declarations;
statements;
}

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This is best shown with the following examples:

function int factorial(int value)

{
if (value > 1)
return factorial(value –1) * value;
else
return 1;
}

function real PI()

{return 3.14159;}

function real sum(real A[])

{
int index;
real temp;

temp = 0;
index = 0;
while (index < size(A))
{
temp = temp + A[index];
index = index + 1;
}
return temp;
}

Functions must always have a return type. If the body of the function
does not execute a return statement, it will return a zero.

User-defined functions are called just like other functions.

Some examples:

real myArray[50];
shift(myArray, “My Signal”);
“My Average Signal” = sum(myArray)/size(myArray);

Arrays that are passed to functions are passed by reference, that means
that the function can modify the contents of the array.

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Variables declared at the start of the function are created when the
function is invoked, and destroyed when the function exits. This is
different than variables declared in the main body of the code. The
value of variables and arrays declared in a function is unpredictable
when the function is called. The function body must initialize them
before they are used.

Functions can access variables declared in the main routine. However,

if a variable or parameter is declared within the function by the same
name, then the function can only see this local variable.

Error handling The following describes the handling of compiler, mathematical, and
unrecoverable errors.

Compiler errors The system will not load a calculation containing compilation errors
(syntax errors, undefined variables, mismatched types, etc.). The
compiler lists the errors it finds, and includes a (line, column)
indication where the error is detected.

However, currently, some errors are not detected until after the code is
parsed, and the (line, column) will point at the end of the code or the
function.

Mathematical errors Arithmetic errors like divide-by-zero, or the square-root of a negative

number set the resulting value to infinity, or “Not-a-Number.” These
values continue to propagate through the calculations, and will
probably result in a limit detector tripping.

Unrecoverable errors Certain errors cannot allow the evaluation of the calculation to
continue.

These errors include:

• Watch-dog timeout caused by overloading the processor

• Array index out of bounds

• Stack overflow

• Invalid number generated (NAN—not-a-number)

When one of these happens, execution of the calculation is terminated,

and the signal is set to an “invalid” state. A message is sent to the log.

If the calculated signal is used by a control mode, then this will cause
an interlock. The watch-dog timeout will cause an interlock anyway.

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The result of a calculation will get clipped to the Fullscale Min/Max

value, set in the Calibration tab described on page 336.

If not-a-number occurs, the signal is set to invalid.

The user can try to recover by pressing Interlock Reset. However, if

the error is not intermittent, it will just trip again.

Helpful hints Remember that:

• All calculations are performed in system units.

• The current compiler does not do any optimization. All operations

that are specified will be executed. This includes implicit
conversions. For example, in the following code, the second
assignment is more efficient than the first, because the first one
needs to convert the integer zero into floating-point. Code is
generated to do this:

real x;
x = 0;
x = 0.0;

• If you have several calculated signals that need the same

expression, except that they operate on different input signals,
then declare a variable at the beginning that is assigned to the
input signal. Use this variable within the rest of the code. Then
you can copy the expression to the other calculation signals, and
just change the one line to point to the different signal.

• Use variable names that help document their use. By convention,

use quotes around signal and parameter names, but define
internal variables so they do not need quotes.

• Put comments, white space, and line terminators in the code to

make it more readable for the next person. These have no impact
on performance.

• Make sure you initialize any variables defined in user-defined

functions. The compiler will not find this error for you.

476 Model 793.00 System Software

 Calculation Editor Window

Station Manager
Parameters Definition Panel

Path Tools menu > Calculation Editor > Calculation Editor window >
navigation pane > Calculation Parameters

This panel defines parameters that can be used in calculated signals’

formulas.

Parameters values display and can be changed in the Station Setup

window’s Calculation Parameters panel, described on page 389.

WARNING
WARNING Small parameter changes can produce large control loop changes,
resulting in violent actuator actions.

Violent actuator movement can result in injury and equipment damage.

Use care in changing parameters and in setting the access level required to
change parameters.

Model 793.00 System Software 477

 Calculation Editor Window
Station Manager

Parameters Definition Panel

ITEM DESCRIPTION
navigation pane Displays a tree view of calculated signals and calculation parameters.
Selections within the navigation pane determine the tab’s right-hand
Panel controls.
Click – to contract the tree view; click + to expand the tree view.
Click and drag to rearrange the parameter order.
Display Name Identifies the calculation parameter.
This name entered here appears in formulas, in the Station Setup
window’s Calculation Parameters panel, and in the Channel
Option window’s Signal Lists.
Enter a name that is meaningful to users.
Internal Name Identifies the calculation name for internal purposes. Typically, this
name is not changed.
Dimension Selects the parameter’s dimension. This selection affects available
Current Value selections.
Range Sets a range in which the parameter value can be changed.
Access Level Sets the access level required to change the Current Value. See
“Setting Access Levels” on page 129 for more information.
Current Value Sets the current parameter value. Parameter values are changed here
and in the Station Setup window’s Calculation Parameters tab,
described on page 389.
Add Adds a new Parameter to the navigation pane list of Calculation
Parameters.
Delete Removes the selected Parameter from the navigation pane list of
Calculation Parameters.

478 Model 793.00 System Software

 Unit Assignment Set Editor Window

Station Manager
Unit Assignment Set Editor Window
Path Tools menu > Unit Set Editor

Save Save As
Open Delete

Toolbar Detail

This window creates and modifies the unit assignment sets (UAS) used
in test data files and the default unit set used by MultiPurpose TestWare
(MPT) and Basic TestWare (BTW).

Normally, unit assignment sets are selected when installing software.

However, the Station Option window’s Unit Selection tab, described
on page 412, can change UAS assignments at any time.

Model 793.00 System Software 479

 Unit Assignment Set Editor Window
Station Manager

Unit Assignment Set Editor Window (part 1 of 2)

ITEM DESCRIPTION
toolbar Manages UAS files.
The standard CGSET, ENGSET, ENGSETSM, SISET - SI, SISET- SM,
and SYSDEF UAS files cannot be changed or deleted.

Displays the Unit Assignment Set Open window. Use this box to
open unit assignment sets.
Select from the following MTS supplied sets:

CGSSET - Centimeters-Grams-Seconds—Units are based on

centimeters, grams, and seconds.

ENGSET - U.S. Engineering Units—Units are based on Customary

U.S. engineering units with force related units in kips.

ENGSETSM - U.S. Engineering Units (small)—Units are based on

Customary U.S. engineering units with force related units in lbf.

SISET - SI (Systeme International d’Unites)—Units are based on

Customary International (metric) units with force related units in kN.

SISETSM - SI (Systeme International d’Unites) - small—Units are

based on Customary International (metric) units with force related
units in N.

SYSDEF - System Units Definition—Contains units used by the

hardware.

Additional user-defined sets can be selected here.

Saves changes to custom unit assignment sets.

Displays the Unit Assignment Set Save As window. Use this box to
name and save custom unit assignment sets.

Deletes the selected custom unit assignment set.

UAS Name Displays the name of the UAS currently selected.

UAS File Displays the file name of the UAS currently selected.
Comment Enter comments about a custom UAS.

480 Model 793.00 System Software

 Unit Assignment Set Editor Window

Station Manager
Unit Assignment Set Editor Window (part 2 of 2)
ITEM DESCRIPTION
Settings Displays UAS Dimension and Units values.
Dimension and For standard sets, clicking a Dimension highlights its default Units.
Units
For custom sets, click a Dimension and then click the Units to be
used as the default.

Model 793.00 System Software 481

 Help Menu
Station Manager

Help Menu

This menu’s commands access electronic documentation and display

general application information.

Help Menu
ITEM DESCRIPTION
Electronic Documentation Opens electronic documentation help.
About Displays the About Station Manager window.
This window displays the Station Manager application version
number and copyright information.

482 Model 793.00 System Software

 Application Controls Panels

Station Manager
Application Controls Panels

Panel Buttons

Button Detail

Function Generator

External Command

Auto Tuning

Basic TestWare

MPT (Optional)

These panels display the controls for the application that is run at the
test station.

Application Controls Panels (part 1 of 2)

ITEM DESCRIPTION
Panel Buttons Change the test station’s controlling application panels.
The Station Manager application will display an error message if you
try to change an active control panel.

Displays the Function Generator control panel. Use this panel to

generate simple commands.

For more about this control panel, see “Function Generator Control
Panel” on page 485.

Model 793.00 System Software 483

 Application Controls Panels
Station Manager

Application Controls Panels (part 2 of 2)

ITEM DESCRIPTION

Displays the External Command control panel. Use this panel to

adjust an incoming program signal.

The Station Builder application must have assigned an external input

to a channel in the station configuration for this panel to display. See
“Enabling External Command Inputs” on page 74 for more
information.

For more about this control panel, see “External Command Control
Panel” on page 493.

Displays the Auto Tuning control panel. Use this panel to

automatically calculate PIDF tuning values.

For more about this control panel, see “Auto-Tuning Control Panel”
on page 495.

Displays the Basic TestWare (BTW) control panel.

This button displays only if the BTW application has been opened
through the Applications menu.

Displays the MultiPurpose TestWare (MPT) control panel. MPT is

an option which your system may not have.

This button displays only after the MPT application has been
opened.

484 Model 793.00 System Software

 Application Controls Panels

Station Manager
Function Generator Control Panel

Path Panel Buttons >

Note The Command Type selected defines this panel’s controls.

Command
Type—Cyclic

Command
Type—Random

Model 793.00 System Software 485

 Application Controls Panels
Station Manager

Command
Type—Sweep

Sweep Up
Dwell
Sweep Down

This control panel generates commands that can be used to warm up a

system or tune actuators.

See “How to Program with the Function Generator” on page 255 for
more about using this panel’s controls.

486 Model 793.00 System Software

 Application Controls Panels

Station Manager
WARNING Changes in Function Generator values made with hydraulic pressure on
can result in unexpected actuator movement.

A moving actuator can injure anyone in its path.

Always clear the actuator area before changing values.

Function Generator Control Panel (part 1 of 3)

ITEM DESCRIPTION
Channel Selects the control channel.
Click the Channel button to toggle between individual channels and a
Master Command Group. See “About Channel Groups” on page 259
for more information.
Selecting a Master Command Group blanks out the Control Mode
and Active Mode entries.
Control Mode Sets the control mode used when the Function Generator starts.
Active Mode Displays the current control mode.
Command Type Selects the type of command:
Cyclic—The function cycles at the specified amplitude and frequency.
Sweep—The function sweeps the command signal between the
specified frequency limits at the rate specified.
Random—The function sweeps randomly according to the RMS
amplitude and frequency limits you specify.
Descriptions of each command type follow this table.
Target Setpoint Specifies the setpoint that the signal’s amplitude centers on.
Amplitude (±) Displays for a Command Type of Cyclic and Sweep.
Specifies the signal’s amplitude. The specified amplitude applies equally
to both sides of the Target Setpoint.
RMS Amplitude (±) Displays for a Command Type of Random.
Specifies the signal’s RMS amplitude.
Note RMS (Root Mean Square) amplitude is always smaller than peak
amplitude. The maximum display range of the RMS amplitude is set to
20% full-scale.

Model 793.00 System Software 487

 Application Controls Panels
Station Manager

Function Generator Control Panel (part 2 of 3)

ITEM DESCRIPTION
Frequency Displays for a Command Type of Cyclic and Sweep.
Specifies the signal’s frequency.
The maximum frequency is limited to 20% of the high system clock rate.
During a Sweep, this control’s pointer tracks the sweep frequency.
Frequency Min/Max Displays for a Command Type of Random.
Sets the minimum and maximum frequencies of the random signal.
Click on the label to view the allowable minimum and maximum limits.
Sweep These controls display for a Command Type of Sweep.
Defines the signal’s sweep.
Type Defines the sweep type:
Linear—Steps the sweep linearly by the Rate between Frequency
Limits.
Logarithmic—Steps the sweep logarithmically by the Rate between
Frequency Limits.
Running the Function Generator makes this control unavailable.
Mode Defines the duration of the sweep.
Single—Sweeps until it reaches a frequency limit and then dwells at that
limit.
Continuous—Sweeps continuously between frequency limits until
stopped.
Running the Function Generator makes this control unavailable.
Rate Sets the change per step and how often the change occurs.
Frequency Sets the sweep command’s upper and lower frequency limits. Click on
Limits the label to view the Frequency Limits range.

488 Model 793.00 System Software

 Application Controls Panels

Station Manager
Function Generator Control Panel (part 3 of 3)
ITEM DESCRIPTION
Sweep Control
Starts an upward sweep.

Holds the sweep at its current frequency.

Starts a downward sweep.

Wave Shape Specifies the signal’s wave shape of Square, Ramp, Sine, Square
Tapered, Ramp Tapered, or Sine Tapered. See the discussion that
follows this table.
Compensator Specifies the compensator used by the Function Generator.
The Station Builder application must have enabled adaptive inverse
control (AIC) and amplitude and phase control (APC) in the station
configuration for these compensation methods to be available. See
“Creating Control Modes” on page 60 for more information.

Model 793.00 System Software 489

 Application Controls Panels
Station Manager

About Wave Shapes The Function Generator provides the following wave shapes.

Square 4.0000

2.0000

0.0000
0.3000 0.9000 1.5000 2.1000 2.7000 3.3000
Time (sec)

Ramp 4.0000

2.0000

0.0000
0.3000 0.9000 1.5000 2.1000 2.7000 3.3000
Time (sec)

Sine
4.0000

2.0000

0.0000 0.3000 0.9000 1.5000 2.1000 2.7000 3.3000

Time (sec)

490 Model 793.00 System Software

 Application Controls Panels

Station Manager
Square tapered Tapered square waves taper from 0% to 100% amplitude at the
beginning of execution, and from 100% to 0% at the end of execution.

4.0000

2.0000

0.0000
2.0000 4.0000
Time (sec)

Ramp tapered Tapered triangle waves taper from 0% to 100% amplitude at the
beginning of execution and from 100% to 0% at the end of execution.

4.0000

2.0000

0.0000
2.0000 4.0000
Time (sec)

Sine tapered Sine waves taper from 0% to 100% amplitude at the beginning of
execution, and from 100% to 0% at the end of execution.

4.0000

2.0000

0.0000
2.0000 4.0000
Time (sec)

Model 793.00 System Software 491

 Application Controls Panels
Station Manager

Random functions The Command Type selection of Random provides random

functions with various pre-emphasis filters. Typically, these random
wave shapes are used to train adaptive compensators such as AIC and
APC.

The convergence rate is typically slower at high frequencies. The

random function pre-emphasis filter is used to make the convergence
rate constant over all frequencies, by boosting high frequencies and
suppressing low frequencies. When training an adaptive compensator,
choose a shape that is roughly an inverse of the shape of the signal
spectrum.

The options are:

• Random - 1/F2

• Random - 1/F

• Random - Flat (no pre-emphasis filter)

• Random - F

• Random - F2

492 Model 793.00 System Software

 Application Controls Panels

Station Manager
External Command Control Panel

Path Panel buttons >

This control panel selects and adjusts external program commands.

Channels must be configured in the Station Builder application to

accept external program commands. For more information, see
“Enabling External Command Inputs” on page 74.

The external programmer should be supplying commands before

adjustments are made in this panel.

See “Working with External Commands” on page 181.

External Command Control Panel (part 1 of 2)

ITEM DESCRIPTION
Channel Selects the control channel that receives the external command.
Click the Channel button to toggle between individual channels and
an External Command Group.
Selecting an External Command Group blanks out the Control
Mode and Active Mode boxes and disables Target Setpoint.
Control Mode Displays the external command’s control mode, assigned in the
Station Builder application.

Model 793.00 System Software 493

 Application Controls Panels
Station Manager

External Command Control Panel (part 2 of 2)

ITEM DESCRIPTION
Active Mode Displays the channel’s current active control mode, assigned in the
Station Builder application.
Target Setpoint Specifies the setpoint on which the external command’s amplitude
centers (only for “Channel” type, not “Group” type).
Segment Generator Select Soft Start/Stop Enable to taper the start and stop of the
Options external command.
The Channel Option window’s Command Options tab, described
on page 423, defines beginning and ending taper times.

494 Model 793.00 System Software

 Application Controls Panels

Station Manager
Auto-Tuning Control Panel

Path Panel Buttons >

This control panel automatically calculates tuning values for PIDF

control modes.

See “About Auto-Tuning” on page 569 for more about using this
panel’s controls.

Model 793.00 System Software 495

 Application Controls Panels
Station Manager

Auto-Tuning Control Panel (part 1 of 2)

ITEM DESCRIPTION
Control Channel Selects the control channel to auto-tune.
Control Mode Selects the control mode to be in when auto-tuning. This mode setting
can different than the “Mode to Tune” setting.
Mode to Tune Selects the mode that is to be tuned.
Active Mode Displays the active control mode.
Auto-Tuning Type Selects an auto-tuning type.
Basic—When you run Basic auto-tuning, the auto-tuner disregards your
current PIDF gain settings and exercises the actuator to within 80% of the
Upper Limit and the Lower Limit.
Advanced—When you run Advanced auto-tuning, the auto-tuner first does
basic auto-tuning. It then runs a sine sweep to exercise the actuator to
within 20% of the Upper Limit and the Lower Limit. This selection
enables Tracking and Sweep Freq.
Actuator Type Normal—Uses tuning algorithms for non-hydrostatic actuators.
Hydrostatic—Uses tuning algorithms for hydrostatic actuators.
Upper Limit/ Sets the limits within which the actuator moves.
Lower Limit
The Station Manager application stops auto-tuning and trips an interlock
if the actuator exceeds these limits.
Tracking Enabled by an Auto-Tuning Type selection of Advanced.
Sets how aggressively Advanced tuning tunes the actuator.
The default setting is 50%. Set the Tracking higher to tune the system
“hotter” and lower to tune the system “cooler.”
Tracking values that are too high may produce tuning values that result
in system instability.
Sweep Freq Enabled by an Auto-Tuning Type selection of Advanced.
Sets the upper frequency limit of the Advanced sweep function. The
default setting is 20 Hz.
For successful Advanced auto-tuning, set the sweep frequency to create
a phase shift greater than 90º for 0% tracking and 135º for 100% tracking
between the command and compensated command.

496 Model 793.00 System Software

 Application Controls Panels

Station Manager
Auto-Tuning Control Panel (part 2 of 2)
ITEM DESCRIPTION
Results Displays tuning results.
New Values Displays the new calculated auto-tuning values.
Current Displays the current tuning values used for this control mode.
The Station Setup window’s Adjustments tab, described on page 337,
also displays these values.
Accept Transfers New Values to Current values and enters these values in the
Station Setup window’s Adjustments tab.

Model 793.00 System Software 497

 Station Controls Panel
Station Manager

Station Controls Panel

Program Controls Detail

Toolbar

Control Application

Program Control

Program Run Program Stop

Program Hold

Station Limits Detail

Upper Limit Out of Range
Inner Error

Lower Limit
Outer Error

This panel starts, stops, and provides general controls for the test
station application’s program.

Station Controls Panel (part 1 of 3)

ITEM DESCRIPTION
toolbar Displays windows used to control station functions. See “Station
Controls Panel Toolbar” on page 501 for more information.
Control Application Identifies the application or function being run at the test station.

498 Model 793.00 System Software

 Station Controls Panel

Station Manager
Station Controls Panel (part 2 of 3)
ITEM DESCRIPTION
Program Control Stops, holds, and starts the test station program.

Stops the program. Red indicates a stopped program.

Holds the program. The application being run determines this

button’s availability. Yellow indicates a hold.

Starts the program. Flashing green indicates that ramping is in

progress. Solid green indicates a running program.

Master Span Sets the master span for all channels included in a master span
group.
MPT procedures where the MPT Option Editor window’s Span
control is set to Disable and Reset makes this control unavailable.
The Channel Options window’s Master Span tab, described on
page 418, defines master span groups.
The Station Option window’s Display Master Span on Main
Window control, described on page 416, must be selected to display
this control. If this selection is not made, Master Span will be
displayed on the Setpoint and Span window. See “Setpoint and
Span Window” on page 513.
Master Gain (Option) Sets the master gain for all station channels. Master gain is a
multiplier of the gains for all the PID control loops in your station.
This optional feature is used primarily for complex systems.
Station Limits Provides a quick view of Error, Limit, and Out of Range detector
status.
White—Detectors within limits.
Red—Detectors out of limits. Sensors saturated.
Yellow—Sensors out of range.
The Station Option window’s Display Station Limits on Main
Window control, described on page 416, must be selected to display
this control.

Model 793.00 System Software 499

 Station Controls Panel
Station Manager

Station Controls Panel (part 3 of 3)

ITEM DESCRIPTION
Rig Commands As an option, the Rig Command Park and Ride buttons can be
displayed.
The Station Option window’s Display Rig Command on Main
Window control, described on page 416, must be selected to display
these buttons.
Interlock A Interlock condition lights this indicator. This type of interlock
stops the program and removes station power.
The number following Interlock and Program indicates which
interlock chain the station is using. This assignment is made in the
Open Station window, described on page 281, when opening the
station configuration.
Note Station Manager saves the last used interlock chain to the station
configuration, and will attempt to restore it if currently available.

Program A Program Interlock condition lights this indicator. This type of

interlock stops the program without removing station power.
Reset Resets the interlocks.
Reset/Override Temporarily overrides interlocks. Each click provides 10 seconds of
override. Use this button where station power is required to clear
interlock conditions.
Station Power The station configuration determines these controls.
HPU—Controls hydraulic power units (HPU), through Power Off,
Power Low, and Power High buttons.
HSM—Controls hydraulic service manifolds through Power Off,
Power Low, and Power High buttons.

500 Model 793.00 System Software

 Station Controls Panel

Station Manager
Station Controls Panel Toolbar

Digital I/Os Manual Command

Detectors Span Setpoint
Auto Offset Remote Setpoint Adjust

Station Controls Panel Toolbar (part 1 of 2)

ITEM DESCRIPTION

Displays the Signal Auto Offset window. Use this window to

monitor station signals and apply auto-offsets as needed.
See “Signal Auto Offset Window” on page 503 for more information
about this window.

Displays the Detectors window. Use this window to view Limit

status and change Limit values.
See “Detectors Window” on page 504 for more information about
this window.

Displays the Digital I/Os window. Use this window to test digital
outputs and view digital input and output status.
See “Digital I/Os Window” on page 508 for more information about
this window.

Displays the Manual Command window. Use this window to

manually command channels.
See “Manual Command Window” on page 510 more information
about this window.

Model 793.00 System Software 501

 Station Controls Panel
Station Manager

Station Controls Panel Toolbar (part 2 of 2)

ITEM DESCRIPTION

Displays the Setpoint and Span window. Use this window to adjust
channels’ setpoints and span.
See “Setpoint and Span Window” on page 513 more information
about this window.

Displays the Remote Setpoint Adjust (RSA) window. Use this

window to make channel and control mode assignments to RSA
knobs.
See “Remote Setpoint Adjust Window” on page 515 more
information about this window.

502 Model 793.00 System Software

 Signal Auto Offset Window

Station Manager
Signal Auto Offset Window
Path Station Controls panel toolbar >

Auto Offset

Use this window to monitor station signals and apply a software-based

offset to zero signals input by conditioners.

Signal Auto Offset Window

ITEM DESCRIPTION
Signal List Select to display lists of signals. The Channel Option window’s Signal
List tab, described on page 432, defines the content of each list.
Signal Value Displays each signal’s current value.
Auto Offset Performs auto offset for all signals currently displayed in the window.
Note If a signal has Auto Offset Lock checked on its Offset/Zero tab on the
Station Setup window Inputs panel it will not be auto offset.

Clear Offset Sets the value to zero for all signals currently displayed in the window.

Displays only next to conditioner input signals that can be auto offset.
Click to apply a zeroing offset to the signal.
Note If a signal is the active feedback and the channel is running, the auto
offset icon will be greyed out.

Model 793.00 System Software 503

 Detectors Window
Station Manager

Detectors Window
Path Station Controls panel toolbar > > Detectors window > Limit
Detectors tab or Error Detectors tab

This window summarizes the status and values of Limit Detectors

and Error Detectors. The Limit Detectors and Error Detectors tabs
are similar.

For FlexTest IIm systems, a Hardware Limit Detectors tab displays

the upper and lower limits of each 497 conditioner.

See “About Detectors” on page 223 for more information.

504 Model 793.00 System Software

 Detectors Window

Station Manager
.

Detectors Window (part 1 of 3)

ITEM DESCRIPTION
Limit Detectors tab Displays the values and status for upper and lower limits.
Upper Limit Displays the input signal’s most positive limit. A detector action can
occur if the signal exceeds this limit.
Lower Limit Displays the input signal’s most negative limit. A detector action can
occur if the signal exceeds this limit.
New values can be entered in the display boxes.
Indicator colors show each detector’s status.
Gray—The detector action is set to Disabled.
White—The detector action is set to Indicate.
Green—The detector action is set to Station Power Off, Interlock,
Program Interlock, Program Stop, Program Hold, or a custom
action.
Red—The detector has tripped.
Error Detectors tab Displays the values and status for the error signal’s outer and inner
limits.
Outer Limit Displays the error signal’s outer limit. A detector action can occur if
the signal exceeds this limit.
Inner Limit Displays the error signal’s inner limit. A detector action can occur if
the signal exceeds this limit.
New values can be entered in the display boxes.
Indicator colors show each detector’s status.

Model 793.00 System Software 505

 Detectors Window
Station Manager

Detectors Window (part 2 of 3)

ITEM DESCRIPTION
Upper Action/ Adjusts the test station’s response when a Limit trips.
Lower Action
Actions include:
Disabled—No action occurs. This setting grays out the Limit
indicator.
Indicate—Writes a message to the Message Log. This setting turns
the Limit indicator white.
Station Power Off—Writes a message to the Message Log, clamps
the servovalve, turns off pressure at the hydraulic service manifold
(HSM), and stops any program. This setting turns the Limit indicator
green.
Interlock—Writes a message to the Message Log, turns off pressure
at both the HSM and hydraulic power unit (HPU), and stops any
program command. This setting turns the Limit indicator green.
Program Interlock—Writes a message to the Message Log, stops
any program command, but does not turn off station hydraulic
pressure. This setting turns the Limit indicator green.
Program Stop—Writes a message to the Message Log and stops
any program command. Produces the same action as clicking the
Program Stop button on the Station Controls panel. This setting
turns the Limit indicator green.
Program Hold—Writes a message to the Message Log and places a
hold on any program command. Produces the same action as
clicking the Program Hold button on the Station Controls panel.
This setting turns the Limit indicator green.
Custom Action—Executes a user-defined action created in the
Event-Action Editor window. This setting turns the Limit indicator
green.See “Event-Action Editor Window” on page 448 for more
about using this window.
A tripped limit turns an enabled detector’s Limit indicator red.

506 Model 793.00 System Software

 Detectors Window

Station Manager
Detectors Window (part 3 of 3)
ITEM DESCRIPTION
Hardware Limit Detectors Displays the upper and lower limit values for each 497 conditioner
tab and the status of each limit.
(FlexTest IIm systems only)

Upper Limit Displays the upper limit that the conditioner’s feedback signal
voltage must exceed to trigger a hardware interlock.
Indicator colors show the detector’s status. For more about the
colors, see “Detectors Summary Tabs” on page 373.
New values can be entered in the display boxes.
Lower Limit Displays the lower limit that the conditioner’s feedback signal
voltage must exceed to trigger a hardware interlock.
Indicator colors show the detector’s status. For more about the
colors, see “Detectors Summary Tabs” on page 373.
New values can be entered in the display boxes.

Model 793.00 System Software 507

 Digital I/Os Window
Station Manager

Digital I/Os Window

Inputs Tab
Path Station Controls panel toolbar > > DI/Os window > Inputs tab

This tab displays the status of digital inputs. The indicator lights when
a digital input is high or on. The Digital Inputs Summary tab,
described on page 367, also shows this information.

508 Model 793.00 System Software

 Digital I/Os Window

Station Manager
Outputs Tab
Path Station Controls panel toolbar > > DI/Os window > Outputs tab

On
Off

This tab’s buttons combine status indicators with manual on and off
functions. The Digital Outputs Summary tab, described on page 368,
provides the same functions.

Outputs Tab
ITEM DESCRIPTION
Buttons/Indicators
Click to turn the output off. Red indicates that the output is off.

Click to turn the output on. Green indicates that the output is on.

Model 793.00 System Software 509

 Manual Command Window
Station Manager

Manual Command Window

Path Station Controls panel toolbar >

This window provides manual control of channels.

Manual Command Window (part 1 of 2)

ITEM DESCRIPTION
Channel Selects the control channel.
Click the Channel button to toggle between individual channels and
a Master Command Group. See “About Channel Groups” on page
259 for more information.
Selecting a Master Command Group blanks out the Control Mode
and Active Mode boxes.
Control Mode Selects a control mode.
Check Enable Manual Command to make a selected Control
Mode the Active Mode.
If Enable Manual Command is checked when selecting a Control
Mode, the selected mode immediately becomes the Active Mode.
Active Mode Displays the current control mode.

510 Model 793.00 System Software

 Manual Command Window

Station Manager
Manual Command Window (part 2 of 2)
ITEM DESCRIPTION
Manual Cmd Applies the manual command to the actuator.
Selecting a Master Command Group that has individual channels
at different Manual Cmd values changes this control. It displays the
highest and lowest Manual Cmd values for the Group. It also
displays pointers that indicate the highest and lowest Manual Cmd
values. Pointers lock together once they have been used to move the
Group to a common Manual Cmd value.
Enable Manual Command Enables the manual command. Closing the Manual Command
window disables this command.
Rig Commands (Option)

Park Moves enabled channels to a predefined Park level prior to hydraulic

shutdown.
Ride Moves enabled channels to a predefined Ride level prior to test
startup.

Model 793.00 System Software 511

 Manual Command Window
Station Manager

Using Manual Command Park/Ride

The optional Rig Command Park and Ride buttons on the Manual
Command window allows you to move enabled channels to a
predefined Park or Ride level (e.g., actuator position, torque).

Press Park to move a specified component to a predefined level prior

to hydraulic shutdown. Press Ride to move a specified component to a
predefined level prior to test startup.

Use the Rig Commands tab on the Channel Options window to define
Park and Ride levels. See “Using Rig Command (Park/Ride)” on page
264.

Important Note The Park and Ride buttons are deactivated under the following
conditions:

• The Setpoint is disabled.

• The test program is in a RUN state.

• The segment generator is in use and the control mode needed to

move to a Park or Ride level is not the active mode.

• When using MPT, if the Setpoint control (in the Execution tab of
the MPT Options Editor) is not set to Enable while the test is
locked down. The Park and Ride functions are deactivated
because they work by ramping each channel’s setpoint between
preset levels.

Also, if the Command Stop and Hold Behavior’s (on the same tab)
are not set to taper or ramp to zero, the command will not be
zeroed on a stop or hold.

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Station Manager
Setpoint and Span Window
Path Station Controls panel toolbar >

This window adjusts channels’ setpoints and spans.

See “How to Adjust Setpoint and Span During a Test” on page 257 for
more about using this window’s controls.

Setpoint and Span Window (part 1 of 2)

ITEM DESCRIPTION
Channel Selects the control channel.
Click the Channel button to toggle between individual channels and
a Master Command Group.
Selecting a Master Command Group blanks out the Active Mode
entry.
Active Mode Displays the control mode that is being adjusted.

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Station Manager

Setpoint and Span Window (part 2 of 2)

ITEM DESCRIPTION
Setpoint Adjusts the program’s signal’s mean (setpoint).
When a Master Command Group is selected, this control changes
the setpoints of channels selected in the Channel Options
window’s Master Command tab, described on page 421.
Selecting a Master Command Group that has individual channels
at different Setpoint values changes this control. It displays the
highest and lowest Setpoint values for the Group. It also displays
pointers that indicate the highest and lowest Setpoint values.
Pointers lock together once they have been used to move the Group
to a common Setpoint value.
Span Adjusts the program signal’s span.
When a Master Command Group is selected, this control changes
the spans of channels selected in the Channel Options window’s
Master Span tab, described on page 418.
Selecting a Master Command Group that has individual channels
at different Span values changes this control. It displays the highest
and lowest Span values for the Group. It also displays pointers that
indicate the highest and lowest Span values. Pointers lock together
once they have been used to move the Group to a common Span
value.

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Station Manager
Remote Setpoint Adjust Window
Path Station Controls panel toolbar >

This window assigns channels and control modes to the Remote

Setpoint Adjust (RSA) box’s control knobs. The RSA allows you to
remotely adjust actuators’ setpoints, away from the computer screen.

See “About the Optional Remote Setpoint Adjust” on page 258 for
more about using this window’s controls.

.
Remote Setpoint Adjust Window (part 1 of 2)
ITEM DESCRIPTION
Channel/Group Assigns a control channel to a knob.
Click the Channel button to toggle between individual channels and
a Master Command Group.
When a Master Command Group is selected, the RSA knob
changes the setpoints of channels selected in the Channel Options
window’s Master Command tab, described on page 421.
Selecting a Master Command Group blanks out the Control Mode
and Active Mode boxes.
Control Mode Selects the control mode.

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Station Manager

Remote Setpoint Adjust Window (part 2 of 2)

ITEM DESCRIPTION
Active Mode Displays the current control mode.
Enable using switch “RSA Click to use the RSA Enable switch to turn on and off the RSA box.
Enable” Closing the Remote Setpoint Adjust window disables this control.

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Tuning
About Tuning 518
If You’ve Never Tuned Before 519
When to Tune 520
Control Mode Characteristics 522
How the Tuning Controls Work 524
Creating a Tuning Program 532
Other Considerations 535
Monitoring Waveforms 536
Tuning Your System 540
How to Set Servovalve Polarity 543
How To Warm Up the System Hydraulics 546
How to Tune the Inner Loop of Three-Stage Valves 549
How to Check and Adjust Valve Balance 557
How to Balance Dual Valves 559
How to Check and Adjust Dither Amplitude 564

Tuning
How to Auto-Tune Control Modes 570
Tuning Displacement 577
Tuning Force 584
How to Tune a CLC Control Mode 592
How to Tune a Dual Compensation Control Mode 597
How to Enable a Tuning Filter 601

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About Tuning
When you tune, you are setting the stability and response of the servo
control loop. Proper tuning improves the performance of the test
system.

Time Lag
Error (phase shift)
Proper tuning reduces
error and phase lag.
Program Command
Feedback (higher Proportional gain)
Feedback (lower Proportional gain)

Inaccurate tuning increases the error and phase lag between the
program command and the sensor feedback. Large error reduces
control accuracy and repeatability, and keeps the full program
command from being applied to the specimen.

Compensating for Optimal system operation may require a level of detuning to

specimen changes compensate for specimen changes during a test.

• A highly tuned system provides the greatest level of response, but

this places the system near the point of oscillation or instability.
Tuning

• As a specimen changes characteristics during testing, the response

of the system also changes. This can cause unstable operation.

• You may need to retune the system response when the

characteristics of the specimen change during a test.

• For the greatest control accuracy, use a compensator. For more

information, see “Working with Compensators” on page 194.

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If You’ve Never Tuned Before

If you are unfamiliar with the tuning controls, review the following
guidelines. Before you start tuning you should:

• Define upper and lower limits for the displacement and force
sensor before you start tuning.

• Tune the displacement control mode first since no specimen is

needed.

• Note the value of the tuning control before adjusting it so you can
return it to that value if necessary.

• Make small initial tuning adjustments. If the waveform does not

appear to change, increase the adjustments.

provides a moderate level of tuning for PIDF control modes

automatically. For more information, see “About Auto-Tuning” on page
569.

What if you adjust If you make an inappropriate adjustment, the system will go unstable
something wrong? or shut down. An unstable system produces humming or screeching
sound. A system shutdown displays an error.

• If an adjustment causes the system to go unstable, quickly readjust

the control until the noise stops. If you cannot eliminate the
sound, shut down the system by pressing the Station Stop or

Tuning
Emergency Stop switch.

Important In multi-station configurations, pressing Emergency Stop

will shut down the HPU and all stations in the interlock
chain. Pressing Station Stop on your Remote Station
Controller shuts down the HSM for the specific station
only.

• If an adjustment causes the system to shut down, readjust the

control to the level where the system was last stable. Then reset
the system and continue tuning.

Saving the tuning The tuning values are saved as part of the controller parameter set. The
parameters parameter set can save one set of tuning values for each control mode.

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When to Tune
Tuning is needed whenever any of the following events occurs:

• A gross change in the compliance or size of the test specimen. For

example, you were testing steel and change to rubber.

• The servohydraulic configuration has changed. For example, a

servovalve is replaced or changed to a different capacity.

• The system is sluggish (slow to react or not reaching the desired

peaks). However, this is not always a tuning problem; it could be
insufficient velocity capability such as a low-capacity servovalve.

• If a control channel or sensor is recalibrated.

• The system is unstable (indicated by a humming or screeching

sound).

• When you observe poorly controlled accuracy.

• When you create a new control mode, or, if the sensor for a
control mode is changed.

• The end levels or frequencies are significantly different from those

observed earlier in the test. For example, you notice that the
specimen characteristics change during the test (this could also
mean the specimen is failing).
Tuning

Checklist Use this checklist when you tune a system. You need to determine the
following:

• What type of control mode do you wish to tune?

Read “Control Mode Characteristics” on page 522.

• What controls should you use?

Read “How the Tuning Controls Work” on page 524.

• What kind of a tuning program should you use?

Read “Creating a Tuning Program” on page 532.

• Do you have a dummy specimen?

Read “Other Considerations” on page 535.

• Where do you connect the oscilloscope and what signal do you

monitor? Read “Monitoring Waveforms” on page 536.

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What to do first The following are tasks that should be completed before you tune. It is
not necessary to perform every task each time you tune. The condition
of your system dictates which of the following tasks you must perform.

For example, a new system or a system under complete recalibration

requires all of the following to be completed. If you are performing
periodic or fine-tuning, review the following and determine which
tasks you need to complete.

• Connect an oscilloscope to your system or use the controller

scope. You need to monitor the sensor signal or error signal for
the control mode you intend to tune. Go to “Monitoring
Waveforms” on page 536 for help.

• Balance the servovalve. The electrical valve balance adjustment

compensates for minor mechanical imbalance—it is an
intermediate adjustment. Go to “How to Check and Adjust Valve
Balance” on page 557 and perform the electrical valve balance
adjustment procedure.

• Calibrate each sensor used for a control mode or data acquisition.

Perform the appropriate calibration procedure.

• If your sensor calibration schedule does not require calibration at

this time, perform a shunt calibration check to determine if your
DC sensor/DC conditioner is within tolerance. See “How to
Perform a Shunt Calibration” on page 251.

• If you have a three-stage (Series 256 or 257) servovalve, tune the

inner loop (gain and rate) before tuning the outer loop. The rules

Tuning
for inner loop tuning are similar to those of the outer loop. Go to
“How to Tune the Inner Loop of Three-Stage Valves” on page 549
for help.

Getting started When you set out to tune your system, it is best to run auto-tuning
first. Auto-tuning establishes reasonable tuning levels that will be
adequate for most control modes. See “About Auto-Tuning” on page
569 for more information.

If the results from auto-tuning are not satisfactory, you should create a
tuning function, and then manually tune each control mode.

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Control Mode Characteristics

A control mode uses a program command and sensor feedback to
control the servovalve. The controller uses a group of gain
controls—proportional, integral, derivative, and feed forward gain.
These controls are called PIDF. The PIDF controller can also
incorporate stabilization gain and an adjustable forward loop filter.

d/dt F Gain
Valve
dt I Gain Driver
+ P Gain FL Filter1
Compensated
Command - - -
d/dt D Gain Stab Filter2 S Gain

Active Stabilization
Feedback
Delta P

1 FL Filter on the Tuning Menu

Set filter frequency and select filter type.
2 Stabilization Filter on the Tuning Menu
Set filter frequency and select filter type.

Each control mode has different tuning characteristics. This section

describes the characteristics of the following control modes:
Tuning

• Displacement control

• Force control

• Strain control

Command sources The program command source can come from an internal source (such
as the Function Generator or the MultiPurpose TestWare
application) or from an external device (such as an external profiler or
function generator).

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CLC control mode Channel limited channel (CLC) control modes are used for specimen
installation and removal. Channel limited channels require two
feedback signals. See “How to Tune a CLC Control Mode” on page 592
for a detailed CLC tuning procedure.

Displacement control A length control mode (also called displacement or stroke control)
uses the LVDT sensor in the actuator as the controlling feedback
source.

• The length control mode only needs to be tuned once.

• Does not need a specimen installed for tuning.

• Displacement control uses a square wave when tuning an LVDT

but not when tuning a displacement gage.

• If gain is too low, there may not be any actuator movement.

• If gain is too high, the actuator will move quickly and noisily.

Force control Force control uses a force sensor (also called a load cell) as the
controlling feedback source.

• Tune for each type of specimen or any changes in the force train.

• Force control requires a specimen to be installed.

• Force control uses a ramp waveform for initial tuning. If the

required results cannot be achieved, change to a square
waveform.

Tuning
• If gain is too low, the system may be sluggish or unresponsive
with large static offsets.

Strain control Strain control uses an extensometer or strain gage bonded to the
specimen as the controlling feedback source.

• Tune for each type of specimen or any changes in the force train.
• Strain control requires a specimen to be installed (you may choose
to use a broken specimen).
• Use a ramp waveform for the initial tuning.
• Do not use a square waveform for tuning. A square wave can
cause the extensometer to move or fall off the specimen, which
can cause the system to go unstable.
• If gain is too low, the system may be sluggish or unresponsive
with large static offsets. Or, it may be uncontrollable.

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How the Tuning Controls Work

The controller system software includes five tuning controls. You do
not need to use all of the controls to properly tune your system. In
fact, most testing can be accomplished with just the proportional gain
adjustment. The other adjustments introduce a signal to the command
to compensate for specific situations.

Note Throughout this chapter the terms gain, rate, and reset represent
proportional gain, rate derivative, and reset integration respectively.

The five available tuning controls have the following functions:

• Proportional gain (P Gain) increases system response.

• Integral gain (I Gain) increases system accuracy during static or

low-frequency operation and maintains the mean level at high
frequency operation.

• Derivative gain (D Gain) improves the dynamic stability when

high proportional gain is applied.

• Feed forward gain (F Gain) increases system accuracy during

high-frequency operation.

• Forward loop filter (FL Filter) adjustments establish a frequency

bandwidth for the servoloop command signal.

Changing adjustment It is possible that the amount of adjustment for a control is too coarse
Tuning

ranges or inadequate. Click the adjustment button (such as P Gain) and use
the Range Select window to change the range of the adjustment.
Reducing the range produces smaller steps between values (higher
resolution) while increasing the range produces larger steps between
values.

Example: Suppose the default range for the Proportional Gain

adjustment is 50. Assume you are adjusting the gain and you reach the
maximum adjustment (50). Clicking the P Gain slider label displays the
P Gain range window where you can change the range of the
adjustment. Change the range by typing a new value in the maximum
entry field.

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Proportional Gain Proportional gain (P Gain) increases the effect of the error signal on
(P Gain) the servovalve to improve system response. Proportional gain is used
in all tuning situations.

The following figures show

the tuning command in grey
and the feedback in black

P Gain Too Low Optimum P Gain P Gain Too High

• As P Gain increases, the error decreases and the feedback signal

tracks the command signal more closely.

• Higher P Gain increases the speed of the system response.

• Too high a P Gain can cause the system to become unstable.

Tuning
• Too low a P Gain can cause the system to become sluggish.

Integral Gain Integral gain (I Gain) introduces “an integral of the error signal” that
(I Gain) gradually, over time, boosts the low-frequency response of the
servovalve command.

I Gain increases system response during static or low-frequency

operation and maintains the mean level during high-frequency
operation. It can offset a DC or steady-state error, such as that caused
by valve imbalance.

The following ramp and hold waveforms illustrate different levels of

reset. The I Gain determines how much time it takes to improve the
mean level accuracy.

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Overshoot Hunting
Droop

I Gain Too Low Optimum I Gain I Gain Too High Excessive I Gain

• I Gain improves the mean level response during dynamic

operations.

• I Gain corrects the feedback droop caused by servovalve spring

characteristics during static and very low-frequency tests.

• I Gain minimizes the amount of time that the system needs to

recover from transitions or transients.
• For best performance, set I Gain as low as possible when using
compensation methods that provide mean correction. These
methods include peak/valley phase (PVP), peak/valley
compensation (PVC), and arbitrary end-level compensation (ALC).

• Higher I Gain settings increase system response.

• Excessive I Gain can cause a slow oscillation or hunting.

• Readings in the Max/Min Meter window can be useful when

adjusting I Gain.
Tuning

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Derivative Gain Derivative gain (D Gain) is used with dynamic test programs. It
(D Gain) introduces a derivative of the feedback signal. This means that it
anticipates the feedback signal’s rate of change and slows the system’s
response at high rates of change.

Overshoot

Ringing

Needs D Gain Optimum D Gain Too Much D Gain Excessive D Gain

• D Gain reduces ringing.

• D Gain provides stability and reduces noise at higher P Gain

settings.

• D Gain tends to amplify noise from sensors.

• D Gain tends to decrease system response when set too high.

• Too much D Gain can create instability at high frequencies.

• Excessive D Gain may cause a ringing or screeching sound.

• Too little D Gain can make a rumbling sound. The correct amount
of D Gain results in the system running quietly.
• Series 256 and 257 Servovalves may require D Gain adjustment on
both the inner and outer control loops.

Tuning

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Feed Forward Gain Feed forward (F Gain) introduces a derivative of the command signal.
(F Gain) It anticipates how large a valve opening is needed to reach the
required response and adds that to the valve command—like
compensating for phase lag.

Adjusting F Gain causes the command

signal to start sooner. This causes the Original Command
feedback signal to track the original
command signal more closely.

Command with F Gain Original Feedback

• F Gain does not compensate for normal changes during testing,

such as temperature changes, and servovalve droop.

• F Gain can be used to minimize phase lag.

• F Gain should be used like D Gain. However, F Gain applies to

the test command signal while D Gain applies to the feedback
signal.

• F Gain gain helps the servocontrol loop react quickly to an abrupt

change in the command signal.

• F Gain is needed when testing a soft specimen in force control.

Tuning

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Stabilization Gain Stabilization gain (S Gain) is available only if the Station Builder
(S Gain) application defined stabilization for the station configuration. Most
systems do not need stabilization gain.

S Gain allows a second signal to be integrated into the composite

command signal as a stabilizing factor. The S Gain enhances stability
for systems that move large masses at high speeds. The input to the
gain is usually a dynamic input signal such as:

• Delta P (differential pressure)

• Acceleration

Delta P stabilization Delta P stabilization uses a differential pressure sensor to measure the
difference in pressure at each end of the actuator. It compensates for
hydraulic compliance when compressed hydraulic fluid acts like a
spring. Delta P improves displacement control of heavy mass loaded
systems.

Delta P is typically used on systems with large hydraulic fluid flow

rates. This adjustment is usually needed when the natural frequency of
the actuator is less than the 90° phase lag frequency of the servovalve.
The servovalve 90° phase lag frequency can be found in the servovalve
product literature. The natural frequency can be approximated with
the following formula.

CA-
Actuator Frequency = ---------
WV

Tuning
Where:
C = constant for SI (1060) or U.S. Customary (2500) units
A = actuator piston area in cm2 or in2
W = any directly coupled mass including the actuator piston mass in kg or lbs
V = fluid volume contained inside the actuator and manifold in cm3 or in3

• If adding Delta P decreases the system’s response, change the

polarity of the signal. If changing polarity does not improve
system response, change the stabilization filter setting. See “How
to Enable a Tuning Filter” on page 601.

• When using Delta P, check all amplitudes for overshoot. No

overshoot is preferable. Do not allow more than 10% overshoot at
any amplitude of a square-wave response.

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• Delta P will not compensate for additional compliance from

swivels, linkages, and test tables. Use a mass accelerometer signal
from an accelerometer for this type of stabilization.

Acceleration Test systems with specimens affected by acceleration resonances can

stabilization use a mass accelerometer signal for stabilization. Acceleration
stabilization dampens the resonances affecting the specimen. (Do not
confuse acceleration stabilization with acceleration compensation,
which corrects the signal from a moving load cell.)

Typical systems that benefit from acceleration stabilization include:

• Load units that operate at high frequencies with massive grips.

• Test systems that employ swivels, linkages, and test tables.

Sensor feedback is provided by an accelerometer attached to or near

the specimen. The controller converts this feedback into a stabilization
signal that is combined with the composite command signal
(post-PIDF correction). The “stabilized” command signal is then sent to
the valve driver.
Tuning

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Forward Loop Filter Forward loop filter (FL Filter) adjustments compensate for noise in the
(FL Filter) servoloop, which usually comes from sensor feedback. FL Filter
adjustments establish a frequency bandwidth for the servoloop
command signal.

Needs FL Filter D Gain Amplifies Noise FL Filter Removes Most Noise

• By default, the FL Filter is set to one-half the system rate, typically

512 Hz for FTIIm/CTC and either 2048 or 3072 Hz for TSIIs.

• The minimum FL Filter setting is 0.01.

• Ensure the FL Filter is set higher than any frequency in the test
program.

• Systems with moving load cells or heavy grips can produce a

noisy force signal.

• If you observe a noisy sensor feedback signal, reduce the FL

Filter setting to about 100, provided your test does not reach 100
Hz. If additional adjustment is needed, reduce the setting in five to
ten Hz increments.

Stabilization Filter Some systems with a higher actuator frequency may benefit from

Tuning
changing the filter setting for the stabilization signal.

See “How to Enable a Tuning Filter” on page 601 for a detailed

procedure for changing the stabilization filter setting.

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Creating a Tuning Program

The purpose of a tuning program is to produce a command that
reflects the most demanding system response expected from a test.

Note The Function Generator is very useful for quickly setting up a

tuning program. If you use the same tuning program on a regular
basis you may wish to create and save your tuning procedure using
Basic TestWare™ or by using the optional MultiPurpose TestWare™
application.

Initial tuning is best done with a waveform that has abrupt changes.
This excites the system at frequencies likely to be unstable with
excessive gain. Square and ramp waveforms are preferred. Final tuning
can be done with the actual program command for the test.

Note Always monitor the sensor feedback or error signal to evaluate the
control accuracy. See “Monitoring Waveforms” on page 536.

A typical tuning program is a low-amplitude (5% to 10% of full-scale),

low-frequency (1 Hz to 2 Hz) square waveform.

This section describes how the amplitude, frequency, and waveform

type of a tuning program can be selected to reflect the capabilities of
the testing system or the testing requirements.

Auto-tuning Auto-tuning provides a moderate level of tuning for PIDF control

modes.
Tuning

Auto-tuning exercises the actuator (with a sweep function) while

monitoring the feedback of the control mode being tuned. The
response of the control mode is determined and the appropriate tuning
parameters are calculated.

For more information, refer to “About Auto-Tuning” on page 569.

Command waveforms A tuning program produces a cyclic program command to exercise the
system while you make the initial tuning adjustments. A square wave is
best because it demands the maximum response of the servo hydraulic
system. The square wave tuning program may not be suitable for all
systems. The following describe the different waveform characteristics:

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Square/Tapered Square A square waveform requires the servovalve to open rapidly to a large
opening. It is the most demanding waveform because it requires the
maximum response from the servoloop system. It also places a large
acceleration on the test system and specimen.

Tapered square waves taper from 0% to 100% amplitude at the

beginning of execution, and from 100% to 0% at the end of execution.

• A square waveform is most useful for tuning displacement.

• A square waveform has an infinite velocity command.

• Do not use a square waveform when tuning a control mode that

uses an extensometer. The large accelerations can cause the
extensometer to move or fall off the specimen, which can cause
the system to go unstable.

• Monitor the feedback or error signal to evaluate the system

stability.

Ramp/Tapered Ramp A ramp waveform (also called a triangle waveform) requires the
actuator to move at a constant rate. This requires the servovalve to
move quickly between two discrete openings. Cycling a ramp
waveform produces a triangle waveform.

Tapered ramp waves taper from 0% to 100% amplitude at the

beginning of execution, and from 100% to 0% at the end of execution.

• A ramp waveform is useful for all levels of tuning.

Tuning
• Use a ramp waveform if a square waveform creates excessive
velocities or acceleration for the type of specimen being tested.

• Monitor the feedback or error signal to evaluate the system

stability.

Sine/Tapered Sine A sine waveform (also called sinusoidal or haversine) requires the
servovalve to move at a variety of rates.

Tapered sine waves taper from 0% to 100% amplitude at the beginning

of execution, and from 100% to 0% at the end of execution.

• Monitor the feedback or error signal to evaluate the system

stability.

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Random function When tuning AIC compensator configurations, it is necessary to

generator generate random functions to properly simulate typical test conditions.

Random functions employ a pre-emphasis filter to make the

convergence rate constant over all frequencies. The random function
options include:

• Random - 1/F2
• Random - 1/F
• Random - Flat (none)
• Random - F

• Random - F2
Frequency A low-frequency waveform is adequate for most testing. Tests at higher
frequencies cause a frequency shift that cannot be completely
corrected with the PIDF adjustments.

• Do your initial tuning at a low frequency, and then fine tune at the
highest frequency in your test program. Common values are
1–2 Hz.

• Servo adjustments that do not improve performance at high

frequencies generally indicate that the servovalve is running at
100% capacity or the HPU is running at 100% capacity.

This characteristic can easily be seen when tuning with a sine

waveform. The feedback waveform appears to be more like a ramp
Tuning

waveform when running at 100% capacity.

Amplitude A system tuned at a low amplitude may become unstable at high

amplitudes. Tuning should be accomplished under conditions similar
to the anticipated usage.

• Use a moderate amplitude (5% to 10% full scale) for initial tuning.

• Be sure the maximum velocity of the tuning command is 10% to

50% of the maximum velocity of the system.

• Increase the amplitude for fine tuning.

• You may find it helpful to check tuning over a variety of

amplitudes by creating a test that cycles once at each of the target
amplitudes. If you have the optional MultiPurpose TestWare™
application, run the test to acquire timed data so you can evaluate
the results for each amplitude.

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Other Considerations

Servovalves Most of the servovalve adjustments are performed during the system
installation and do not require periodic adjustment. There are two
types of servovalves:

• Three-stage servovalves, such as the MTS Series 256 and 257

Servovalves, have an inner loop control system which must be
tuned before the outer loop can be tuned.

• Two-stage servovalves, such as the MTS Series 252 Servovalves,

do not have inner loop tuning requirements.

After initial system tuning and before final tuning, the valve balance
should be checked and adjusted if necessary.

Using specimens Specimens can be very expensive. A dummy specimen is an

inexpensive material that has similar characteristics to the specimen
selected for testing. The most important specimen characteristic is its
spring rate.

The advantage of a dummy specimen is that it can simulate how your

testing system reacts to real specimen. You can establish a more
precise level of tuning with a dummy specimen.

Tuning without dummy If you do not have a dummy specimen or if a dummy specimen is not
specimens practical, review the following recommendations if you must use a real
specimen:

Tuning
• Start your PIDF controls at minimum settings.

• Do not use a square waveform for a massive specimen or a

specimen prone to vibrations.

• Adjust rate to minimize any oscillation, overshoot, or ringing in

the waveform.

• Be very conservative by beginning with a ramp waveform to

establish initial control. Then use a waveform that resembles the
test waveform to provide a precise level of control.

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Tuning without a A specimen is required to tune force and strain control modes. Initial
specimen force tuning may be accomplished with the actuator up against the
force sensor. The actuator acts as a specimen reacting against the force
sensor.

1. If you are using a load frame, adjust the load unit crosshead so the
actuator can reach the force sensor.

2. Carefully adjust the actuator using a tuned length control mode so

it contacts the force sensor.

3. You can now switch to force control and proceed with initial
tuning.

Monitoring Waveforms
When you tune the servoloop you need to monitor the results of your
adjustments. There are two ways to monitor a waveform during tuning.

• An oscilloscope is preferred.

• The controller scope is adequate if you do not have an

oscilloscope.
Note Set up your scope to monitor the area of the waveform that shows
characteristics useful for tuning. You can monitor the sensor
feedback or the error signal of the control mode.

What to monitor The accuracy of the waveform represents how well it reaches the
Tuning

amplitude of the command or how repeatable the end levels are. The
peaks and valleys of triangle and sine waveforms should be consistent.
Use the area of the square wave after the ringing settles to monitor the
end levels.

These are the areas of

interest on these
You do not need to monitor waveforms
the entire waveform.
Instead, zoom in on the
area of interest.

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If the amplitude of the feedback cannot be achieved without going

unstable, and the end levels are repeatable, simply increase the
command to achieve the desired end levels.

Monitoring the The error signal shows similar characteristics as a feedback signal. The
error signal error signal represents the difference between the command and
sensor feedback. The following diagrams show the error signal
characteristics for each type of waveform.

A square waveform is best suited to view the overshoot and ringing

characteristics that occur when tuning a system. Review the following
waveforms to determine the kind of characteristics that can be found
in an error signal.

Tuning

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The error signal from a square Command

wave should show the Feedback
feedback ringing centered on
the zero reference. Static
Zero Accuracy
A static accuracy difference in Difference
the error signal can be
corrected with reset. Error
Signal

The square wave shape of the Command Feedback

error signal represents the
phase lag of the feedback
signal. Following Error
Zero Difference

Error
Signal

The error signal from a sine Command

Tuning

Feedback
should be a small amplitude
Actuator
sine waveform that looks like a Friction
rounded square waveform.
Zero

Error
Signal

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Using the If you do not have an oscilloscope, use the controller scope feature for
controller scope tuning control modes. Review the following:

• On the Display menu to select Scope.

• Select a continuous sweep.

• Enter the minimum and maximum ranges on the Y axis to zoom

into the area of interest.

For more information on the controller scope, see “About the Scope”
on page 159

Using an oscilloscope An oscilloscope has a higher resolution and is faster than the software
controller scope. Review the following:

• You must have a Readout channel defined in the Station Builder.

• Set up the Readout channel in the Station Manager program to

monitor the sensor signal of the control mode you intend to tune.

• Or, you could monitor the error signal. You can tune using either
signal.

• Connect the oscilloscope to the appropriate BNC connector on the

Analog Out transition module (Ch 1 - Ch 6) located at the rear
panel of the Model 493.10 Chassis.

Tuning

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Tuning Your System

About Tuning
A properly tuned system responds smoothly and accurately to
commands. Before you run tests on your system, you should tune each
control mode that you intend to use.

Setting servovalve All servovalves must have their polarity determined and set
polarity appropriately before you start system tuning. This polarity setting, in
conjunction with the sensor input polarity establishes actuator
movement to a positive or negative command. For more information
see “Setting the Servovalve Polarity” on page 542.

Warm up hydraulics You should run a small program to warm up the system hydraulic fluid
and servovalve before you adjust the valve balance, dither, inner loop,
or outer loop. For more information on warming up system hydraulics,
see “How To Warm Up the System Hydraulics” on page 546.

Inner loop If your system is equipped with a three-stage valve, first tune the inner
servoloop to make sure your three-stage valve spool responds
correctly to your valve commands.

For more information on tuning the inner servoloop, see “How to

Tune the Inner Loop of Three-Stage Valves” on page 549.

Outer loop When you tune your system, you are basically configuring how quickly
Tuning

the outer servoloop responds to changes in the command signal.

For more information on tuning the outer servoloop, see “About

Tuning the Outer Loop” on page 568.

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Additional See “Station Manager Controls and Displays” on page 273 for a
information complete description of this application’s controls and indicators.

For specifics about the controls referenced in this section, see:

• “Station Setup Window/Drive Panel—Two Stage Valves” on page

327.
• “Station Setup Window/Drive Panel—Three Stage Valves” on page
329.
• “Station Setup Window/Tuning Panel Tabs” on page 337.
• “Station Setup Window/Compensators Panel Tabs” on page 343.
• “Scope Window” on page 395.
• “Function Generator Control Panel” on page 485.
• “Auto-Tuning Control Panel” on page 495.
• “Manual Command Window” on page 510.

Tuning

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Setting the Servovalve Polarity

The valve polarity is set during system installation. Normally, you will
not need to change the valve polarity unless you replace a hydraulic
component.

Note The combination of the conditioner polarity and the valve polarity
affect the final output signal. The conditioner polarity should be set
before the valve polarity.

About valve polarity There are two polarity settings, Normal and Inverted.

The procedures in this section assume you are using normal polarity.
This results in a positive command retracting the piston.

Normal Valve Polarity

A positive valve command (+ 10 cm)
retracts the actuator and results in a
positive feedback.

LVDT Feedback = + 10 cm
Tuning

If you do not know your valve polarity, refer to “How to Set

Servovalve Polarity” on page 543 to verify your current valve polarity.

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How to Set Servovalve Polarity

Servovalve polarity determines the direction the servovalve moves the
actuator in response to a positive command. It can be set to normal or
invert.

Typically, a servovalve set to normal polarity extends the actuator in

response to a positive command. Conversely, a servovalve with an
inverted polarity retracts the actuator in response to a positive actuator
command.

Before you can set servovalve polarity, you must determine if the
current servovalve polarity follows the normal convention.

Please note the following:

• The polarity of the servovalve must be checked before sensor

calibration begins and before hydraulic pressure is applied for the
first time.

• The polarity of any servovalve is generally set when the valve is

installed.
Important The combination of the conditioner polarity and the servovalve
polarity affects the final output signal. The conditioner
polarities should be set before the servovalve polarity because
they do not need hydraulics to be turned on. In general, you
will set the conditioner and servovalve polarity the same.

Procedure This procedure allows you to determine servovalve polarity by

Tuning
observing actuator movements while applying a positive Setpoint
command to the actuator.

1. Get things ready.

This step establishes the required conditions for the remaining

steps.

A. You need displacement control mode. If you have not created

this type of a control mode, create it now.

B. Ensure that the actuator can be fully extended without

contacting anything. You may need to remove any
obstructions.

C. On the Station Manager Toolbar, select Tuning in the User

Level access box.

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2. Enter an initial tuning value (first time only).

The actuator cannot move unless an adequate gain tuning value is

set. If you already have a gain setting for the displacement control
mode, skip this step.

A. On the Station Manager Display menu, select Station Setup,

B. Ensure that the correct displacement control channel is

selected in the navigation panel.

C. Click the Channel Tuning icon to open the Tuning panel.

D. In the P Gain box, type 1. No other tuning controls need to

be set.
Note For three-stage servovalves, the initial maximum P Gain setting is
0.8, so enter an initial value 0.5.

3. Select the polarity of the servovalve signal.

A. Ensure that the correct displacement control channel is

selected in the navigation panel.

B. Click the Channel Drive icon to open the Channel Drive

panel, and then click the Valve tab.

C. Set the valve polarity. If you do not know which polarity to

use for your servovalve, click Normal (default).

4. On the Station Controls panel perform the following setup.

Tuning

A. Click the Manual Command button to open the Manual

Command window.

B. In the Channel selection box, select the desired control

channel.

C. In the Control Mode selection box, ensure that displacement

control mode is selected.

D. Click on the Enable Manual Command check box to enable

manual command.

E. On the Station Controls panel, ensure that the Master Span

is set for 100%.

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F. If the Interlock indicator is lit, determine the cause, correct

it, and then click Reset.

G. If it lights again, you will need to determine the cause of the

interlock and correct it before proceeding.

H. In the power selection box, click the Power Low button, and
then Power High for the appropriate hydraulic service
manifold (HSM).

5. Check the movement of the actuator.

Perform this step to verify that the actuator moves as you want.
A. On the Manual Command window, increase the Manual
Cmd adjustment for a positive command.
Note The following conditions assume you want a positive command to
retract the actuator.

Actuator fully retracted B. If the actuator is fully retracted and applying a negative
or extended Manual Cmd does not extend it, zero the command, remove
hydraulic pressure, and change the servovalve polarity. Then
retry this test. If it still does not move, return to Step 2 and
increase the gain setting.

• If the actuator is fully extended and applying a positive

Manual Cmd does not retract it, zero the command,
remove hydraulic pressure, and change the servovalve
polarity. Then retry this test. If it still does not move,
return to Step 2 and increase the gain setting.

Tuning
Actuator not fully • If the actuator does not move at all, return to Step 2 and
retracted or extended increase the gain setting.

• If the actuator retracts, the servovalve polarity is correct.

• If the actuator extends, the servovalve polarity must be

reversed. Check the Polarity setting (on the Valve tab of
the Drive panel) and change it (from Normal to
Inverted or vice versa).

C. Check the movement of the actuator. Adjust the Manual Cmd

slider to extend the actuator, and then adjust the Manual
Cmd slider to retract the actuator.

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6. Disable manual command.

A. On the Station Controls Toolbar, click the Manual

Command button to open the Manual Command window.

B. Click on the Enable Manual Command check box to

disable manual command.

How To Warm Up the Remove any specimen and run the system in displacement control for
System Hydraulics at least 30 minutes using a 80% full-scale length command at about 0.1
Hz.

1. In the Station Manager navigation pane, click the Function

Generator icon to display the Function Generator panel.
Tuning

2. Enter the following settings in the Function Generator panel

CONTROL SETTING
Control Channel The control channel associated with the
valve you are adjusting.
Control Mode Displacement
Adaptive None
Compensator

Target Setpoint 0

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CONTROL SETTING
Amplitude 80% of the full-scale actuator displacement
Frequency 0.1 Hz
Wave Shape Sine

3. In the Station Manager window’s Station Controls panel:

A. Click Reset to clear interlocks.

B. Apply station power.

C. Click Program Run to start the function generator.

4. If necessary, correct P Gain during warm up.

A. On the Station Manager window’s Display menu, select

Station Setup.

B. Click the Channel Tuning icon to open the Tuning panel,

and then click the Adjustments tab.

Tuning

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C. If the actuator does not move very well, increase the P Gain
setting on the Adjustments tab.

D. If you hear a unusual or unexpected sound, decrease the P

Gain setting on the Adjustments tab.

5. After 30 minutes, click Stop on the Station Controls panel

(under Function Generator) to stop the command.

6. Turn off hydraulic pressure.

Tuning

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How to Tune the Inner Loop of Three-Stage Valves

This section applies only to systems using three-stage servovalves such
as the Model 497.15 or 493.15 Servovalve.

Perform inner loop tuning when initially installing a system or

fine-tuning a system that employs 3-stage valve drivers. The inner loop
proportional gain and rate derivative adjustments are the same types of
adjustments as used with the PIDF tuning controls.

Note During initial system installation, inner loop gain and rate
adjustments must be performed before tuning the servo outer loop.
For fine tuning, an initial inner loop gain adjustment may be needed
if the outer loop is sluggish.

The inner control loop is similar to a displacement control mode for

the outer loop. The Model 493.15 Three-Stage Valve Driver module
includes the electronics necessary to support the inner control loop.

The innerloop (proportional) Feedback

gain and rate (derivative) Outer
adjustments are the same Loop
Inner
types of adjustments as the Loop HSM
proportional and derivative gain
adjustments of the outerloop
tuning controls. Control Hydraulic
Power
Signal
Supply
Program

Tuning
Command 493.15 Valve
Driver

Important Always tune the inner loop without the hydraulics applied to
the actuator. Perform the inner loop gain adjustments with
hydraulic pressure removed from the main spool while
maintaining pressure at the pilot stage. This prevents
interaction between the inner and outer loops.

Prerequisites • The hydraulic fluid and the servovalve are at operating

temperature. See “How To Warm Up the System Hydraulics” on
page 546.

• Command compensators are turned off.

• The specimen should be removed.

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Prepare to tune Perform the following procedure to prepare to tune the inner loop:

1. Turn off hydraulic pressure.

2. Disconnect the hydraulic service manifold (HSM) control cable

from the controller.

TestStar™ IIm and FlexTest™ GT controllers—At the back of the

controller chassis, disconnect the cable from connector J28.

TestStar™ IIs controllers—At the back of the controller chassis,

disconnect the cable from connector J20 (proportional HSM’s
only) or J28.

FlexTest™ IIm and FlexTest™ CTC controllers—At the 497.05

Hydraulic Control module’s rear panel, disconnect the cable from
connector J28.

Disconnecting this cable disables pressure to the main spool, but

leaves pressure applied to the pilot stage of the servovalve.

On systems with multiple HSMs, be sure to disconnect the correct

cables.
Note On systems with no HSM, remove the outer loop LVDT cable from
the actuator to disable the outer loop.

3. Apply system hydraulic pressure.

Tuning

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Tune the inner loop 1. Perform the steps listed in “Prepare to tune” on page 550.

2. In the Station Manager window’s toolbar, select an access level

of Tuning.

3. In the Station Manager window’s Display menu, select Station

Setup.

4. In the Station Setup window navigation pane’s Channels, locate

and select the channel you want to tune.

5. In the Station Setup window, click to display the Drive

panel.

6. In the Drive panel, click the Conditioner tab.

7. In the Conditioner tab, set these LVDT conditioner parameters

for the channel’s displacement control mode:

A. Set Excitation to 10V.

B. Set Phase to between 10 and 30 deg.

C. Set Offset to 0 V.

D. Set Gain to 10.

E. Set Polarity to Normal.

Tuning

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8. Configure a meter to monitor the spool position signal. Refer to

“How to Configure a Meter” on page 173.

A. On the Station Manager window’s toolbar, select Create

Meters on the Meters icon pull-down menu.

B. Select Create Meters again to display a second Meters

window.

C. In the Meters window, click the Meter Setup button. Use the
Meter Setup window to define the meter.

D. For Meter Type, select Timed.

E. For Signal Selection, select the desired Channel name and

Spool Position for Signal type.

F. For Display Mode, select Volts.

G. Set a Display Resolution.

9. Produce a Spool Position output signal of -10 V DC with the

spool driven into the end cap.

In the Drive panel Conditioner tab:

A. Reverse the Polarity setting to drive the inner loop spool into
one of the end caps.

B. Adjust Gain until the meter reads approximately -8 V DC.

C. Adjust Phase until the meter displays maximum voltage.

Tuning

The phase adjustment matches the phase of the inner loop

LVDT feedback with the 10 kHz demodulator reference
signal. This adjustment provides a maximum output for the
maximum LVDT spool position offset.
Note This adjustment must be set for the initial calibration, servovalve
replacement, cable replacement, or valve driver replacement. Once
the phase is correctly set, readjustment is not necessary during
routine calibration.

D. Readjust Gain until the meter reads -10 V DC.

E. Return Polarity to its original setting.

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10. In the Drive panel, click the Valve tab.

In the Valve tab, produce a Spool Position output signal of +10 V

DC with the spool driven into the opposite end cap.

A. Reverse the Polarity setting to drive the inner loop spool into
the other end cap.

B. Check the meter. It should read +10 V DC (±0.5 V DC).

If the voltage is correct, proceed to the next step in this

procedure.

If the voltage is off by more than 0.5 V, you may need to

mechanically center the pilot spool. Refer to “Zero the Spool
Position Signal” in your Controller Service manual for a
detailed procedure. Complete this procedure, then recheck
spool position voltages at each endcap before you resume
inner loop tuning.

C. Return Polarity to its original setting.

11. Open a Scope window and set up to monitor the spool position
signal. Refer to “About the Scope” on page 159 for detailed
information about scope window setup

A. In the Station Manager window’s toolbar, click once

to display a single Scope window.

Tuning
B. In the Scope window’s toolbar, click to open the Setup
for Scope window.
12. In the Station Manager window’s navigation pane, click .

13. In the Function Generator panel, set up a tuning program:

A. In Channel, select the channel controlling the servovalve.

B. In Control Mode, select a displacement control mode.

C. In Command Type, select Cyclic.

D. For Target Setpoint, select 0 cm.

E. For Amplitude, select 50% of full scale.

You may have to increase Amplitude while tuning.

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F. For Frequency, select 1 Hz.

G. For Wave Shape, select Square.

H. For Compensator, select None.

14. In the Station Controls panel, click to start the Function

Generator.

15. Display the spool position signal.

If the Spool Position signal is too small to be properly displayed

Tuning

on the Scope window during tuning, increase the Function

Generator panel’s Amplitude.

If the Amplitude setting does not amplify the spool signal as

expected:

A. In Station Setup window’s navigation pane click .

B. In the Inputs panel, click the Adjustment tab.

C. In the Adjustment tab, increase the P Gain.

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16. Tune the inner loop.

For optimal system response, tune the inner loop to be relatively

less responsive and more stable than a typical outer loop.

In the Station Setup window’s Drive panel, click the Inner

Loop tab.

In the Inner Loop tab:

A. For Rate Input Selection, select Spool Position.

B. Increase Inner Loop Gain until you see a little overshoot on

the oscilloscope.

Overshoot

Ringing

C. Slightly increase the Inner Loop Rate to eliminate this

overshoot. When properly tuned, the waveform should be a
square wave with rounded corners, having no overshoot.

Tuning
Too Low Correct Too High

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Inner Loop Signals

To monitor inner loop signals on TestStar™ IIm and FlexTest™ GT
Controllers:

1. Connect a service calibration cable package (MTS part number

100-026-213) to connector J3 Service on the I/O carrier module.

2. Connect a DVM or oscilloscope to the appropriate BNC Output

Channel on the service cable, depending on which slot the valve
driver occupies in the I/O Carrier module.

3. In Station Setup, click the Channel Drive icon to display the

Drive panel, and then click the Conditioner tab.

4. From the Service Port Output, select one of signals described in

the following Service Port Output Signals list.
Note Only the Spool Position signal is available to the digital meters or
software scope.

Service Port Output Signals

SIGNAL DESCRIPTION
Valve Current The final output to the servovalve. The
voltage represents the current output
[10 V (DC) = 50 mA; standard].
Demod Filter Output The analog output of the demodulator
prior to gain.
Tuning

Innerloop Command The input signal to the 3-Stage Valve

Driver (the test program command).
Spool Position The Conditioner Out signal summed with
the Spool Zero signal.
Spool Offset Signal that is summed with spool position
to remove any DC offset. ±10 V represents
±4 V of zero summing.
Preamp Output The raw AC input from the spool LVDT.
Conditioner Out The conditioned feedback signal from the
servovalve LVDT.
Voltage Reference (5V) Internal board reference test only.

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About Valve Balance

The valve balance control electrically compensates for minor electrical
and mechanical imbalances in the servoloop. Valve balancing adjusts
the electrical input to the servovalve so that the feedback and
command signals are equal.

How to Check and Adjust Valve Balance

1. In the Station Manager window’s toolbar, select an access level
of Calibration.

2. Remove any specimen.

3. Apply hydraulic pressure.

WARNING Selecting the Enable Manual Command allows you to manually

position actuators.

A moving actuator can injure anyone in its path.

Always clear the actuator area before selecting Enable Manual Command.

4. In the Station Controls panel’s toolbar, click .

In the Manual Command window:

A. Select the Channel whose valve balance needs checking.

Tuning
B. For the Control Mode, select a displacement control mode.

C. Select Enable Manual Command.

D. Use the Manual Cmd to position the actuator at or near its

midstroke position.

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5. In the Station Manager window’s Display menu, select Station

Setup.

6. In the Station Setup window navigation pane’s Channels, select

the channel whose valve balance needs checking.

7. In the Station Setup window, click .

In the Tuning panel, click the Adjustments tab. In this tab:

A. Write down the current I Gain.

B. Zero the I Gain.

8. Set up a meter to view displacement error.

Tuning

A. Select the Meters icon on the Station Manager tool bar.

B. Select the Meter 1 - Setup button.

C. For Meter Type, select Timed.

D. In Signal Selection, select the channel whose valve balance

needs checking. For Signal, select Displacement Abs.
Error.

9. Zero the displacement error with the Valve Balance control.

A. In the Station Setup window, click .

Three-stage valves: In the Drive panel, click the Valve tab.

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B. While observing Displacement Abs. Error on the Meters

panel, adjust the Valve Balance control until Displacement
Abs. Error is zero.

10. In the Station Setup window, click .

In the Tuning panel, click the Adjustments tab.

In this tab, return I Gain to its original setting.

How to Balance Dual Valves

Use the following procedure if you need to balance dual servovalves.

1. In the Station Manager window’s toolbar, select an access level

of Calibration.

2. Remove any specimen.

3. Determine which servovalve of the dual valve pair you want to

balance first, then mount a blocking plate on the port of the other
servovalve.
Note When installing the blocking plate ensure that its holes are aligned
with the servovalve port holes and a gasket is used.

4. Apply hydraulic pressure.

WARNING Selecting the Enable Manual Command allows you to manually

Tuning
position actuators.

A moving actuator can injure anyone in its path.

Always clear the actuator area before selecting Enable Manual Command.

5. In the Station Controls panel’s toolbar, click .

In the Manual Command window:

A. Select the Channel with the dual valves that need balancing.

B. For the Control Mode, select a displacement control mode.

C. Select Enable Manual Command.

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D. Use the Manual Cmd to position the actuator at or near its

midstroke position.

6. In the Station Manager window’s Display menu, select Station

Setup.

7. In the Station Setup window navigation pane’s Channels, select

the channel with the dual valves that need balancing.

8. In the Station Setup window, click .

In the Tuning panel, click the Adjustments tab. In this tab:

A. Write down the current I Gain.

B. Zero the I Gain.

Tuning

9. Set up a meter to view displacement error.

A. Select the Meters icon on the Station Manager tool bar.

B. Select the Meter 1 - Setup button.

C. For Meter Type, select Timed.

D. In Signal Selection, select the channel whose valve balance

needs checking. For Signal, select Displacement Abs.
Error.

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10. Zero the displacement error with the appropriate valve balance
control.

A. In the Station Setup window, click .

B. While observing Displacement Abs. Error on the Meters

Tuning
panel, adjust the valve balance control for the non-blocked
servovalve (Valve Balance 1 or Valve Balance 2) until
Displacement Abs. Error is zero.

11. Balance the other servovalve of the dual valve pair.

A. Remove the blocking plate from the port of the other

servovalve.

B. Reinstall the servovalve.

C. While observing Displacement Abs. Error on the Meters

panel, adjust the valve balance control for the other
servovalve (Valve Balance 1 or Valve Balance 2) until
Displacement Abs. Error is zero.

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12. In the Station Setup window, click .

In the Tuning panel, click the Adjustments tab.

In this tab, return I Gain to its original setting.

Tuning

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About Dither
Dither is a small, high frequency sine wave applied to a servovalve’s
spool to improve the valve’s response to low amplitude signals by
reducing sticking.

Dither
(exaggerated)

Test
Waveform

The following are signs of an improper dither adjustment:

• Dither amplitude is too low—While running a sinusoidal test on

a properly tuned system, you notice that the waveform distorts at
its maximum and minimum points. This will normally be more
apparent during a test that has either a low frequency or a low
amplitude test waveform.

• Dither amplitude is too high—You hear unusual sounds, such

as hammering, squealing, or pounding coming from the test
system.

Tuning

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How to Check and Adjust Dither Amplitude

There are two methods for checking and adjusting dither. Method 1
uses an oscilloscope. Method 2 uses your hearing.

Method 1 1. In the Station Manager window’s toolbar, select an access level

of Tuning.

2. Remove any specimen.

3. In the Station Manager window’s navigation pane, click .

4. In the Function Generator panel, set up a tuning program.

These are typical Function Generator settings:

A. For Channel, select a channel whose dither needs checking.

B. For Control Mode, select a displacement mode.

C. For Target Setpoint, select 0 mm.

D. For Amplitude, select 5 mm.

E. For Frequency, select 0.001 Hz.

F. For Wave Shape, select Ramp.

G. For Compensator, select None.

Tuning

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5. Set up the Station Manager window’s Scope to display the

channel’s command and feedback signals.

A. In the Station Manager window’s toolbar, click .

B. Set up the Scope window to display the channel’s command

and feedback signals. The following shows a typical setup.

Tuning
WARNING Applying station hydraulic pressure can put actuators in motion.

A moving actuator can injure anyone in its path.

Always clear the actuator area before applying hydraulic pressure.

6. Apply station hydraulic power.

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7. In the Station Manager window’s Station Controls panel, click

to start the displacement command.

8. Use the scope to observe the feedback signal.

If the feedback signal shows a smooth ramp, you do not need to

adjust the dither amplitude.

If the feedback signal shows a jagged ramp—caused by the

actuator sticking before moving—continue on to the next step to
adjust the dither amplitude.

9. In the Station Manager window’s Display menu, select Station

Setup.

10. In the Station Setup window navigation pane’s Channels, locate

and select the channel whose servovalve dither you want to
adjust.

11. In the Station Setup window, click .

Three-stage valves: In the Drive panel, click the Valve tab.

Increase Dither Amplitude until the feedback is smooth.

If you hear an unusual sound coming from the servovalve, the

dither amplitude is set too high.
Tuning

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Method 2 1. In the Station Manager window’s toolbar, select an access level

of Tuning.

2. Remove any specimen.

3. Apply station hydraulic power.

4. In the Station Manager window’s Display menu, select Station

Setup.

5. In the Station Setup window navigation pane’s Channels, locate

and select the channel whose servovalve dither you want to
adjust.

6. In the Station Setup window, click .

Three-stage valves: In the Drive panel, click the Valve tab.

Increase Dither Amplitude until you can hear the dither and
then decrease Dither Amplitude until the noise goes away.

Dither Frequency In addition to Dither Amplitude, TestStar IIm, TestStar IIs, and
Adjustment FlexTest GT controllers have a Dither Frequency control.

For most applications, the dither frequency should never have to be

adjusted. Dither frequency may need to be adjusted if the dither
frequency interacts with the test and sets up resonances.

Tuning

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About Tuning the Outer Loop

Proper outer-loop tuning improves the stability of your servocontrol
loop, ensuring that each command is fully applied to your specimen.

Before you tune the outer loop, always set limit detectors to prevent
equipment and specimen damage. See “About Limit Detectors” on
page 226.

When to tune Tune the system when:

• There is a change in the compliance or size of the test specimen.

• There is a change in the servohydraulic configuration.

• System performance is sluggish.

• A sensor is recalibrated.

• You create a new control mode or change sensors.

• There is system instability, typically indicated by abnormal

humming or squealing sounds.

Getting started It is best to auto-tune your PIDF control modes first. Auto-tuning
establishes adequate tuning levels for most control modes.

If the results from auto-tuning are not satisfactory, you should

manually tune each control mode.
Tuning

See the following sections for more tuning information:

• “About Auto-Tuning” on page 569 provides more information

about automatically tuning PIDF control modes.

• “About Manual Tuning” on page 575 provides more information

about manually tuning PIDF control modes.

• “About Channel Limited Channel (CLC) Control Modes” on page

590 provides more information about tuning CLC control modes.

• “About Dual Compensation Control Modes” on page 594 provides

more information about tuning dual compensation control modes.

• “About Tuning Filters” on page 600 provides more information

about using notch filters to filter out control feedback signal noise.

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About Auto-Tuning
Auto-tuning is available for PIDF control modes only. The Station
Manager application supports Basic and Advanced auto-tuning.

Basic auto-tuning When you run Basic auto-tuning, the auto-tuner disregards your
current PIDF gain settings. It applies the minimum required drive signal
to ramp the feedback to 80% of the auto-tuning limits. It then measures
the relationship between the feedback velocity and the valve opening
signal and then derives the minimum PIDF gains required to track the
command.

The majority of tests will run adequately with the settings calculated
through basic auto tuning, however, advanced auto tuning may be
used to optimize the results obtained through basic auto tuning.

Advanced auto-tuning When you run Advanced auto-tuning, the auto-tuner first does basic
auto-tuning. It then runs a sine sweep to exercise the actuator to 20% of
the auto-tuning limits with frequencies between 0.5 Hz and a user set
maximum of 100 Hz.

Note The advanced auto tuner will reduce the sweep amplitude if it
detects a valve opening that is more than 50% of full scale.

Advanced auto-tuning Selecting an Auto-Tuning Type of Advanced displays Tracking and

controls Sweep Freq controls in the Auto-Tuning applications control panel.

Tracking Tracking specifies how closely the advanced tuner attempts to track
the command. Tracking values should be appropriate for the test to

Tuning
be performed. Too high Tracking values may produce tuning values
that are unstable for some systems and can cause auto-tuning to fail.
The 50% default setting is usually a good starting point. If auto-tuning
fails with this default setting, lower the Tracking value.

Sweep Freq Sweep Freq specifies the upper frequency limit of the sine sweep
used by the Advanced auto-tuner. The 20 Hz default setting is usually
a good starting point.

For Advanced auto-tuning, you should change the sweep frequency

to create a phase shift greater than 90º for 0% tracking (or 135º for
100% tracking) between the command and compensated command.

You can monitor the advanced tuner command and compensated

command on the scope.

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How to Auto-Tune Control Modes

This section covers how to perform basic auto-tuning.

First auto-tune the displacement control mode. Then install a dummy

specimen and auto-tune the force control mode.

Auto-tune the 1. In the Station Manager window’s toolbar, select an access level
displacement control of Tuning.
mode
2. Remove any specimen.

3. Use the Station Setup window’s Limits tab to set and enable the
displacement feedback signal’s limits. Set the limits just outside the
signal’s full-scale range.

See “How to Set Limit Detectors” on page 227 for more about
setting limit detectors.

4. In the Station Manager window, click .

Tuning

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In the Auto-Tuning control panel:

A. For Control Channel, select the channel to be auto-tuned.

B. For Control Mode, select a displacement control mode.

C. For Mode to Tune, select the displacement mode.

D. For Auto-Tuning Type, select Basic or Advanced.

Basic provides an adequate level of tuning for most control

modes.

Advanced provides a higher level of tuning based on

Tracking% values.

E. For Actuator Type, select Normal or Hydrostatic.

For most cases select Normal. If you receive a “Feedback is

not responding to drive signal” message during tuning, select
Hydrostatic. This setting allows more and faster valve
movements, which results in more actuator movement.

F. For Upper Limit and Lower Limit, set the upper and lower
limits for actuator travel during auto-tuning.

Basic auto-tuning exercises within 80% of these limits.

Advanced auto-tuning function exercises within 20% of these

limits. If the limits are exceeded, the auto-tuner will quit and
trip an interlock.

Tuning
G. For Advanced auto-tuning—Set the Tracking% value.

The 50% default setting is appropriate for most systems.

H. For Advanced auto-tuning—Set the Sweep Freq.

The Sweep Freq sets the upper frequency limit of the sine
sweep. The 20 Hz default setting is a good starting point.

WARNING Pressing the Station Controls panel’s Run button will put actuators in
motion.

A moving actuator can injure anyone in its path.

Always clear the actuator area before pressing the button.

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5. Auto-tune the displacement control mode.

Note While auto-tuning is in process you cannot changes channels or
control modes. Also, the active and auto-tuning signal’s tuning
parameters will be disabled.

A. In the Station Controls panel, click to start the

auto-tuning process.

B. Auto-tuning displays the following message:

Click OK to dismiss this message.

6. Accept and save the auto-tuning values.

A. If tuning is successful, auto-tuning displays this message:

Tuning

Click OK to dismiss this message.

The Auto-Tuning panel’s Results shows Current tuning

values and New Values.

B. In the Auto-Tuning panel, click Accept to apply the New

Values.

C. In the Station Manager window’s File menu, select Save

Parameters to save these New Values.

7. Continue on to “Auto-tune the force control mode.”

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Auto-tune the force 1. Install a dummy specimen.

control mode
2. Use the Station Setup window’s Limits tab to set and enable the
force feedback signal’s limits. Set the limits just outside the signal’s
full-scale range.

See “How to Set Limit Detectors” on page 227 for more about
setting limit detectors.

3. In the Auto-Tuning control panel’s Control Mode, select a

displacement control mode.

4. In the Auto-Tuning control panel’s Mode to Tune, select the

force control mode.

WARNING Pressing the Station Controls panel’s Run button will put actuators in
motion.

A moving actuator can injure anyone in its path.

Always clear the actuator area before pressing the button.

5. Auto-tune the force control mode.

Note While auto-tuning is in process you cannot changes channels or
control modes. Also, the active and auto-tuning signal’s tuning
parameters will be disabled.

Tuning
A. In the Station Controls panel, click to start the
auto-tuning process.

B. Auto-tuning will display the following message:

Click Yes if you have tuned the channel’s displacement mode

and installed a specimen.

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C. Auto-tuning displays the following message:

Click OK to dismiss this message.

6. Accept and save the auto-tuning values.

A. If tuning is successful, auto-tuning displays this message:

Click OK to dismiss this message.

The Auto-Tuning panel’s Results show both Current tuning

values and New Values.

B. In the Auto-Tuning panel, click Accept to apply the New

Values.
Tuning

C. In the Station Manager window’s File menu, select Save

Parameters to save the New Values.

How to improve You can attempt to further improve tuning using the following techniques:
auto-tuning results
• Use the auto-tuning settings as a starting point when manually
tuning each control mode.
• If your feedback signal is noisy, use a tuning filter (see “About
Tuning Filters” on page 600).

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About Manual Tuning

PIDF tuning controls The following block diagram shows how the manual tuning controls
interact.

d/dt F Gain
Valve
dt I Gain Driver
+ P Gain FL Filter1
Compensated
Command - - -
d/dt D Gain Stab Filter2 S Gain

Active Stabilization
Feedback
Delta P

1 FL Filter on the Tuning Menu

Set filter frequency and select filter type.
2 Stabilization Filter on the Tuning Menu
Set filter frequency and select filter type.

For more information on tuning controls, see the following:

• “Proportional Gain (P Gain)” on page 525

• “Integral Gain (I Gain)” on page 525

Tuning
• “Derivative Gain (D Gain)” on page 527

• “Feed Forward Gain (F Gain)” on page 528

• “Stabilization Gain (S Gain)” on page 529

• “Forward Loop Filter (FL Filter)” on page 531

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Manual Tuning Guidelines

While it is impossible to provide precise tuning guidelines since tuning
procedures depend on both the specimen type and test system
response, here are some general guidelines:

• Set limits to protect you, your equipment, and your specimen. See
“About Limit Detectors” on page 226 for more information.

• Tune a channel’s displacement control mode first, without a

specimen installed.

• Tune a channel’s force control mode second, with a dummy

specimen installed.

• If possible, re-tune the force and displacement control modes with

a dummy specimen installed.

• Make small changes to tuning values and monitor the results in

the Scope and Meters windows.
Tuning

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Tuning Displacement
A displacement control mode uses the feedback signal from an LVDT
(linear variable differential transformer). You do not need a specimen
to tune a displacement control mode.

When to tune A displacement control mode usually only needs to be tuned once.

However, you may want to retune a displacement control mode if:

• The fixtures attached to the actuator have changed (such as grips).

The main tuning factor is a change in the mass attached to the
actuator.

• Any time hydraulic system potential has changed, such as after

servovalve, hose, or pump replacement.

• You want to fine tune the control mode.

• The LVDT ranges are changed.

• You deem it necessary as a result of scheduled system calibration

or you feel system response should be improved or reduced.

Prerequisites Be sure the following items are completed before you begin tuning the
displacement control mode:

• Hydraulic pressure is off.

• The specimen is not installed.

Tuning
• You have created a station configuration file.

• You have created a station parameter set.

Tuning procedure This basic displacement tuning procedure should work for most
applications—consider it a guideline. You should be familiar with the
background information presented in this chapter so you can modify
the following procedure for your specific system.

1. Define the displacement command.

This step defines the tuning command using the function

generator.

A. Click on Station Manager.

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B. Select the Channel that uses the displacement signal you

want to tune.

C. On the Control Mode selection list, select a Displacement

control mode.

D. Set the Target Setpoint to zero.

Tuning

E. Set the Amplitude to about 10% of full scale.

F. Set the Frequency to 1 Hz.

G. Under Wave Shape, select Square.

2. Set up the Scope.

Note You can use an oscilloscope instead of the software scope if you
want. To do that you must define a Readout channel to connect the
oscilloscope.

A. On the Display menu select Scope.

B. Select the displacement feedback signal for Channel A.

C. Set the Trace Time to 5 seconds.

D. Ensure Auto-Scale is on (the default position is ON).

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Note To improve your view of the waveform, click the Rescale button to
maximize the waveform on the display.

WARNING Do not place any part of your body in the path of a moving actuator.

A crush zone exists between the actuator and any equipment in the
path of its movement. Immediate and unexpected actuator response is
possible when you apply hydraulic pressure to your system.
Stay clear of the actuators when applying hydraulic pressure.

3. Turn on hydraulic pressure.

A. In the power selection box, click (Low) and then

(High) for the HPU. If an HPU is not listed, start the HPU at
the pump.
Note The HPU can be configured for “first on”. If this is the case, start the
appropriate HSM.

B. If an HSM is present, click (Low) and then (High)

for the appropriate HSM.

4. On the Station Manager Display menu, select Station Setup.

5. In the Station Setup window navigation pane, locate and select

the channel associated with the displacement sensor signal you
are tuning.

Tuning
6. In the Station Controls panel toolbar, click to display the
Manual Command window.

In the Manual Command window:

A. Select the appropriate Channel associated with the

displacement sensor signal you are tuning.

B. For the Control Mode, select displacement associated with

the displacement sensor signal you are tuning.

C. Click Enable Manual Command.

7. Install a dummy specimen.

Adjust the Manual Command window slider to position the

actuator during specimen installation.

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8. On the Station Controls panel, ensure the Master Span is set for
100%.

9. If the Interlock indicator is lit, click Reset. If the indicator lights

again, you must determine the cause and correct it before
proceeding.

10. Set up the Tuning panel.

A. In the Station Setup window navigation pane, select the

channel that uses the displacement signal you intend to tune.

B. Click to display the Tuning panel.

C. In the Tuning panel, click the Adjustments tab.

D. Select the Show References check box.

Notice the Reference column on the right side of the

window. This column shows the current set of tuning
parameters. Use the buttons to update reference settings with
new values or replace the current values with the last set that
worked properly.
Note The Reference settings are saved with the parameter set.

11. Adjust the P and D tuning controls.

For most systems, you can adjust the controls as described below.
Not all of the adjustments are used. You should be familiar with
Tuning

“About Manual Tuning” on page 575 to use all of the controls.

A. Click on the Station Controls panel to start the

function generator.

B. On the Scope toolbar, select Continuous Sweep.

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Overshoot
C. On the Adjustments tab, increase the P Gain adjustment
until you see a little overshoot and a little ringing.

D. Increase the D Gain adjustment to reduce the overshoot and

ringing.

Ringing E. Repeat C and D until you achieve a optimum waveform.

High

The middle waveform is a

optimum waveform. In
some cases the optimum
Rate (D)
waveform will have no
overshoot or ringing, and
the waveform will look more
like a square waveform with
rounded corners.

Low Gain (P) High

Unstable sounds For actual testing, if your system goes unstable it will sound
unstable—that is, it will emit an annoying high-pitched sound that
is quite different from the usual tuning sound (“ka-chunk,

Tuning
ka-chunk”). If your system begins to go unstable, quickly readjust
the control that caused the instability or click the < button on the
Adjustments tab to return the control to its previous setting.

Rule-of-thumb Adjust the P Gain and D Gain controls as high as possible without
going unstable.

12. Adjust the I Gain tuning control.

To adjust reset (I Gain) you may want to set up a peak/valley

software meter, or you could monitor the error waveform with the
oscilloscope.

Peak/valley Monitor the peaks and valleys of the sensor signal. The peaks and
meter valleys should be balanced. Before adjusting reset (I Gain), be
sure the feedback signal is repeatable (that is, the same peaks and
valleys are achieved).

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For example, assume the test command is centered on zero and

the meter displays +3 mm and -5 mm. You want to adjust the reset
(I Gain) control to achieve ±4 mm.

If the command is not centered on zero, monitor the difference

between peaks and valleys of the sensor feedback to the upper
and lower levels of the test command. Any difference should be
the same.

Square wave Monitor the amplitude of the settled portion of the error signal.
error signal The settled portion of the error signal should be the same level for
both segments.

Adjust I

Ideal Waveform

Triangle wave Monitor the amplitude of the settled portion of the error signal.
error signal The settled portion of the error signal should be balanced.

Balance difference
Zero
around zero

Upset recovery method

Tuning

This is the best method for adjusting the reset integration gain.
You need to monitor the error signal (use the scope or meter).
Then you need to disrupt the system by changing the
command—simply adjust the Manual Cmd control on the
Manual Command window to a different value. The error should
return to zero within 5–10 seconds. If not, increase the reset (I
Gain) setting and repeat the procedure until the error zeros itself
within a reasonable time period.

13. Save your tuning settings.

It is important that you save your parameter set as you complete

the various parts that make up a parameter set. Throughout this
manual you will be performing discrete procedures while building
a single parameter set.

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On the Station Manger File menu, select Save Parameters As.

• If this is the first time you are working with the Station
Manager program and are optimizing the initial set of
station parameters for a station configuration, save the
tuning parameters under the name station1_params.

• If you have already established your default parameter

set for the current station and you are creating a new
parameter set for a specific test or a different station,
save the parameters with a different name (do not use
station1_params).

• Different tests and/or specimens may require different

parameter sets.

Tuning

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Tuning Force
To complete this task, you will make sure the force tuning values
established in your station parameter set are appropriate for the test
you are about to run. To do this, you will:

• Create and apply a simple tuning program.

• Evaluate the current force tuning values by comparing command

and feedback signals.

The displacement tuning values established in the station parameter set

are unlikely to require adjustment. Optimal force tuning values,
however, are a function of your specimen’s compliance, which may
change over time, or from test-to-test. You should also tune force
whenever you make any change to the force train (such as changing
fixtures).

Prerequisites Be sure the following items are done before you begin tuning the force
control mode:

• Hydraulic pressure is off.

• The specimen is not installed.

• You have created a station configuration file.

• You have created a station parameter set.

Tuning procedure The following is a step-by-step tuning procedure for a force control
Tuning

mode. It is a basic procedure that should work for most applications.

However, you should consider it a guideline. The background
information presented in this chapter should help you modify the
following procedure for your specific system.

1. Define the force command.

This step defines the tuning command using the Function

Generator.

A. Click on Station Manager.

B. Select the Channel that uses the force signal you want to
tune.

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C. On the Control Mode selection list, select the force control

mode associated with the force sensor signal you are tuning.

D. Set the Target Setpoint to zero.

E. Set the Amplitude to about 10% of full scale.

F. Set the Frequency to 1 Hz.

Tuning
G. Under Wave Shape, select Ramp.

2. Set up the Scope.

Note You can use an oscilloscope instead of the software scope if you
want. To do that you must define a Readout channel to connect the
oscilloscope.

A. On the Display menu, select Scope.

B. Select the Force Abs. Error signal for Channel A.

C. Set the Trace Time to 2 seconds.

D. Ensure Auto Scaling is on (the default position is ON).

Note To improve your view of the waveform, click the Rescale button to
maximize the waveform on the display.

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WARNING Do not place any part of your body in the path of a moving actuator.

A crush zone exists between the actuator and any equipment in the
path of its movement. Immediate and unexpected actuator response is
possible when you apply hydraulic pressure to your system.
Stay clear of the actuators when applying hydraulic pressure.

3. Turn on hydraulic pressure.

A. In the power selection box, click (Low) and then

(High) for the HPU. If an HPU is not listed, start the HPU at
the pump.
Note The HPU can be configured for “first on”. If this is the case, start the
appropriate HSM.

B. If an HSM is present, click (Low) and then (High)

for the appropriate HSM.

4. On the Station Manager Display menu, select Station Setup.

5. In the Station Setup window navigation pane, locate and select

the channel associated with the force sensor signal you are tuning.

6. In the Station Controls panel toolbar, click to display the

Manual Command window.
Tuning

In the Manual Command window:

A. Select the appropriate Channel associated with the force

sensor signal you are tuning.

B. For the Control Mode, select displacement.

C. Click Enable Manual Command.

7. Install a dummy specimen.

Adjust the Manual Command window slider to position the

actuator during specimen installation.

8. In the Manual Command window, select force for Control

Mode.

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9. On the Station Controls panel, ensure the Master Span is set for
100%.

10. If the Interlock indicator is lit, click Reset. If the indicator lights
again, you must determine the cause and correct it before
proceeding.

11. Set up the Tuning tab

A. In the Station Setup window navigation pane, select the

channel that uses the force signal you intend to tune.

B. Click to display the Tuning panel.

C. In the Tuning panel, click the Adjustments tab.

D. Select the Show References check box.

Notice the Reference column on the right side of the

window. This column shows the current set of tuning
parameters. Use the buttons to update reference settings with
new values or replace the current values with the last set that
worked properly.
Note The Reference settings are saved with the parameter set.

12. Adjust the P and D tuning controls.

A. Click on the Station Controls panel to start the

Tuning
function generator.

B. On the Scope toolbar, select Continuous Sweep.

C. On the Adjustments tab, increase the P Gain adjustment

until you see a little overshoot and a little ringing.

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Overshoot D. Slowly increase the D Gain adjustment to reduce the

overshoot and ringing. Small adjustments of D can have large
effects on the system.

Ringing E. Repeat C and D until you achieve a optimum waveform.

High

The middle waveform is

the optimum waveform. In Rate (D)
some cases the waveform
will have no overshoot or
ringing.

Low Gain (P) High

Unstable sounds For actual testing, if your system goes unstable it will sound
unstable—that is, it will emit an annoying high-pitched sound that
is quite different from the usual tuning sound (“ka-chunk,
ka-chunk”). If your system begins to go unstable, quickly readjust
the control that caused the instability or click the reset button (<)
on the Adjustments tab.
Tuning

Rule-of-thumb Adjust the P gain and D gain controls as high as possible without
going unstable or causing excessive overshoot or ringing.

13. Adjust the I tuning control.

To adjust reset (I Gain) you may want to set up a peak/valley

meter, or you could monitor the error waveform with the
oscilloscope.

Peak/valley Monitor the peaks and valleys of the sensor signal. The peaks and
meter valleys should be balanced. Before adjusting reset (I Gain), be
sure the feedback signal is repeatable (that is, the same peaks and
valleys are achieved).
If the command is not centered on zero, monitor the difference
between peaks and valleys of the sensor feedback to the upper
and lower levels of the test command. Any difference should be
the same.

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Square wave Monitor the amplitude of the settled portion of the error signal.
error signal The settled portion of the error signal should be at the same level.

Adjust I-Gain

Ideal Waveform

Ramp error signal Monitor the amplitude of the settled portion of the error signal.
The settled portion of the error signal should be balanced.

Balance difference
Zero
around zero

Upset recovery method This is the best method for adjusting the reset integration gain.
You need to monitor the error signal (use the scope or meter).
Then you need to disrupt the system by changing the command.
Simply adjust the manual command control to a different value.
The DC error should return to zero within 5–10 seconds. If not,
increase the reset (I Gain) setting and repeat the procedure until
the DC error zeros itself within a reasonable time period.

Tuning

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About Channel Limited Channel (CLC) Control Modes

Use a channel limited channels (CLC) control mode for specimen
installation and removal.

Before CLC control modes can be tuned, they must first be defined in
the Station Builder application. See “Creating Control Modes” on page
60 for more information.

A CLC control mode requires an active and a limiting feedback signal:

• The active feedback signal controls the actuator’s movement. It is

normally the channel’s displacement feedback signal.

• The limiting feedback signal limits the actuator’s force. It is

normally the channel’s force feedback signal.

When CLC is used as the control mode, the controller will not allow
the actuator to exceed limits set for either the active or limiting
feedback signals:

• Interlocks can trip if the actuator’s active (displacement) feedback

signal exceeds limits set for it in the Station Setup window’s
Limits tab.

• The actuator’s limiting (force) feedback signal cannot exceed

limits set for it in the Station Setup window’s Adjustment tab.
Tuning

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Upper Upper Limit If force feedback ≥ upper limit

+ And displacement error is positive
Limit − Error Then use upper limit error

Force Limit P Gain 10.0

Feedback

If force feedback ≤ lower limit

Lower − Lower Limit
+ And displacement error is negative
Limit Error Then use lower limit error

Manual Displacement
+ Otherwise use displacement error
Command − Error

Displacement Active P Gain 10.0

Servovalve
Feedback
Command
Proportional Gain

The CLC control mode uses one of three error signals. The Limiting P Gain
adjustment acts as a conversion factor to scale the limit feedback to similar
units as the active P feedback.

Tuning

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How to Tune a CLC Control Mode

Tune the control modes that will supply the active and limiting
feedback signals.

1. In the Station Manager window’s toolbar, select an access level

of Tuning.

2. Display the Adjustments tab for the CLC control mode to be

tuned.

A. In the Station Manager window’s Display menu, select

Station Setup.

B. In the Station Setup window navigation pane’s Channels,

locate and select the CLC control mode you are tuning.

C. In the Station Setup window, click .

D. In the Tuning panel, click the Adjustments tab.

Tuning

3. In the Adjustment tab, set the gain for the active and limiting
feedback signals.

A. For Active P Gain, enter the value used for the displacement
control mode’s P Gain.

B. For Limiting P Gain, enter the value used for the force
control mode’s P Gain.

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4. Select the CLC control mode to test system response.

Adjust the Active P Gain if the actuator’s displacement response is

sluggish.

Adjust the Limiting P Gain if the actuator’s force response is

sluggish.
Note If actuator response to a command is sluggish, increasing Limiting
P Gain from its initial value can improve actuator performance.

5. To save tuning values, in the Station Manager window’s File

menu, select Save Parameters.

Tuning

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About Dual Compensation Control Modes

Before dual compensation modes can be tuned, they must first be
defined in the Station Builder application. For more information, see
“Creating Control Modes” on page 60.

Sometimes force feedback signals may be too noisy or otherwise

unsuitable for use in control modes. For example, accelerometer
feedback signals have only dynamic characteristics, making them
unsuitable for use in a control mode.

Select a dual compensation control mode for a channel when the

feedback for the desired control mode is unsuitable for maintaining
closed-loop control.

A dual compensation mode requires a primary and a secondary feedback

signal:

• The more stable primary feedback signal is used by the PIDF

controller to maintain closed-loop control.

• The less stable secondary feedback signal is used for command

compensation in command programs provided by the Function
Generator and other applications.

Conversion
Command
Gain
(Force)
Disp. Full Scale
Compensator --------------------------------------- PIDF
+
Force Full Scale
–
Tuning

Compensated
Command
(Displacement)

Integrator
– Integrator Primary Feedback to
Gain PIDF (Displacement)

Dual compensation control modes compensate based on a

secondary feedback signal and maintain closed-loop control with a
primary feedback signal.
Secondary Feedback to In this Force/Displacement dual compensation control mode,
Compensator (Force)
programming and compensation use the secondary force feedback
signal. The PIDF controller maintains closed-loop control using the
primary displacement feedback signal.

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 Tuning Your System

Dual compensation Dual Compensation controls display at the bottom of the Station
controls Setup window’s Compensators panel tabs when the a dual
compensation mode is selected in the navigation pane.

The Integrator Gain control becomes available by selecting, in the

Station Builder application, the Edit Dual Compensation Modes
window’s Mean and Amplitude Control. For more information, see
“Creating Control Modes” on page 60.

Tuning
About compensation When reading this section, assume that the Station Builder application
gain settings has defined a Force/Displacement dual compensation control mode
and that:

• The force signal is the less stable secondary feedback signal, used
for command compensation. Command programs produced by
the Function Generator and other applications use this signal’s
dimension.

• The displacement signal is the more stable primary feedback

signal, used by the PIDF controller to maintain closed-loop
control.

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 Tuning Your System

Conversion Gain Conversion Gain applies the gain that converts the force command to
a displacement command for a PIDF or external controller.

The force signal provided by the compensator is multiplied by the

following equation to create the displacement signal used to program
the PIDF or external controller.

Full Scale Displacement

Conversion Gain Value x  ----------------------------------------------------------
Full Scale Force

The Conversion Gain setting depends on the specimen stiffness. See

“Calculating conversion gain.”

Integrator Gain The Integrator Gain improves the static accuracy when the command
is paused or stopped.

I Gain For best performance, set I Gain as low as possible when using
compensation methods that provide mean correction. These methods
include peak/valley phase (PVP), peak/valley compensation (PVC),
and arbitrary end-level compensation (ALC).

Calculating conversion Use this method to calculate the proper Conversion Gain setting.
gain Assume a Force/Displacement dual compensation control mode.

1. Using the Station Manager window’s Function Generator,

excite the specimen in displacement control using a small
amplitude sine wave.
Tuning

2. Configure two Peak/Valley meters to measure force feedback and

displacement feedback signals.

3. Calculate the specimen stiffness (K):

( Force Peak – Force Valley )

K = -----------------------------------------------------------------------------------------------------------
( Displacement Peak – Displacement Valley )

4. Calculate the Conversion Gain value:

1 Full Scale Force
Conversion Gain =  ---- ×  ----------------------------------------------------------
 K  Full Scale Displacement

Note For a more conservative estimate, use 80% of the calculated

Conversion Gain value.

When using asymmetrical Fullscale values enter the difference

between the values.

596 Model 793.00 System Software

 Tuning Your System

How to Tune a Dual Compensation Control Mode

1. Tune the control mode that supplies the primary feedback signal.

2. In the Station Manager window’s toolbar, select an access level

of Tuning.

3. Display the Compensation tab for the dual compensation control

mode being tuned.

A. In the Station Manager window’s Display menu, select

Station Setup.

B. In the Station Setup window’s navigation pane, locate and

select the dual compensation control mode being tuned.

C. In the Station Setup window, click .

D. In the Compensators panel, click the tab for the

compensation method being used.

Tuning

Model 793.00 System Software 597

 Tuning Your System

4. In the selected Compensation tab, set the Conversion Gain and

Integrator Gain.

A. Set Conversion Gain to either:

– The calculated conversion gain value. (See “Calculating

conversion gain” on page 596 for the calculation
formula.)

– A value between 0.8 and 1.0. (The stiffer the specimen,

the smaller the value.)

B. Set Integrator Gain to 0.

5. Install a dummy specimen.

6. Set Limits to protect you, your equipment, and your specimen.

See “About Limit Detectors” on page 226 for more information.

7. Set up a simple test program using the Station Manager

application’s Function Generator.

A. In the Station Manager window, click .

B. In the Function Generator panel, for Control Mode, select

the dual compensation control mode to be tuned.

C. For Command Type, select Cyclic.

D. Create a command with an amplitude and frequency

appropriate for the specimen.
Tuning

E. For Wave Shape, select Sine.

F. Select a Compensator method.

8. Configure the Scope window to monitor command and secondary

(force) feedback signals.

A. In the Station Manager window’s toolbar, click .

B. Configure the Scope window to monitor the program

command and force feedback for the dual compensation
mode. See “About the Scope” on page 159 for more
information.

598 Model 793.00 System Software

 Tuning Your System

WARNING Pressing the Station Controls panel’s Run button will put actuators in
motion.

A moving actuator can injure anyone in its path.

Always clear the actuator area before pressing the button.

9. Start the test program.

A. Apply station hydraulic power.

B. In the Station Manager window’s Station Controls panel,

click to start the tuning program.

10. Adjust the Conversion Gain and Integrator Gain.

In the Station Setup window’s selected Compensators tab:

A. For Adaptation State, select Hold and Reset or Reset All.

B. Gradually increase the Conversion Gain until the scope

shows that the secondary (force) feedback is approximately
80% of its commanded value.

During normal operation, the compensator will increase the

feedback amplitude until it matches the command amplitude.

C. Increase the Integrator Gain if the scope shows that the

Tuning
primary and secondary signals are offset.

11. To save tuning values, in the Station Manager window’s File

menu, select Save Parameters.

Model 793.00 System Software 599

 Tuning Your System

About Tuning Filters

Some systems experience mechanical resonances that effectively limit
the amount of controller gain you can use before the system becomes
unstable.

A filter may be used in the forward path of the controller to reduce the
system response at the resonance frequency. This makes it possible to
increase the controller gain to improve command and feedback
tracking while maintaining system stability.

The Station Manager application has two types of filters:

• Forward loop filters

• Stabilization filters

Forward loop filters are available for all control modes, and include:

• A Low-Pass filter that attenuates signals above a specified

frequency.

• A Band-Stop filter that attenuates signals in a specified band

around a specified frequency.

Stabilization filters are available for control modes equipped with

stabilization resources (see “Stabilization” on page 101) and include:

• A 1 Hz High-pass filter that attenuates signals below 1 Hz.

Tuning

• A Band-pass filter that attenuates signals outside of a

user-definable band.

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 Tuning Your System

How to Enable a Tuning Filter

1. In the Station Manager window’s toolbar, select an access level
of Tuning.

2. Display the Filter tab for the control mode being tuned.

A. In the Station Manager window’s Display menu, select

Station Setup.

B. In the Station Setup window’s navigation pane, locate and

select the control mode being filtered.

C. In the Station Setup window, click .

D. In the Tuning panel, click the Filter tab.

3. To select a Forward Loop filter, select and set up the desired

filter type of None, Low-Pass, or Band-Stop.

– For Low-Pass filters, set the Frequency.

– For Band-Stop filters, set the Frequency and Bandwidth.

Tuning

Model 793.00 System Software 601

 Tuning Your System

4. To select a Stabilization filter, select and set up the desired filter

type of 1 Hz High-pass or Band-pass.

– For Band-pass filters, set the frequency band with the

Frequency Limits control.

Note Some systems with a higher actuator frequency may benefit by

selecting the following Frequency Limits: a low cut-off
frequency that is approximately the actuator frequency and a
high cut-off frequency approximately 5-10 times the actuator
frequency.
Tuning

5. To save filter values, in the Station Manager window’s File

menu, select Save Parameters.

602 Model 793.00 System Software

Chapter 4
Basic TestWare
Learning about Basic Application Overview 604
TestWare About Test Files 606

Performing common Getting Started with Basic TestWare 607

tasks Defining the Test Command 608
Configuring Data Acquisition 611

Basic TestWare
Configuring Peak Detectors 619
Configuring Return Home 622
Configuring Test Counters 624
Running Your Test 626
Working with Test Files 628

Window and control Basic TestWare Windows 641

descriptions Basic TestWare Toolbar 644
Open Test Window 645
Save Test/Save Test As Window 646
Test Setup Window 647
Message Logs Window 664

Model 793.00 System Software 603

 Application Overview

Application Overview
The Basic TestWare application allows you to create simple test
programs that do not require complex signal management or mode
switches for station configuration files. This application is included
with Series 793 System Software.

To create more sophisticated test programs use the optional Model

793.10 MultiPurpose TestWare application.

Basic TestWare main window

Basic TestWare

Toolbar

Test command

Test Counters

Peak Detectors Return home

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 Application Overview

With the Basic TestWare window controls, you can:

• Define a basic test command

• Configure data acquisition

• Configure peak detectors

• Configure home control

• Configure test counters.

After you configure your test, you can save it to a Basic TestWare test
file (or .tst file). For more information, see “About Test Files” on page
606.

Basic TestWare

Model 793.00 System Software 605

 About Test Files

About Test Files

You can save each test configuration (including all detector and data
acquisition settings) to a Basic TestWare test file (or .tst file).

Test File Information A test file typically includes the following types of test configuration
information:

• Test command (command type, test channel definition)

• Data acquisition definition (type, signals, buffer size/type)

Basic TestWare

• Data file definition (file name, data header, file format)

Default Location The default location for saved Basic TestWare test files is:

• C:\ftiim\btw (for FlexTest IIm, CTM, and CTC controllers)

• C:\tsiis\btw (for TestStar IIs and AP controllers)

• C:\ftgt\btw (for FlexTest GT)

• C:\tsiim\btw (for TestStar IIm)

For more information on creating your test files, see “Getting Started
with Basic TestWare” on page 607. For information on opening, saving,
previewing, and printing test files, see “Working with Test Files” on
page 628.

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 Getting Started with Basic TestWare

Getting Started with Basic TestWare

How to Start the Basic TestWare Application
In order to start the Basic TestWare application, you must first start the
Station Manager application and open your station configuration file.

Once the configuration file is open, there are two ways to start the
Basic TestWare application.

Method 1 On the Station Manager Applications menu, click Basic TestWare.

Basic TestWare
Method 2 Start the Basic TestWare application from the Station Desktop
Organizer. See “How to Start an Application from the Station Desktop
Organizer” on page 675

How to Create a Basic TestWare Test

Refer to the following sections to create your Basic TestWare test:

• “Defining the Test Command” on page 608

• “Configuring Data Acquisition” on page 611

• “Configuring Peak Detectors” on page 619

• “Configuring Return Home” on page 622

• “Configuring Test Counters” on page 624

• “Working with Test Files” on page 628

Model 793.00 System Software 607

 Defining the Test Command

Defining the Test Command

About Test Commands
The Basic TestWare application can generate both cyclic and
monotonic commands.

Cyclic commands include wave shapes such as sine, square, and ramp.
Monotonic commands start at a level and end at a different level.
Basically, a monotonic command is a ramp command from one level
to another.
Basic TestWare

For information on how to define these commands, see:

• “How to Define a Cyclic Command” on page 609

• “How to Define a Monotonic Command” on page 610

608 Model 793.00 System Software

 Defining the Test Command

How to Define a Cyclic Command

1. On the Basic TestWare toolbar, click to open the Test

Setup window.

Basic TestWare
2. In the Test Setup window, click the Command tab.

3. In the Type list, click Cyclic.

4. In the Channel list, click the desired channel.

5. In the Control Mode list, click the desired control mode.

6. Set the remaining command attributes.

7. Repeat steps 4 through 6 for all other channels.

After the initial command definition is set you can change the setpoint,
amplitude, and frequency controls on the main Basic TestWare panel
while the test is running.

Note The maximum frequency for a cyclic command is 20% of the

system rate. See “About Update Rates” on page 42 for more
information about system rate.

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 Defining the Test Command

How to Define a Monotonic Command

1. On the Basic TestWare toolbar, click to open the Test

Setup window.
Basic TestWare

2. In the Test Setup window, click the Command tab.

3. In the Type list, click Monotonic.

4. Select the End Level Type.

5. In the Channel list, click the desired channel.

6. In the Control Mode list, click the desired control mode.

7. Set the remaining ramp attributes.

8. Repeat steps 5 through 7 for all other channels.

After the initial command definition is set you can change the end level
and test time/rate controls on the Basic TestWare display while the
test is running.

610 Model 793.00 System Software

 Configuring Data Acquisition

Configuring Data Acquisition

About Data Acquisition
With the Basic TestWare data acquisition controls, you can collect the
following types of test data:

• Timed data acquisition—records the output of all selected signals

at a specified time interval.

• Peak/Valley data acquisition—records the output of all selected

signals when the software detects a peak or valley in the master

Basic TestWare
signal that you specify.

• Running Max/Min data acquisition—records the highest peak

and lowest valley for all selected signals during a test.

• Level Crossing data acquisition—records the output of all

selected signals each time the defined master signal changes by a
specified amount.

Data collected during your test is written to a buffer. When the buffer
gets full, the data is saved to your specified data file. For more
information on data files and buffers, see “More About Data Files and
Buffers” on page 612.

For information on configuring data acquisition, see:

• “How to Configure Timed Data Acquisition” on page 614

• “How to Configure Peak/Valley Data Acquisition” on page 616

• “How to Configure Running Max/Min Data Acquisition” on page

617

• “How to Configure Level Crossing Data Acquisition” on page 618

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 Configuring Data Acquisition

More About Data Files and Buffers

When you set up data acquisition, you specify the signals for which
data is acquired and the method of buffering data before it is recorded
in a file.

Buffers Each type of buffer offers different operational characteristics:

• The buffer size specifies the maximum number of data elements

that the buffer will store before data is written to disk. (A data
element includes the data from each selected signal.) You can set
the buffer size between 1 and 16,000 data elements (the default is
2048).
Basic TestWare

• Acquiring and saving data at fast rates can cause the computer to
become sluggish (slow to respond to selections). If the acquisition
rates are too fast, data over-run can occur. If this happens, a
message will be displayed.

Linear buffer A linear buffer records data until it is full, and then
saves the data to disk. The size of the buffer determines
how much data is acquired before it is written to disk.
Data is continuously saved to disk until the test ends or
is stopped. When the test ends, any data in the buffer is
sent to disk. The only limit is the amount of space
available on your hard drive.

Circular buffer A circular buffer records data continuously. When the

buffer is full, new data overwrites the oldest data. This
type of buffering saves data to disk when the test is
stopped, when the test reaches its preset count, or
when the test ends. The circular buffer is useful for
acquiring data just before some crucial event (such as
specimen failure), while data is not required for the
whole test.

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 Configuring Data Acquisition

Data File Header The first line of a data file includes information like the decimal
separator, column separator, time formats, and date formats. The
format of this header line is as follows:

MTS793|progName|sLanguage|version|iDelim|sDecimal|sDate|sTime|iCountry|iDate|iTime|sCode
Where:
progName= MPT or BTW
sLanguage= Natural language (standard three-character abbreviation)
version= Version of this format string
iDelim= Data delimiter: 0 for space (plain), 1 for comma (Lotus), 2 for tab (Excel)
sDecimal= International decimal separator
sDate= International date separator

Basic TestWare
sTime= International time separator
iCountry= International country value
iDate= International date format
iTime= International time format
sCode= Character Set Code: A for ANSI, O for OEM (currently always A)

A typical header looks like this:

MTS793|BTW|ENU|1|0|.|/|:|1|0|0|0|A

Model 793.00 System Software 613

 Configuring Data Acquisition

How to Configure Timed Data Acquisition

1. On the Basic TestWare toolbar, click to open the Test

Setup window.

2. In the Test Setup window, click the Data Acquisition tab.

3. In the Type list, click Timed.

4. Double-click on each signal name that you want to collect data

on. The selected signal name will move to the Signals Included
list. You can also click on the signal name, and then click the >
button.
Basic TestWare

5. Set the timed data acquisition interval and units using Time
Between Points or enter a Sample Rate frequency.

6. Set Buffer Size parameters and select the Buffer Type used.

See “Timed data acquisition” on page 649 for more detailed

information.

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 Configuring Data Acquisition

Data file options To specify data file options for the acquired data:

1. Click the Data File tab.

2. Select the data Destination File. If you select User Specified,

enter a name for the data file in the File Name box.

3. In the Data Header box, type a brief description of your test.

4. Select the Data File Mode and the Data File Format.

Basic TestWare
See “Data File tab” on page 656.

Model 793.00 System Software 615

 Configuring Data Acquisition

How to Configure Peak/Valley Data Acquisition

1. On the Basic TestWare toolbar, click to open the Test

Setup window.

2. In the Test Setup window, click the Data Acquisition tab.

3. In the Type list, click Peak/Valley.

4. Double-click on each signal name that you want to collect data

on. The selected signal name will move to the Signals Included
list. You can also click on the signal name, and then click the >
button.
Basic TestWare

5. In the Master Signal list, click the signal name that will be
monitored for peaks and valleys.

6. Set the Sensitivity and Buffer Size parameters.

Sensitivity specifies how much the signal must increase or

decrease before a peak or valley is recorded. Sensitivity settings
should be used to prevent signal noise from being misinterpreted
as peaks or valleys.

7. Select the Buffer Type used.

To specify data file options for the acquired data see “Data file options”
on page 615.

For more information, see “Peak/Valley data acquisition” on page 651.

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 Configuring Data Acquisition

How to Configure Running Max/Min Data Acquisition

1. On the Basic TestWare toolbar, click to open the Test

Setup window.

2. In the Test Setup window, click the Data Acquisition tab.

3. In the Type list, click Running Max/Min.

4. Double-click on each signal name that you want to collect data

on. The selected signal name will move to the Signals Included
list. You can also click on the signal name, and then click the >
button.

Basic TestWare
5. To specify data file options for the acquired data see “Data file
options” on page 615.

See “Running Max/Min data acquisition” on page 653 for more detailed
information.

Model 793.00 System Software 617

 Configuring Data Acquisition

How to Configure Level Crossing Data Acquisition

1. On the Basic TestWare toolbar, click to open the Test

Setup window.

2. In the Test Setup window, click the Data Acquisition tab.

3. In the Type list, click Level Crossing.

4. Double-click on each signal name that you want to collect data

on. The selected signal name will move to the Signals Included
list. You can also click on the signal name, and then click the >
button.
Basic TestWare

5. Select the Master Signal that will be monitored for level crossing.

6. Set the Level Increment and Buffer Size parameters.

7. Select the Buffer Type used.

To specify data file options for the acquired data “Data file options” on
page 615.

For more information on level crossing data acquisition, see “Level

crossing data acquisition” on page 654.

618 Model 793.00 System Software

 Configuring Peak Detectors

Configuring Peak Detectors

About Peak Detectors
You can use peak detectors to ensure that your feedback signal
reaches the programmed peaks and valleys within a specified
tolerance range. If your feedback falls outside the tolerance range, the
detector will trigger a specific detector action.

When you configure a peak detector, you must specify the reference
values that the detector will use to establish the tolerance range. If you
select the Default reference type, the detector will use the first peak

Basic TestWare
and first valley as its initial reference values. Reference values will
change during a test. If you select the User-specified reference type,
the detector will use the reference values that you enter.

New Peak/Valley Tolerance Band

Peak/Valley Levels Set by
Levels Set by Detector
Detector
Peak
Default Reference
Type Selected

Valley

Detector Trips
Manual Reset

User Specified Enter

Reference Type Peak/Valley
Selected Reference
Values

Detector Trips
Manual Reset

If a peak or valley occurs outside of the specified tolerance range,

Basic TestWare will trigger the detector action. Only the first peak or
valley outside tolerance will be reported. To clear the detector action,
click the Peak Detectors reset button on the main Basic TestWare
window.

For information on detector actions, see “About Detectors” on page

223.

Model 793.00 System Software 619

 Configuring Peak Detectors

Detector Indicator The Basic TestWare main window provides a Peak Detectors
Colors indicator to monitor the detector actions that you have set for a
channel.
The indicator colors are as follows:
Grey indicates that all detectors are set to Disabled.

Green indicates that one or more detectors are enabled and

defined.

White indicates that one or more detectors are set to Indicate.

Red indicates that a detector has been tripped.

Basic TestWare

How to Configure Peak Detectors

1. On the Basic TestWare toolbar, click to open the Test

Setup window.

2. In the Test Setup window, click the Peak Detectors tab. See
“Peak Detectors tab” on page 659.

3. In the Channel and Signal lists, select the channel and signal that
you want to monitor with a peak detector.

4. Under Detector Parameters, specify the detector settings. See

“Peak Detectors tab” on page 659 for a description of detector
parameters.

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 Configuring Peak Detectors

5. Set the Reference Type:

– Default will use the first peak and valley as the reference for
the tolerance range.

– User-specified will use the values you enter as the reference

for the tolerance range.

6. Set the Upper Reference and Lower Reference values.

7. Repeat steps 3 through 6 for additional detectors.

Basic TestWare

Model 793.00 System Software 621

 Configuring Return Home

Configuring Return Home

About Return Home
You can configure the Return Home button (shown below) to make it
easier to return your actuators to a default or starting position. When
the hydraulics are active, clicking the Return Home button returns the
actuator to the defined home position.
Basic TestWare

Return Home

Note The Return Home button is not available while a test is running.
When you click Return Home, the Run indicator on the Basic
TestWare display blinks.

Note If one or more of the channels is saturated when you click Return
Home, a window appears that allows you to override the saturation
detectors. Allowing the override causes the command to step to
110% of full scale and ramp to the defined end level in the defined
time interval.

622 Model 793.00 System Software

 Configuring Return Home

How to Define the Home Position

1. On the Basic TestWare toolbar, click to open the Test

Setup window.

2. In the Test Setup window, click the Home tab. See “Home tab”
on page 658.

Basic TestWare
3. In the Channel list, click the desired channel.

4. In the Control Mode list, click the desired control mode.

5. In the Absolute End Level box, type the desired end level.

6. In the Time box, type the desired home command ramp time.

7. Repeat steps 3 through 6 for other channels.

How to Use the Home Control

When hydraulics are active, click Home on the Basic TestWare main
panel to ramp to the home position.

Model 793.00 System Software 623

 Configuring Test Counters

Configuring Test Counters

About Test Counters
You can use the Test Counters panel to run a test that requires a
preset number of cycles or segments. The Test Counters panel can
also be used to run your test for a limited cycle or segment count to
help you evaluate your test settings before running a longer test.
Basic TestWare

The Test Counters panel on the Basic TestWare window displays the
following controls:

ITEM DESCRIPTION
Preset Specifies the number of cycles (or
segments) your test will run. There is a
checkbox that enables or disables this
counter. The checkbox is greyed out until a
cyclic command type is specified.
Note The counter only works with cyclic
commands. You cannot enter half
cycles or an odd number of segments
in the Preset counter box.

Current Displays the number of cycles (or

segments) that passed since you clicked the
Run button. When this counter reaches the
Preset count, the test stops.
Note Current cycle count is not
automatically reset when you click the
Run button on the Station Controls
panel. Click the Current reset button
to reset the current count.

Total Displays a second counter that can be used

to monitor the total number of cycles or
segments.

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 Configuring Test Counters

Logging counter The following counter actions are written to the message log:
events
• Resetting the Current or Total counters.

In each case, the Total counters, Current counters, and Preset

counter values are logged with a time and date stamp.

How to Configure a Test Counter

1. Select the Enable check box on the Test Counters panel.

1. Select
2. Enter Count

Basic TestWare
3. Reset

2. Type a preset count in the Preset box, and then set the units.
(This is the number of cycles or segments that your test will run.)

3. Click the Reset buttons for both the Current and Total counters.

When the Current counter reaches the Preset count, the test stops.
(At this point you can evaluate your test, perform any required
maintenance, or change your test parameters.) If desired, you can reset
the Current counter and run the test again. The Total counter can be
used to maintain the ongoing count.

Model 793.00 System Software 625

 Running Your Test

Running Your Test

Use the controls in the Station Manager Station Controls panel to
start, stop, and hold your test.

Note Reset the interlocks and apply station power before starting your
test.
Basic TestWare

626 Model 793.00 System Software

 Running Your Test

How to Start a Basic TestWare Test

Click the Program Run button on the Station Controls panel to start
the command and counters, and begin acquiring data.

Program Program Stop

Run
Program Hold

Basic TestWare
Note If a tapered wave shape is selected for “Cyclic” command
generation, the segment generator will soft start the segment
generator as specified in Begin/End Times (Taper Times) on the
Command Options tab on the Channel Options window (Station
Manager). See “Command Options Tab” on page 423.

How to Hold a Basic TestWare Test

Click the Program Hold button on the Station Controls panel to pause
the test command generator and stop data acquisition.

How to Stop a Basic TestWare Test

Click the Program Stop on the Station Controls panel to stop the test
command generator, stop data acquisition, and stop the segment
counters.

Note If a tapered wave shape is selected for “Cyclic” command

generation, the segment generator will soft stop the segment
generator as specified in Begin/End Times (Taper Times) on the
Command Options tab on the Channel Options window (Station
Manager). See “Command Options Tab” on page 423.

Model 793.00 System Software 627

 Working with Test Files

Working with Test Files

Use Basic TestWare test files (or .tst file) to save each test configuration.
A test file typically includes the following types of test configuration
information:

• Test command (command type, test channel definition)

• Data acquisition definition (type, signals, buffer size/type)

• Data file definition (file name, data header, file format)

Basic TestWare Use the buttons on the Basic Testware toolbar to work with test files
Basic TestWare

Toolbar and message logs.

Open Test Print Test Options Editor Help Exit

Save Test Test Setup Message Log

Open Test Print Test Test Setup

New Test Print Preview Command
Printer Setup Home
Save Test
Print to File Data Acquisition
Save Test As Data File
Peak Detectors
Peak Det. Summary
Test Log

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How to Open a Test File

1. On the Open Test button, click Open Test to display the Open
Test window.

2. Select the test file you want, and then click Open to open the file.

Basic TestWare
Select your
test file, and
then click
Open

How to Save a Test File

On the Save Test button, click Save to save your test file. To save the
file with a different name, click Save As.

Name the file, and

then click Save

Note Basic TestWare automatically appends “.tst” to the file name you
enter. If you do not want to include the .tst extension, type a period
(.) at the end of your file name.

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How to Preview a Test

On the Print Test button, click Print Preview for an on-screen view
of the current test configuration. A toolbar facilitates access and display
of test changes.

Note Print Preview allows you to preview the test configuration currently
in memory, but this configuration may not have been saved to a test
file.
Basic TestWare

Items preceded by an asterisk (*) have been modified since the

configuration file was open or after the last save. In addition, you can
choose to highlight these changes by clicking the Enable Change
Highlighting button on the Print Preview toolbar.

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Print Preview Toolbar

Enable/Disable Changed Highlighting

Refresh Print
Previous Change
Next Change

Basic TestWare
Print Preview Toolbar
ITEM DESCRIPTION
Next Change Goes to the next change on the Print Preview window.
Previous Change Goes to the previous change on the Print Preview window.
Refresh Allows you to see current test configuration changes without closing and
reopening the Print Preview window. The current change(s) are
highlighted.
Enable/Disable Allows you to enable or disable highlighting of test configuration
Changed Highlighting changes.
Print Prints the current test configuration.

How to Print a Test

Click the Print icon on the Basic TestWare Print Preview window
toolbar or click Print Test on the Print Test icon on the Basic
TestWare toolbar, to print the current test configuration.

Click Print to File on the Basic TestWare toolbar Print Test button to
save the current test configuration as a separate text file.

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 Working with Test Files

Using the Message Logs Window

About Message Logs Message Logs record test events as they occur, including:

• File events

• Resource mismatches

• Hydraulic and station state changes

• Detector activity

When you save a new station test file, the Basic TestWare application
automatically creates a Message Log file to record events that occur
Basic TestWare

during the current test.

The Basic TestWare application saves the Message Log file in your
Basic TestWare folder. The Basic TestWare application names the
Message Log file, using the station test name with a .log extension.

Closing the Basic TestWare application closes the Basic TestWare

Message Log file. When the test reopens and station activity resumes,
new messages are appended to the old.

Auto-archive message

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Auto-archiving When the Message Logs window accumulates 1000 messages, it

automatically saves these messages to an archive file and then clears
them from the Message Logs window.

Message log file naming The first archived file is named test file name000.log, the second is
named test file name001.log, and so on. This continues until a file is
named test file name499.log, and then it starts again with test file
name000.log

Note The maximum number of archive log files that can be saved for a
particular test is 500.

Once you reach 500 archive log files, additional log files overwrite the

Basic TestWare
oldest log files in order (typically archiving restarts at test file
name000.log).

When a log file is saved (either manually or automatically), a log entry

is made noting the archive file. This entry includes a time/date stamp
and information on where the file was saved. This entry becomes the
first entry in the current log.

CAUTION Too many messages combined with the auto-archive feature can use up
all disk space.

Running out of disk space can stop your test and result in data loss.

If you think your test may generate an excessive number of message log
entries, you should filter the messages written to the Basic TestWare
message log with the Test Log tab in the Test Setup window. For
information on filtering message log entries, see “Test Log tab” on page 662.

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Working With Message Logs

The Message Logs window toolbar has graphic buttons to control its
operations.

Open Close Print to File Delete Entry

Save Print Add Entry Copy

Basic TestWare

Enable All Display Options

Date/Time

Severity

Source

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How to Open a Message Log

On the Basic TestWare Toolbar, click to display the Message

Logs window.

Note The Message Logs window is disabled if no test file is loaded or a

newly created test file has not been saved.

On the Message Logs window toolbar, click to open an archived

message log. On the Open Message Log File window, select the
required archived message log file, then click Open.

Basic TestWare

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How to Print a Message Log

1. In the Basic TestWare Toolbar, click .

2. In the Message Logs window, click .

3. In the Message Log Print window box:

A. As needed, click Print Range selections to define what is

printed.

B. As needed, click Print Filters to apply Severity and Source

Basic TestWare

filters to what is printed.

C. Click OK to print the log.

How to Print the Message Log to File

1. In the Basic TestWare Toolbar, click .

2. In the Message Logs Toolbar, click .

3. In the Message Log Print to File window, specify the File Name
and its location. By default, the file is saved as a text (.txt) file.

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How to Add a User Entry to the Message Log

1. In the Basic TestWare Toolbar, click .

2. In the Message Logs Toolbar, click .

3. In the Message Log-Add Entry window:

A. Select a Message Severity level.

B. Select a Message Log source to specify an existing log file.

C. Enter the required message in Message Text.

Basic TestWare
D. Click Add to enter the message.

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How to Delete a User Entry from the Message Log

Only user entries can be deleted.

1. In the Basic TestWare Toolbar, click .

2. In the Message Logs window, highlight the user entry to be

deleted.

3. In the Message Logs Toolbar, click .

4. In the Delete Confirmation window, click OK to delete the

Basic TestWare

selected entry.

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How to Define What Messages Are Logged

Use the following procedure to specify the types of messages that are
logged into the Basic TestWare test log:

1. On the Basic TestWare toolbar, click Test Setup.

2. Click the Test Log tab on the Test Setup window.

Basic TestWare
3. Under Minimum Severity, select the least severe level of
messages logged.

4. Under Source:

• Select This Application Only to log only Basic TestWare

messages.

• Select All Applications to log both Basic TestWare and

Station Manager messages.

5. If needed, under Archive Auto Deletion, click Delete Older

Than to enable automatic deletion and then enter the number of
Days.

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How to Manually Archive All of the Messages in the Message Log

1. In the Basic TestWare Toolbar, click .

2. In the Message Logs Toolbar, click to archive the file.

3. In the Archive Confirmation window, click Yes.

The Message Logs window displays a message showing when

the file was archived and its name and location.

How to Manually Archive Part of the Messages in the Message Log

Basic TestWare

1. In the Basic TestWare Toolbar, click .

2. In the Message Log window, select a message you wish to

archive, so that it is highlighted. In the next step, the highlighted
message—and all messages that precede it—will be archived.

3. In the Message Logs Toolbar, click to archive the file.

4. In the Archive Confirmation window, click Yes.

The Message Logs window displays a message showing when

the file was archived and its name and location.

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Basic TestWare Windows

When you start the Basic TestWare application within Station Manager,
the Basic TestWare main display opens with an untitled test
configuration.

Toolbar

Basic TestWare
Test Command
Controls

Test Counters

Peak Detectors Return Home

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 Basic TestWare Windows

Basic TestWare - Main Display (part 1 of 2)

ITEM DESCRIPTION
Toolbar Provides quick access to frequently used commands and displays.
See“Basic TestWare Toolbar” on page 644.
Test Name: Displays the name of the currently opened test.
Data File: Displays the name of the data file currently in use.
Test Command Controls Provides controls to set up a test command. After the initial
command is defined, you can adjust the slider controls on the
display while the test is running as follows:
Basic TestWare

• For cyclic commands you can adjust the target setpoint,

amplitude, and frequency.

• For monotonic commands you can adjust the end level and
ramp time.

See “Defining the Test Command” on page 608.

Wave Shape Allows you to select the required wave shape for the test command.
Compensator Allows you to activate a compensator for the test command. See
“Working with Compensators” on page 194.
Test Counters Establishes a preset count that can be repeated, while maintaining
two counters that monitor the current count and the total count for
the test. See “Configuring Test Counters” on page 624.

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Basic TestWare - Main Display (part 2 of 2)

ITEM DESCRIPTION
Peak Detectors Provides an indicator to monitor the detector actions you have set for
a channel.
Indicator colors are as follows:
Grey indicates that all detectors are set to Disabled.

Green indicates that all detectors are set to Station Power Off,
Interlock, Program Interlock, Program Stop, Program
Hold, or Custom Actions.

Basic TestWare
White indicates that one or more detectors are set to Indicate.

Red indicates that a detector has been tripped.

A peak detector reset button is provided to clear the detector

action after the detector trips.
See “Configuring Peak Detectors” on page 619.
Return Home button Click the Return Home button to return your actuators to a
default or starting position.
This button is not available while a test is running. See “Configuring
Return Home” on page 622.

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Basic TestWare Toolbar

Clicking the Basic Testware toolbar buttons display the Basic
TestWare windows and tabs described in the following pages.

Open Test Print Test Options Editor Help Exit

Save Test Test Setup Message Log

Basic TestWare

Open Test Print Test Test Setup

New Test Print Preview Command
Printer Setup Home
Save Test
Print to File Data Acquisition
Save Test As Data File
Peak Det. Summary
Test Log
Peak Detectors

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Open Test Window

Path Basic TestWare toolbar > > Open Test.

Use the Open Test window to open existing, previously saved Basic
TestWare test files.

Basic TestWare
Open Test Window
ITEM DESCRIPTION
Look in Lists the available drives and directories.
File name Displays the file name of the selected file.
Files of type Lists the types of files available. The extension for test files is (*.tst).

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 Basic TestWare Windows

Save Test/Save Test As Window

Path Basic TestWare toolbar > > Save Test.

Use the Save Test command to save your current test.

If you have not saved the test previously, the Save Test As window
prompts you to specify a name and location.
Basic TestWare

Save Test As Window

ITEM DESCRIPTION
Save in Lists the available drives and directories.
File name Sets the name of your test file.
Save as type Lists the types of files available. The extension for test files is (*.tst).

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Test Setup Window

Path Basic TestWare toolbar > .

Use the Test Setup window’s tabs to define Basic TestWare tests.

Command tab Use the Command tab to define the program attributes for your test
command. The controls in this window change depending on whether
you select a cyclic or monotonic command.

Basic TestWare

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Command Tab
ITEM DESCRIPTION
Type Specifies the command type (Monotonic or Cyclic).
Channel Allows you to select a control channel for the test command from a
list of all station channels.
Control Mode Specifies the control mode for the selected control channel.
Target Setpoint Cyclic commands only—Sets the target mean level.
Amplitude Cyclic commands only—Sets the command amplitude.
Basic TestWare

Frequency Cyclic commands only—Sets the command frequency.

Note The maximum frequency is limited to 20% of the system rate.

Wave Shape Cyclic commands only—Sets the command wave shape.

End Level Type: Monotonic commands only—Sets the end level of the command.
Each channel can have a different end level.
Absolute or Relative
The end level value depends on the end level type selection
(absolute or relative). Absolute values are relative to zero. Relative
values are relative to the current output.
The end level value can be changed while a test is running, but the
end level type cannot.
Time/Rate Monotonic commands only—Defines the ramp of the command. The
command ramp can be defined in terms of time or as a ramp rate.
The ramp starts at the current actuator position and ends at the
specified end level. Each channel can have a different time/rate. The
time/rate value can be changed while a test is running, but the end
level type cannot.
Compensator Specifies a compensator for your command signal. See“Working with
Compensators” on page 194.
Done Action Specifies a system action at the end of a test.
Note The specified action is completed only if a predefined test
endpoint is reached, as defined by a preset cycle count, or the
end levels for each monotonic channel have been reached.

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Data Acquisition tab Use the Data Acquisition tab to configure how data is acquired
during your test. The Basic TestWare application supports four types of
data acquisition: timed, peak/valley, running max/min, and level
crossing. For more information, see “About Data Acquisition” on page
611.

Timed data acquisition Timed data acquisition records the values of selected signals at user-
specified time intervals as Time Between Points or as a frequency
(Sample Rate). For example, if you want to acquire data for the
selected signals every second, set the Time Between Points value to 1
second.

Basic TestWare

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Timed Data Acquisition Tab

ITEM DESCRIPTION
Type Timed (selected for this description)
Signals Available/ The Signals Available list displays the names of signals that are
Signals Included accessed using the current station. Highlight each signal in the list that
you want to acquire data from. Click the > button to move the signal to
the Signals Included list.
To remove signal names from the Signals Included list, highlight the
name of each signal that you want to remove, and then click the <
button.
Basic TestWare

Note The order of the signal names in the Signals Included list determines
the order in which the signals are recorded in the data file.

Time Between Points Specifies the time interval between data acquisitions.
Note When you enter a time increment, the Basic TestWare application may
change your entry slightly to reflect your controller’s system clock rate.

Sample Rate Specifies the sample rate frequency for data acquisitions.
Note Basic TestWare may change the entered frequency slightly to reflect
the resolution of your controller’s system clock rate. For instance, if
you type in “1000 Hz” and press the enter key, BTW may change the
number to 1024 Hz.

Buffer Size Specifies the maximum number of data elements the buffer will store (1
to 16000).
Buffer Type Specifies a buffer type: Linear or Circular. See “Buffers” on page 612.

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Peak/Valley data Peak/Valley data acquisition records the values of selected signals
acquisition when Basic TestWare detects a peak or valley in the master signal you
specify.

The sensitivity value specifies the amount the signal must change to be
considered a peak or valley. Adjusting the sensitivity lets you ignore
signal noise and still detect low amplitude signals. The output of a
selected master signal is monitored until the master signal reverses by
the amount defined by the Sensitivity parameter. The highest or
lowest value is remembered (along with the signal data) until the
change in the master signal amplitude exceeds the specified
Sensitivity value. See “How to Configure Peak/Valley Data
Acquisition” on page 616.

Basic TestWare

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Peak/Valley Data Acquisition Tab

ITEM DESCRIPTION
Type Peak/Valley
Signals Available/ The Signals Available list displays the names of signals that are
Signals Included accessed using the current station. Highlight each signal in the list that
you want to acquire data from. Click the > button to move the signal to
the Signals Included list.
To remove signal names from the Signals Included list, highlight the
name of each signal that you want to remove, and then click the <
button.
Basic TestWare

Note The order of the signal names in the Signals Included list determines
the order in which the signals are recorded in the data file.

Master Signal Specifies the signal that is monitored for peak/valley changes.
Sensitivity Defines how much the signal must change before a peak or valley is
detected and data is acquired.
Buffer Size Specifies the maximum number of data elements the buffer will store.
Buffer Type Specifies a buffer type: Linear or Circular. See “Buffers” on page 612.

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Running Max/Min data When Running Max/Min data acquisition is active, Basic TestWare
acquisition monitors the selected signals for maximum and minimum values
achieved. When Basic TestWare is stopped, it writes these maximum/
minimum values to the data file. See “How to Configure Running Max/
Min Data Acquisition” on page 617.

Basic TestWare
Running Max/Min Data Acquisition Tab
ITEM DESCRIPTION
Type Running Max/Min
Signals Available/ The Signals Available list displays the names of signals that are
Signals Included accessed using the current station. Highlight each signal in the list that
you want to acquire data from. Click the > button to move the signal to
the Signals Included list.
To remove signal names from the Signals Included list, highlight the
name of each signal that you want to remove, and then click the <
button.
Note The order of the signal names in the Signals Included list determines
the order in which the signals are recorded in the data file.

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Level crossing data Level Crossing data acquisition records the selected signal values
acquisition when the master signal changes by the level increment you specify.
See“How to Configure Level Crossing Data Acquisition” on page 618.
Basic TestWare

For example, suppose you want to acquire data every time the
displacement signal moves 2 millimeters:

1. First, you would make the desired displacement feedback signal

the Master Signal.

2. Then you would set the Level Increment to two millimeters.

3. Select signals to be stored in the data file. The Master Signal

need not be one of them.

Now, when the master signal reaches 2, 4, 6, etc. millimeters, signal

values will be recorded for all of the selected signals.

Note Do not set the level increment below the level of any signal noise.

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Level Crossing Data Acquisition Tab

ITEM DESCRIPTION
Type Level Crossing
Signals Available/ The Signals Available list displays the names of signals that are
Signals Included accessed using the current station. Highlight each signal in the list that
you want to acquire data from. Click the > button to move the signal to
the Signals Included list.
To remove signal names from the Signals Included list, highlight the
name of each signal that you want to remove, and then click the <
button.

Basic TestWare
Note The order of the signal names in the Signals Included list determines
the order in which the signals are recorded in the data file.

Master Signal Specifies the signal that is monitored for level changes.
Level Increment Defines how much the signal must change before acquiring data.
Buffer Size Specifies the maximum number of data elements the buffer will store.
Buffer Type Specifies a buffer type: Linear or Circular. See “Buffers” on page 612.

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Data File tab Use the Data File tab to specify where to save the data that is acquired
during your test.
Basic TestWare

Data File Tab (part 1 of 2)

ITEM DESCRIPTION
Destination File Specifies whether data is saved to the default data file or a user-specified
data file.
The default data file name is “btw-default.dat” and it is saved in the
default directory (see “Options Editor Window” on page 663).
File Name Enter the File Name of the test file for which you are acquiring data. The
default file is the currently selected file. Click the Browse button for a list
of available test files. You can also create a new data file by entering a
new file name.
Data Header This header is written at the top of every buffer. You should provide a
brief description of your test in the data header.

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Data File Tab (part 2 of 2)

ITEM DESCRIPTION
Data File Mode Specifies if new data is appended to or overwrites the old data.
Data File Format Specifies the format of the data file: Plain, Excel, or Lotus.
Plain results in space-delimited test data. This is most useful for direct
printouts.
Lotus results in comma-delimited test data, with text strings in double
quotes (sometimes referred to as the CSV format). Use this format when
importing data files into Lotus 1-2-3.
Excel results in tab-delimited test data. Use this format when importing

Basic TestWare
data files into Microsoft Excel.

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Home tab Use the Home tab to define a home position and transition time for
your station actuator(s). For more information on the Home control,
see “About Return Home” on page 622.
Basic TestWare

Home Tab
ITEM DESCRIPTION
Channel Specifies the actuator drive channel that the Home command is
programmed to control.
Control Mode Specifies the control mode for the channel.
Absolute End Level Specifies the value and units of the channel.
Time Specifies the amount of time it takes the actuator to move from the
current position to the specified Absolute End Level for the channel.

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Peak Detectors tab Use the Peak Detectors tab to define peak detectors that can monitor
an input signal for peak/valley changes. For information on peak
detectors, see “About Peak Detectors” on page 619.

Basic TestWare
Peak Detectors Tab (part 1 of 2)
ITEM DESCRIPTION
Signal Selection

Channel Specifies the channel that will be monitored by the peak detector.
Signal Specifies the signal that will be monitored by the peak detector.
Detector Parameters

Action Specifies the action that occurs when the detector is tripped. For
information on detector actions, see “About Detectors” on page 223.
Enable After Specifies how many cycles will be executed before the detector begins to
monitor the selected signals. This allows the signals to stabilize before
they are monitored.
Sensitivity Specifies how much the signal must increase or decrease before a peak
or valley is determined. Sensitivity settings should be used to prevent
signal noise from being misinterpreted as peaks or valleys.

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Peak Detectors Tab (part 2 of 2)

ITEM DESCRIPTION
Tolerance Specifies a tolerance band for the peaks and valleys. If a peak or valley
occurs outside the tolerance band, the action (specified in the Action
list) occurs. See the figure below.
Reference Specifies how the upper and lower reference values are established. The
Type selections are Default and User-specified. See the figure below
Default—Basic TestWare uses the first peak and valley values as the
reference.

User-specified—The user specifies the upper and lower reference

Basic TestWare

values which are kept unchanged until the test stops.

Upper Specifies the upper (peak) reference value (reference type must be user-
Reference specified).
Lower Specifies the lower (valley) reference value (reference type must be user-
Reference specified).
Examples New Peak/Valley
Peak/Valley Tolerance Band
Levels Set by
Levels Set by Detector
Detector
Peak
Default Reference
Type Selected

Valley

Detector Trips
Manual Reset

User Specified Enter

Reference Type Peak/Valley
Selected Reference
Values

Detector Trips
Manual Reset

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Peak Det. Summary Use the Peak Det. Summary tab to determine the current status of
tab each sensor signal.

Basic TestWare
Peak Det. Summary Tab
ITEM DESCRIPTION
Signal Specifies the sensor feedback signal monitored by a limit detector.
Over Indicates when a signal peak is above its “peak reference” tolerance
band or a signal valley is below its “valley reference” tolerance band.
Peak Over
Reference Tolerance Band
Value

Under
Valley
Reference
Value Over

Under Indicates when a signal peak is below its “peak reference” tolerance
band or a signal valley is above its “valley reference” tolerance band.

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Test Log tab Use the Test Log tab to select the level and source of the messages
that are logged to the Basic TestWare test log. Automatic deletion of
archived log files of a specified age can also be selected here.
Basic TestWare

Test Log Tab

ITEM DESCRIPTION
Message Capture

Minimum Allows you to select the level of messages logged.

Severity

Source Allows you to select the source of your logged messages.

Select This Application Only to log only Basic TestWare messages.
Select All Applications to log messages from both Basic TestWare and
Station Manager.
Archive Auto Deletion Allows you to automatically delete old archived log files.
Click the Delete Older Than check box and select the age (days) of the
archive log file required for automatic deletion.

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Options Editor Window

Path Basic TestWare toolbar > .

Directories tab Use the Options Editor window’s Directories tab to establish default
directory paths for the test files. These selections are system-wide and
are not saved with any configuration.

Basic TestWare
Directories Tab
ITEM DESCRIPTION
Set Default Updates the directory path in the registry file to match the current
directory path.
Note If you click Set Default, the registry is changed immediately. The
changes will apply when Basic TestWare is opened again.

Directory Path Displays the directory path for the selected file type.
Test Files Displays the files in the selected directory according to the extension
shown.
Files of type Displays the extension of the type of file selected.

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Message Logs Window

Path Basic TestWare toolbar > .

The Message Logs window records station and test events as they
occur. Events that can be logged include file events, resource
mismatches, hydraulic status changes, station state changes, and
detector activity.

For information on defining what level of messages are logged, see

“How to Define What Messages Are Logged” on page 639.
Basic TestWare

Message Log (part 1 of 2)

ITEM DESCRIPTION
Toolbar Controls basic Message Logs window functions.
Open Displays the Open Message Log File window, used to open an archived
message log.
Save Saves the current message log. You are given the option to clear the
current message log or save it as is. See “How to Manually Archive All of
the Messages in the Message Log” on page 640.
Close Closes any open archived message logs.

Print Prints the current message log. See “How to Print a Message Log” on
page 636.

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Message Log (part 2 of 2)

ITEM DESCRIPTION
Print to Displays the Message Log Print To File window where you can save
File your log as a text (*.txt) file. See “How to Print the Message Log to File”
on page 636.
Add Displays the Message Log-Add Entry window used to add your own
Entry messages to the message log. See “How to Add a User Entry to the
Message Log” on page 637.
Delete Deletes selected messages that were added by the user.
Entry

Basic TestWare
Copy Copies the selected entries to the clipboard.

Display Enable All Display Options, Date/Time, Severity, and Source

Options selections control the details displayed in the message log.
Log Select to display the Station Manager, the Basic TestWare log, open
archive logs.
Scroll to new entry Check this box to automatically scroll to the newest Message Log entry.

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Basic TestWare

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Chapter 6
Station Desktop Organizer
Learning about the Overview 668
Desktop Organizer

Performing common Starting the Station Desktop Organizer 669

tasks Positioning the Station Desktop Organizer 671
Setting Up the Station Desktop Organizer 672

Window and control Station Desktop Organizer Controls and Indicators 677
descriptions

Station Desktop Organizer

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 Overview

Overview
The Station Desktop Organizer is a convenient utility that helps you
manage and navigate the numerous software windows required to
operate each station. It is especially useful for reducing screen clutter
when you manage multiple stations at the same time.

With the Station Desktop Organizer controls you can:

• Show or hide all station windows with a single mouse click.

• Monitor critical information for multiple stations on a single

taskbar.

• Start other MTS applications including MultiPurpose TestWare,

Basic TestWare, Profile Editor, and Station Builder.
Station Desktop Organizer

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 Starting the Station Desktop Organizer

Starting the Station Desktop Organizer

How to Start the Station Desktop Organizer Manually
If the Station Desktop Organizer did not start automatically when you
started the Station Manager application, you can start it manually from
the Start menu or from Applications on the Station Manager File
Menu.

To start the Station Desktop Organizer manually, follow either of these

two paths:

From the Station Manager File menu:

File Menu > Applications > Station Desktop Organizer

From the Start menu:

Start > Programs > MTS FlexTest (or TestStar) > Applications > Station
Desktop Organizer

When you start the Station Desktop Organizer, it automatically loads

any open stations in the organizer taskbar. If no stations are currently
open, a button labeled Start Station Manager appears on the
organizer taskbar. Click this button to start the Station Manager
application.

How to Start the Station Desktop Organizer Automatically

FlexTest IIm, FlexTest CTC, FlexTest CTM, and FlexTest GT systems are
configured (by default) to start automatically when you start the Station
Manager application.

Station Desktop Organizer

Model 793.00 System Software 669

 Starting the Station Desktop Organizer

For TestStar IIs, TestStar IIs AP, and TestStar IIm systems, you can
configure the Station Desktop Organizer utility to start automatically
when you start the Station Manager application as follows:

1. Right-click the taskbar handle, title bar, or open task bar area to
access the Station Desktop Organizer.

2. Select Properties on the Station Desktop Organizer menu.

3. Click on the Start Station Desktop Organizer automatically

checkbox to enable auto startup.
Station Desktop Organizer

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 Positioning the Station Desktop Organizer

Positioning the Station Desktop Organizer

The first time you start the Station Desktop Organizer, it docks on the
bottom of your Windows desktop.

The organizer taskbar can be docked on the upper, lower, right, or left
edge of the desktop, or it can be placed in a floating position
anywhere on your screen.

Docked Taskbar

Floating Taskbar

How to Move the Station Desktop Organizer Taskbar

Click the taskbar handle, the title bar, or on an open taskbar area, and
then drag it to the desired location.

Taskbar Handle Open Area

When you move the Station Desktop Organizer to a floating position, a

title bar is added above the first station. When you move the taskbar
towards the edge of the desktop, it docks on that edge.

Note If you want to position the taskbar near the desktop edge without

Station Desktop Organizer

docking it, press and hold Ctrl while dragging the taskbar.

To resize the floating taskbar horizontally, drag the right or left edge of
the taskbar.

Model 793.00 System Software 671

 Setting Up the Station Desktop Organizer

Setting Up the Station Desktop Organizer

You can perform commands and configure Station Desktop Organizer
properties from the organizer menu.

How to Access the Station Desktop Organizer Menu

Right-click the taskbar handle, title bar, or open taskbar area to access
the Station Desktop Organizer menu.
Station Desktop Organizer

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 Setting Up the Station Desktop Organizer

Station Desktop Organizer Menu (part 1 of 2)

ITEM DESCRIPTION
Refresh Station List Loads any new stations into the Station Desktop Organizer.
Note In the Properties window, you can set the organizer to refresh
the station list automatically. By default, the organizer will refresh
every five seconds.

Properties Opens the Properties window. Use this window to edit, enable, or
disable the following taskbar properties:

• Automatically refresh station list every seconds allows

you to set the Station Desktop Organizer to refresh the station
list automatically. By default, this property is enabled and set to
refresh the station list every five seconds.

• Always on top is enabled by default to ensure that the Station

Desktop Organizer taskbar is displayed on top of any other
windows you have open.

• Clicking “Show” hides other stations is enabled by default to

hide all station windows except the windows for the current
station when you click .

• Display the Stop button is enabled by default to display on

Station Desktop Organizer

the Station Desktop Organizer.

• Start Station Desktop Organizer Automatically is enabled by

default (FlexTest systems only) to automatically start Station
Desktop Organizer when Station Manager is started.
For TestStar systems, you must enable this property if desired.

Model 793.00 System Software 673

 Setting Up the Station Desktop Organizer

Station Desktop Organizer Menu (part 2 of 2)

ITEM DESCRIPTION
About Station Desktop Displays version and copyright information.
Organizer

Exit Station Desktop Quits the Desktop Organizer.

Organizer
Station Desktop Organizer

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 Using the Station Desktop Organizer

Using the Station Desktop Organizer

Use the buttons on the Station Desktop Organizer taskbar to hide and
display your station windows, and to start other MTS applications.

How to Hide Station Windows

Click the Hide button to hide all of the station windows for that
station.

When you click Hide, all windows for the current station are hidden
and their related icons are removed from the Windows taskbar.

How to Display Hidden Station Windows

Click the Show button to display all of the station windows for
that station.

When you click , all the windows for the current station are
restored to their last locations and their related icons are returned to
the Windows taskbar. If the window was minimized when the station
was hidden, the window will restore to a minimized position when
you click .

Note If Clicking “Show” hides other stations is enabled on Station

Desktop Organizer Properties, all station windows except
windows for the current station will be hidden.

If you only want to display a particular station window, click the

station button, and then select the name of the window you want to
display.

Note An indicator next to each window name displays whether the

window is currently hidden.

How to Start an Application from the Station Desktop Organizer

Station Desktop Organizer
If no stations are currently open, click Start Station Manager to start
the Station Manager application. If a station is currently loaded in the
organizer taskbar, click the station button, and point to Start
Application to access a list of available applications.

Model 793.00 System Software 675

 Using the Station Desktop Organizer

How to Quit the Station Desktop Organizer

There are three ways to quit the Station Desktop Organizer:

• Click on the organizer taskbar, press Alt+F4, and then click Yes on
the exit window.

• Right-click the taskbar handle, title bar, or open taskbar area to

access the organizer menu, and then left-click Exit Station
Desktop Organizer.

• Click the Close button.

Note The close button appears on floating taskbars only.

How to Refresh the Station Desktop Organizer Display

Right-click the taskbar handle, title bar, or open taskbar area to access
the organizer menu, and then left-click Refresh Station List.

Note In the Properties window, you can set the organizer to refresh the
station list automatically. By default, the organizer will refresh every
five seconds
Station Desktop Organizer

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 Station Desktop Organizer Controls and Indicators

Station Desktop Organizer Controls and

Indicators
The Station Desktop Organizer is equipped with the following controls
and indicators:

• Station Buttons and Action Menus

• Hide and Show Buttons

• Stop Button

• Status Indicators

To set your organizer taskbar preferences, see “Setting Up the Station

Desktop Organizer” on page 672.

Station Desktop Organizer

Model 793.00 System Software 677

 Station Desktop Organizer Controls and

Station Buttons and Action Menus

The name of each open station appears on a station button. Click the
button to access a station-specific action menu.

Station Buttons

Station Action Menu

From the station action menu you can:

• Navigate through the windows that are open for each station.

• Start other MTS applications such as Station Manager, Station

Builder, Profile Editor, MultiPurpose TestWare, and Basic
TestWare. When applicable, the current configuration will be
loaded into the application as required.
Station Desktop Organizer

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 Station Desktop Organizer Controls and Indicators

Hide and Show Buttons

You can use the hide and show buttons to hide or show all station
windows with a single click.

Icons

Hide/Show Buttons

Desktop organizer Icons (to the right of the hide/show buttons) indicate whether
icons windows are currently hidden for that station. Refer to the following
table for icon descriptions.

Display Icon Descriptions

ICON DESCRIPTION

When the station windows are all visible, the

display shows a solid outline of several windows.

When the station windows are all hidden, the

display appears dimmed.

If a station has some windows displayed and some

windows hidden, the display shows a combination
of solid and dimmed images.
This display results when:
• You start another application for a station that
Station Desktop Organizer
is hidden.

• A pop-up status window appears for a hidden

station.

• You use the station action menu to show

particular windows for a hidden station.

Model 793.00 System Software 679

 Station Desktop Organizer Controls and

Stop Button
The stop button can be used to stop any program currently running on
the station.

Note In the Station Desktop Organizer Properties window, you can

specify whether or not the Stop button is displayed on the organizer
taskbar.

Clicking on the organizer taskbar has the same effect as clicking

on the Station Manager Station Controls or the Stop button on the
remote station controller (RSC).

Stop Button
Station Desktop Organizer

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 Station Desktop Organizer Controls and Indicators

Status Indicators
This portion of the Station Desktop Organizer taskbar indicates the
following items:

• The application actively in control of the station

• The test state

• The station hydraulics status

• The station interlock status

Controlling Test and Station

Application Status Displays

Test indicator The Test LED displays the current program status.

INDICATOR COLOR STATUS

Red Stopped

Yellow Holding

Green Running

Station Desktop Organizer

Model 793.00 System Software 681

 Station Desktop Organizer Controls and

Power indicator The Pwr LED displays the highest power setting for any HSM or
servomotor on the station. If the station is configured with an HPU
only, the LED displays the greatest HPU power setting.

INDICATOR COLOR HIGHEST POWER SETTING

Green High

Yellow Low

Black Off

Note If a station has no HSMs and you have not assigned an HPS to any
channel, the Pwr LED will be disabled (gray).

Interlock indicator The Intlk LED indicates the interlock status for the station. This
includes station interlocks and software interlocks.

INDICATOR COLOR INTERLOCK STATUS

Red Interlock is tripped (Open)

Black No interlock (Closed)

Station Desktop Organizer

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 Remote Station Controller (RSC)
Chapter 7
Remote Station Controller (RSC)
Introduction About the Remote Station Controller 684
Defining the RSC (.HWI File) 685
Cabling the RSC to the Controller 686

Using the RSC Enabling a Remote Station Controller 687

RSC Controls and Indicators 688
Signal Lists and Pages 702

Model 793.00 System Software 683

Remote Station Controller (RSC)
About the Remote Station Controller

About the Remote Station Controller

The Remote Station Controller (RSC) is a portable device that can be
used to:

• Reset interlocks.

• Activate and disable system hydraulics.

• Manually control your actuator.

• Start and stop tests.

• Monitor and zero sensor inputs.

• Shut down the station in an emergency.

Typically, the RSC is placed on a table or stand near your load frame or
test table.

Remote Station Controller

810 Material Test System

m Power

TestStar™
IIs Command

647 Hydraulic Wedge Grip

647 Hydraulic Wedge Grip

Remote Station Control

F1 F2 F3 F4 Status

Interlock HSM HPS Test Manual Control

Enable /
Reset High High Run Disable

Emergency Stop

Low Low Hold

Off Off Stop

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 Remote Station Controller (RSC)
Defining the RSC (.HWI File)

Defining the RSC (.HWI File)

In order to use an RSC with your station, it must be defined in your
.hwi file. When you start the system loader utility, each RSC defined in
the .hwi file is reset and made ready to communicate with your station.

FTIIm/CTC/CTM/GT/ The .hwi file entry for an RSC (shown below) defines which port the
TSIIm RSC should be connected to, which firmware file is used, and which
interlock chain the RSC is on. Contact MTS for information on editing
the .hwi file to accommodate RSCs for the following controllers:
FlexTest IIm, FlexTest II CTM, FlexTest II CTC, FlexTest GT, and
TestStar IIm.

GRES III connector Interlock Chain

RSC
NAME="RSC 1" HOST PORT="GRES COM 1" FILENAME="POD.HEX" INTERLOCK="1"

RSC name Identifies the RSC firmware

TSIIs/TSIIs AP The .hwi file entry for an RSC defines which port the RSC should be
connected to and which firmware file is used. For information on
editing the .hwi file to accommodate RSCs with these controllers (as
shown below), see the TestStar IIs Controller Installation and
Calibration Manual that accompanied your test system.

Europa Board

RSC
NAME="RSC 1" HOST PORT="EUROPA COM 1" FILENAME="POD.HEX"

RSC name Identifies the RSC firmware

Model 793.00 System Software 685

Remote Station Controller (RSC)
Cabling the RSC to the Controller

Cabling the RSC to the Controller

TestStar IIs/AP For TestStar IIs and TestStar IIs AP controllers, you can connect a
single RSC to connector J50. The proper connectors must be defined
in the .hwi file. For more cabling information, refer to the TestStar IIs
Controller Installation and Calibration Manual.

TestStar IIm For TestStar IIm controllers, you can connect one or more RSCs (up to
four) to connector J50A–J50D on the 498 RS-485 transition module.
The proper connectors must be defined in the .hwi file. For more
cabling information, refer to the Model 493.10/793.00 Controller
Installation and Calibration manual.

Note This controller requires a Model 498.71B Global Resources III

module.

FlexTest Controllers For the following FlexTest controllers, you can connect one or more
RSCs (up to four) to connector J50A–J50D on the 498 RS-485 transition
module: FlexTest IIm, FlexTest II CTM, FlexTest II CTC, and FlexTest
GT. The proper connectors must be defined in the .hwi file. For more
cabling information, refer to the appropriate controller setup manual.

Note All of these controllers require a Model 498.71B Global Resources

III module.

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 Remote Station Controller (RSC)
Enabling a Remote Station Controller

Enabling a Remote Station Controller

You must enable your RSC when you open your station configuration
file in Station Manager.

How To Enable an RSC

In the Open Station window, select Enable Remote Station Control
to enable the RSC connected to the selected interlock chain.

If a Remote Station Controller is not available on the interlock chain,

the Enable Remote Station Control checkbox is “greyed out.”

Model 793.00 System Software 687

Remote Station Controller (RSC)
RSC Controls and Indicators

RSC Controls and Indicators

This section describes the various Remote Station Controller (RSC)
controls and indicators. The RSC control panel is available in two
configurations; one provides an E-Stop and HPS control, and the other
provides a Station Stop with no HPS control. Your system may have
one or both of these panel configurations.

Contrast Adjustment
Remote Station Control
(located on rear panel)

Display Controls

Interlock Reset F1 F2 F3 F4 Status

Function Keys
Interlock HSM HPS Test Manual Control

Enable /
Reset High High Run Disable*

Emergency Stop

Low Low Hold

Off Off Stop

HSM HPS Manual Control

Emergency Stop Test
Controls Controls Controls

Station Stop

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 Remote Station Controller (RSC)
RSC Controls and Indicators

For descriptions of the RSC controls and indicators, see the following:

• “Interlock indicator and Reset button” on page 690

• “Emergency Stop” on page 691

• “HSM controls” on page 690

• “HPS controls” on page 691

• “Emergency Stop” on page 691

• “Station Stop” on page 691

• “Test controls” on page 691

• “Manual Control” on page 693

• “Display Controls” on page 694

• “Function keys” on page 696

Model 793.00 System Software 689

Remote Station Controller (RSC)
RSC Controls and Indicators

Interlock indicator The Interlock indicator lights when an Interlock

and Reset button interlock has been triggered.

To reset the interlock and clear the indicator, Reset

press the Reset button.

To override the interlock, press and hold the Reset button. While
holding the Reset button, you can apply hydraulic pressure and bring
the actuator back into range with the Manual Control dial. The
interlock will reset when you release the Reset button.

HSM controls The HSM controls manage the pressure to the

HSM
hydraulic service manifold. If there is more than one
HSM, the controls affect the HSM currently selected
on the RSC Station Manager page. High

Changing channels on the RSC changes which HSM is

selected.

• Off—turns off the HSM. Low

• Low—applies low pressure, typically 2 MPa (300

psi).

• High—applies high pressure, typically 21 MPa Off

(3000 psi).
Note The HPS must be on before the HSM can be turned on.

Group mode Selecting Group Mode on the RSC allows control of all HSMs in the
group. Indicators show the current state of each HSM. Press an HSM
control button to bring all HSMs in the group to the selected level.

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 Remote Station Controller (RSC)
RSC Controls and Indicators

HPS controls The HPS controls manage the pressure from the
HPS
hydraulic power unit. Turning the HPS off also turns
off all HSMs.
High
• Off—turns off the HPS.

• Low—applies low hydraulic pressure, typically 2

MPa (300 psi).
Low
• High—applies high hydraulic pressure, typically
21 MPa (3000 psi).

Off

Emergency Stop To immediately stop the test and disable station

Emergency Stop
hydraulics, press the Emergency Stop button.

To restore normal operation:

1. Reset the Emergency Stop button by

twisting the dial as indicated by the arrows
on the dial.

2. Press the Reset button to clear the

interlock indicator.

3. Activate hydraulic pressure.

Station Stop To stop a test on a specific test station and turn off the test station
HSM, press the Station Stop button.

To restore normal operation of the test station:

1. Reset the Station Stop button by pressing once.

2. Press the Reset button to clear the interlock indicator.

3. Use the HSM controls to turn on the test station HSM.

Test controls The Test buttons work similarly to the test buttons on the Station
Controls Panel for the Function Generator, External Command,
Basic TestWare, and MultiPurpose TestWare applications.

Depending on the application that currently has control of the system,

the Test buttons have a different function.

Model 793.00 System Software 691

Remote Station Controller (RSC)
RSC Controls and Indicators

• When you select a specimen in MultiPurpose TestWare, the

controlling application shown on the RSC is automatically
switched to MultiPurpose TestWare control. For example, if Basic
TestWare is the controlling application shown on the RSC and
then you select a specimen in MultiPurpose TestWare, the RSC is
automatically switched to MultiPurpose TestWare control.

Remote Station Control

Test

Station Manager <test.cfg : default>

Run Application: MPT
HSM 1
Stmgr-Exerciser
Channel 1 Displacement HSM 1

Hold

• The Application field displays which application is the source of

the test program.
Stop
• You can change the controlling application while it is stopped.
Remote Station Use the or button to highlight the application field and
Control buttons use the F4 key to scroll through the list box and select an
application.

• Only one application can have control at a time.

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 Remote Station Controller (RSC)
RSC Controls and Indicators

Manual Control Use the Manual Control dial to position the

actuator. With hydraulic power on, adjusting the Manual Control
manual control causes the actuator to extend or
Enable /
retract. Disable˜

You can use the Manual Control adjustment to:

• Install or remove a specimen

• Calibrate a sensor

The control mode for the Manual Control dial

is selected in the Station Manager page of the
Remote Station Control module.

1. Use the F2 and F3 buttons to select the channel or channel group

you want to control.

2. Use the up and down buttons to select the Manual Ctrl field.

3. Press F4 to select the available control modes (setpoint, span,

manual command, or master span) until you find the one you
want.
Note Setpoint must be enabled on the Station View Options tab to be
available as a control mode selection here. See “RSC Setpoint
control” on page 694.

4. Press Enable to activate the manual control mode and Manual

Control dial. The Manual Control indicator should be lit.
Note If you have selected Command (manual command) for Manual
Ctrl, enabling Manual Control disables the function generator.
Also, both Manual Command and Setpoint on the system controller
PC are disabled.

5. Use the Manual Control dial to position the actuator.

Velocity limiter A 10 mm/sec velocity limit, required for CE compliance, can be

enabled in the .hwi file. Removing the comment symbols (/* and */)
from the VELOCITY LIMITER statement in the .hwi file enables the
feature. See the .hwi file appendix in the appropriate Service manual.

When enabled, CE velocity limitation is performed on manual

command or setpoint adjustments made from the RSC Manual Control
dial only.

Model 793.00 System Software 693

Remote Station Controller (RSC)
RSC Controls and Indicators

RSC Setpoint control You can enable RSC control of setpoint by selecting the Setpoint
enabled on RSC checkbox on the Station View Options tab in the
Station Options window.

When Setpoint enabled on RSC is checked, you can select setpoint

for Manual Control on the RSC Station Manager page. See “Station
View Options Tab” on page 416 for more information.

Enabling Setpoint on the RSC does not disable Setpoint on the system
controller PC. If having Setpoint active on both devices is a concern,
disable RSC Setpoint control by unchecking Setpoint enable on RSC.

Display Controls Use the RSC display controls to move the cursor and navigate through
the pages on the RSC display.

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 Remote Station Controller (RSC)
RSC Controls and Indicators

This bar indicates if all of the information is

The cursor highlights the field you displayed:
want to change or adjust.
• If the bar reaches the bottom of the
display, all information is shown.

Remote Station Control

• If the bar does not reach the top or
bottom of the display, more
information is available. Use the up
Station Manager <test.cfg : default> and down buttons to reveal the hidden
Application: Function Generator
information.
Channel 1 Displacement HSM1

Manual Ctrl: Displacement 1.0272 mm

Up and down buttons move the
Channel 1 Current Value cursor around the display.
Channel 1 Displacement 1.3188 mm
Channel 1 Force -4.2111 kN

Left and right arrow buttons step

between pages that show Station
Ch/Grp- -
Auto Offset Ch/Grp Ch/Grp + Select Manager, MultiPurpose TestWare,
and Signal List information. Signal
F1 F2 F3 F4 Status lists reside on Signal Pages created
in Station Manager (Channel
Options window).
The function buttons have appropriate
functions for the page being displayed.

The Status button brings the

Station Manager page to the top.

Model 793.00 System Software 695

Remote Station Controller (RSC)
RSC Controls and Indicators

Changing what is You can change what is shown in the display. Use the left and right
displayed arrow buttons (along the right side of the RSC) to step between the
following available page displays.

• The Station Manager page shows the selected control channel,

control modes, and the current value of each input signal. See the
“Station Manager Page” on page 697.

• The MultiPurpose TestWare page (only available when

MultiPurpose TestWare™ is running) shows the selected
specimen, test procedure, and the current state of the test. See the
“MultiPurpose TestWare Page” on page 700.

• Signal pages are defined for RSC display in Station Manager. Each
signal page contains a created signal list, which is a group of
signals and their current values. See “Signal Lists and Pages” on
page 702.

Function keys The function of the F1–F4 keys changes depending on what
application is controlling the station.

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 Remote Station Controller (RSC)
RSC Controls and Indicators

Station Manager Page

The title bar displays

the selected Remote Station Control Active Control
configuration file and Mode
parameter set.
Station Manager <test.cfg : default>
Application: Function Generator
Control Channel HSM under
or Group Channel 1 Displacement HSM1
RSC control
Manual Ctrl: Displacement 1.0272 mm

Channel 1 Current Value Manual Control

Channel 1 Displacement 1.3188 mm Mode
Control Channel
Channel 1 Force -4.2111 kN
Input Signals

Ch/Grp- -
Auto Offset Ch/Grp Ch/Grp + Select

F1 F2 F3 F4 Status

Function Key Descriptions (part 1 of 2)

FUNCTION KEY DESCRIPTION
F1 Auto Offset Press F1 to zero the output of the selected sensor signal. You can use the
Auto Offset feature if:
• The selected signal has the cursor on its output value.

• The selected signal offset must not be locked. Check the Offset/
Zero tab in Station Setup for the selected signal to ensure that
Auto Offset Lock is not enabled.

Model 793.00 System Software 697

Remote Station Controller (RSC)
RSC Controls and Indicators

Function Key Descriptions (part 2 of 2)

FUNCTION KEY DESCRIPTION
F2 Ch/Grp- Press F2 or F3 to step up or down through different channel/input signal
F3 Ch/Grp+ groups.
F4 Select Press F4 to step through a list of selections for the selected parameter.
• The selectable field has the cursor on its current selection.

• Each time you press F4, the highlighted selection changes, stepping
through the possible selections.

Changing control Perform the following procedure to change the control mode for the
modes manual control on the RSC module.

1. Ensure that the Manual Control indicator is not lit.

2. Use the F2 and F3 buttons to select the desired channel or group.

3. Press the or button until the manual control mode name

is highlighted (next to the Manual Ctrl label on the RSC display).

4. The display above the F4 button should show Select. Press F4

repeatedly until the required manual control mode is displayed.

5. Press the Manual Control Enable/Disable button to light the

indicator.

Zeroing a sensor You can zero a sensor’s output from the RSC module when the Station
signal Manager page is displayed. This performs the same function as the
Auto Offset button found on the Offset/Zero tab on the Inputs panel
in Station Setup.

1. Press the or button until the signal value you want to

zero is highlighted.

2. The display above the F1 button should show Auto Offset. Press
F1 to zero the highlighted value.

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 Remote Station Controller (RSC)
RSC Controls and Indicators

Active control The name of the application that is actively controlling the station is
application displayed on the RSC display title bar and next to the Application
label on the display.

The available applications are:

• Station Manager (External Command, Function Generator, or Auto

Tuning)

• MultiPurpose TestWare (when running)

• Basic TestWare (when running)

The Run/Hold/Stop buttons in all other applications are disabled

until the active application stops the test. When a test is stopped,
clicking Run from any application locks out all other applications. See
“Test controls” on page 691.

HSM display The Station Manager page displays the current HSM under RSC control.

Note If the RSC is controlling the setpoint of a group of channels, the

HSM under control will not be displayed. In its place, the upper
value of the setpoint will be displayed.

Channel groups Channel groups for RSC control are defined on the Master Command
tab in the Channel Options window. See “About Channel Groups”
on page 259 for more detailed information.

Model 793.00 System Software 699

Remote Station Controller (RSC)
RSC Controls and Indicators

MultiPurpose TestWare Page

The title bar displays the

selected application for the
Remote Station Control
display along with the selected
configuration file. MPT <test.cfg>

Specimen: Spec1
Procedure Name: PROC2.000
Procedure State: Edit
Run Time: 00:05:31

New Reset Exec/Edit

F1 F2 F3 F4 Status

Function Key Descriptions

FUNCTION KEY DESCRIPTION
F1 New Press F1 to create a new test (specimen).
F2 Reset Press F2 to reset the current test so another test can be started.
F4 Execute/Edit Press F4 to toggle between the Execute and Edit modes of the
procedure.

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 Remote Station Controller (RSC)
RSC Controls and Indicators

Message Window Displays

Note While using the RSC, Warning
and Error windows will appear on Remote Station Control
the display as they do on a PC.
Always acknowledge the Stn. Mgr <test.cfg : default>
message before issuing another
command from the software.
WARNING
Station Exerciser window is closed. Do you
want to open and run it?

Yes No

F1 F2 F3 F4 Status

Remote Station Control

Stn. Mgr <test.cfg : default>

ERROR
The HPS must be enabled before turning on
the HSM.

OK No

F1 F2 F3 F4 Status

Warning messages A warning message will appear when the system detects a potential
problem with executing the current command. Press the F1 key to
dismiss the window if “OK” is the only selection. If there is a “Yes” and
“No” selection, answer the question by pressing the corresponding F1
or F2 button.

Error messages An error message will appear when the system detects an error and
cannot execute the requested command. The message tells you the
cause of the error. Press the F1 key to dismiss the window.

Model 793.00 System Software 701

Remote Station Controller (RSC)
Signal Lists and Pages

Signal Lists and Pages

Signal lists are convenient for reducing the number of signals displayed
on the RSC or Station Manager Station Signals window. This section
describes signal list creation and editing, and the creation of signal
pages.

On the RSC, this feature helps you avoid scrolling through long lists of
signals on the small display. By limiting each RSC signal list to five
signals, you can avoid scrolling to find the desired signal.

Note When you change control channels on the RSC, the corresponding
input signal list for the selected control channel will be displayed.
This signal list corresponds to the Included list for this channel on
Signal Lists in the Channel Options window.

How to Create Signal Lists

You can create custom signals lists for use on the RSC display or
Station Signals window as follows:

1. On the Station Manager Tools menu, select Channel Options to

open the Channel Options window.

2. Click the Signal Lists tab, and then click Add to create a new
signal list. In the Name box, rename the signal list (initially named
“Signal List 1”) as desired.

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 Remote Station Controller (RSC)
Signal Lists and Pages

3. From the Available Signals list, choose the signals for your signal
list. Hold down the Ctrl key, and then select each required signal.

4. Click the > button to move the selected signals to the Included
list.
Note Each signal list can include up to 10 signals.

How to Edit Signal Lists

1. In the Station Manager window’s Tools menu, select Channel
Options to display the Channel Options window.

2. In the Channel Options window, click the Signal Lists tab.

3. In the Signal Lists tab:

A. Create a new signal list or edit an existing signal list:

To create a new signals list, click Add and enter the new list’s
Name.

To edit an existing list, select its name.

Note List Filter applies a filter to predefined signal lists, displaying only
Available Signals that are likely to be used with the list. Enter a
whole or partial text description of the type of signal(s) you want to
display. See “Signal Lists Tab” on page 432.

B. Use the < > and << >> buttons to move signals between
Available Signals and Included.

Model 793.00 System Software 703

Remote Station Controller (RSC)
Signal Lists and Pages

How to Create Signal Pages

You can create custom signal pages for display on the RSC up to a
maximum of three. Each signal page contains a created signal list,
which is a group of signals and their current values.

1. On the Station Manager Tools menu, select Channel Options.

2. Click the RSC tab.

3. In the Additional Pages panel, click Add to create a new signal

page. Rename the signal page (initially named “Signal Page 1”) as
desired.

4. In the Current Signal List: selection box highlight and select the
desired signal list for display on your newly created RSC signal
page.
Note You have the option of hiding the application name and/or channel
information lines on the added page. Click the Hide Application or
Hide Channel Information checkboxes as desired.

5. Press the Apply button to add this new signal page (and its
assigned signal list) to the RSC display.
Note If you forget to click Apply after making RSC display changes,
closing Channel Options displays a window that allows you to save
your changes.

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Appendix A
Acceleration Compensation
About Acceleration Compensation 706
How to Configure Acceleration Compensation 707

Acceleration Compensation

Model 793.00 System Software 705

 About Acceleration Compensation

About Acceleration Compensation

Acceleration compensation is an option, typically used in:

• Tests that have a moving force transducer

• Tests that apply loads at high frequencies

• Tests that apply loads using massive grips or fixturing

Acceleration Compensation

• Tests that use a load washer for feedback

Your system may not have acceleration compensation.

The acceleration compensation applied to force input signals

minimizes unwanted feedback from vibrations caused by a mass
attached to the force transducer. The unwanted effects of this vibration
increase exponentially as the test frequency increases.

The acceleration compensation option requires an accelerometer

mounted to the load cell and additional conditioning hardware. During
a typical operation, the conditioned accelerometer signal is inverted
and summed with the feedback signal to null out any false load
feedback.

706 Model 793.00 System Software

 About Acceleration Compensation

How to Configure Acceleration Compensation

Acceleration compensation must be optimized whenever you change
fixturing or make other major mechanical changes.

1. Remove any installed specimen.

2. In the Station Manager window’s Toolbar, select an Access Level

of Tuning.

Acceleration Compensation
3. In the Station Manager window’s Display menu, click Station
Setup to display the Station Setup window.

4. In the Station Setup window’s Navigation pane, locate and click

the Channels control mode that will use acceleration
compensation.

5. In the Station Setup window, click .

6. In the Inputs panel, click the Accel tab.

7. In the Station Manager window’s Toolbar, click .

8. Set up the Scope window to display the command and force

feedback signals for the channel using acceleration compensation.

9. In the Station Manager window’s Navigation pane, click .

10. Set up a tuning program in the Function Generator panel.

A. For Channel, click the channel using acceleration

compensation.

B. For Control Mode, select a displacement control mode.

C. For Command Type, click Cyclic.

D. For Target Setpoint, set 0 cm.

E. For Amplitude (±), select an amplitude appropriate for the

test.

F. Set Frequency to approximately 80% of the test frequency.

G. For Wave Shape, click Sine.

H. For Compensator, click APC or PVC.

Model 793.00 System Software 707

 About Acceleration Compensation

WARNING Applying station hydraulic pressure can put actuators in motion.

A moving actuator can injure anyone in its path.

Always clear the actuator area before applying hydraulic pressure.

11. Apply station hydraulic pressure.

12. Start the tuning program.

Acceleration Compensation

13. Adjust the acceleration compensation.

In the Station Setup window’s Accel tab, adjust Acceleration

Compensation to minimize feedback.

If Acceleration Compensation has an additive or no effect on

the feedback signal, for Polarity click Invert.

14. To save the values, go to the Station Manager window’s File

menu and click Save Parameters.

708 Model 793.00 System Software

Appendix B
Command Line Options and Shortcuts
Station Manager Shortcuts 710
Station Builder Shortcuts 712
System Loader Shortcuts 713
Basic TestWare Shortcuts 715
Decorator-Based vs. Precedence-Based Formats 717

Using Shortcuts Creating a Shortcut 722

Editing the Shortcut Command Line 723

Command Line Options and Shortcuts

Model 793.00 System Software 709

 Station Manager Shortcuts

Station Manager Shortcuts

Creating command line shortcuts greatly reduce the number of steps it
takes to get your station open and running. For Station Manager, you
can use a shortcut to automatically specify the following station
parameters:

• Configuration file name

• Parameter set

• Interlock chain

• Station views

• RSC (remote station control)—optional, not available on all systems

• User level and password

• .HWI file name

• Test system name

Command Line Options and Shortcuts

Shortcut command To create a Station Manager shortcut command line, first specify the
line application (stmgr), then the desired station options.

The syntax of the shortcut command line is critical. If you do not use a
supported command-line format, the shortcut will not work.

To view a list of available Station Manager command-line options,

enter stmgr /H from the command line. These options are also
described in the following table.

Note If the parameter name contains spaces (for example, test 257.000),
the name must be enclosed in quotation marks (“test 257.000“).

The Station Manager application supports two command-line formats:

decorator-based and precedence based. See “Decorator-Based vs.
Precedence-Based Formats” on page 717 for more information about
these formats.

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 Station Manager Shortcuts

Station Manager Command-Line Options

DESCRIPTION OPTION ABBREVIATION1 DEFAULT VALUE EXAMPLE

Configuration file /Station /St None /St practice.cfg

name

Parameter set name /ParameterSet /Par Parameter set last /Par “set 1”
used by
configuration
Interlock number /Interlock /I Interlock last used /I 1
by configuration
RSC name2 /RSC /R RSC detected /R RSC-1
Restore view /View /V Default view /V default
/V saved
/V no
User level /Userlevel /U Operator /U Tuning
Password3 /Password /Pas None /Pas Tuning

Command Line Options and Shortcuts

.HWI file name /hwi /Hw None /Hw tsiis.hwi
System name /System /Sy None /Sy “810 mat test”
Controller name (to /Controller /Cont None /Cont “Control A”
connect to)

Import parameters /Import None None /Import Aero1.txt

file

Launch application /Launch None None /Launch BTW

No Restart /NoRestart None None
(saved applications)

Display the Station ? or /Help /H

Manager command-
line options

1. Option names can be abbreviated to anything that is unique.

2. Optional—not available on all systems.
3. The password parameter is case-sensitive.

Command line Stmgr /St test.cfg /Par “param set 1” /I 1 /V saved U/ tuning /Pas
example Tuning

Model 793.00 System Software 711

 Station Builder Shortcuts

Station Builder Shortcuts

For Station Builder, you can use a shortcut to automatically specify the
following parameters:

• Configuration file name

• Controller name (to connect to)

• .HWI file name

Shortcut command To create a Station Builder shortcut command line, first specify the
line application (stbd), then the desired station options.

The syntax of the shortcut command line is critical. If you do not use a
supported command-line format, the shortcut will not work.

To view a list of available Station Builder command-line options, enter

stbd /H. These options are also described in the following table.

Note If the parameter name contains spaces (for example, test 257.000),
the name must be enclosed in quotation marks (“test 257.000“).
Command Line Options and Shortcuts

The Station Builder application supports two command-line formats:

decorator-based and precedence based. See “Decorator-Based vs.
Precedence-Based Formats” on page 717 for more information about
these formats.

Station Builder Command-Line Options

PARAMETER PREFIX ABBREVIATION1 DEFAULT VALUE EXAMPLE

Configuration file /Station /St None /St practice.cfg

.HWI file name /hwi /Hw None /Hw tsiis.hwi
Controller name (to /Controller Cont None /Cont “Control A”
connect to)

Display the Station ? or /Help /H

Builder command-
line options

1. Option names can be abbreviated to anything that is unique.

Command line Stbd /St stat1.cfg

example

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 System Loader Shortcuts

System Loader Shortcuts

For System Loader, you can use a shortcut to automatically launch a
simulated DSP or supervisor, load/unload a simulated system, and
specify the following parameters:

• Controller name

• .HWI file name

• Test system name

Shortcut command To create a System Loader shortcut command line, first specify the
line application (sysload), then the desired station options.

The syntax of the shortcut command line is critical. If you do not use a
supported command-line format, the shortcut will not work.

To view a list of available Station Builder command-line options, enter

sysload /H. These options are also described in the following table.

Note If the parameter name contains spaces (for example, test 257.000),

Command Line Options and Shortcuts

the name must be enclosed in quotation marks (“test 257.000“).

The System Loader application only supports the decorator-based

command-line format. See “Decorator-Based vs. Precedence-Based
Formats” on page 717 for more information about this format..

System Loader Command-Line Options (part 1 of 2)

DESCRIPTION OPTION ABBREVIATION1 DEFAULT VALUE EXAMPLE

Launch simulated /DSP /DSP None

DSP

Launch simulated /Sup /Sup None

Supervisor

Minimize launch /Minimize /Min None

applications

Load simulated /Simulation /Sim None

system

System name /System /Sy None

.HWI /Hwi /Hw None /Hwi tsiis.hwi

Model 793.00 System Software 713

 System Loader Shortcuts

System Loader Command-Line Options (part 2 of 2)

DESCRIPTION OPTION ABBREVIATION1 DEFAULT VALUE EXAMPLE

Controller name /Controller /Cont None /Cont “Control A”

(to connect to)

Unload simulated /UnloadSimulation /Un None

system

Sysload open after /NoExit /NoE None

load completed

Display the ? or /Help /H None

System Loader
command-line
options

1. Option names can be abbreviated to anything that is unique.

Command line Sysload /Cont “Control A”

example
Command Line Options and Shortcuts

714 Model 793.00 System Software

 Basic TestWare Shortcuts

Basic TestWare Shortcuts

For Basic TestWare you can use a shortcut to automatically specify the
following parameters:

• Test name

• Station name

• System name

• Controller name (to connect to)

Shortcut command To create a Basic TestWare shortcut command line, first specify the
line application (btw), then the desired station options.

The syntax of the shortcut command line is critical. If you do not use a
supported command-line format, the shortcut will not work.

To view a list of available Station Builder command-line options, enter

btw /H. These options are also described in the following table.

Command Line Options and Shortcuts

Note If the parameter name contains spaces (for example, test 257.000),
the name must be enclosed in quotation marks (“test 257.000“).

The Basic TestWare application supports two command-line formats:

decorator-based and precedence based. See “Decorator-Based vs.
Precedence-Based Formats” on page 717 for more information about
these formats.

Basic TestWare Command-Line Options (part 1 of 2)

DESCRIPTION OPTION DEFAULT VALUE EXAMPLE
ABBREVIATION1
Test name /Test Name /T None /T FirstTest
Station (to /Station /St None /St practice.cfg
connect to)

System name /System /Sy None /Sy “810 mat test”

Model 793.00 System Software 715

 Basic TestWare Shortcuts

Basic TestWare Command-Line Options (part 2 of 2)

DESCRIPTION OPTION DEFAULT VALUE EXAMPLE
1
ABBREVIATION
Controller name /Controller /Cont None /Cont 001
(to connect to)

Display the BTW ? or /Help /H

command-line
options

1. Option names can be abbreviated to anything that is unique.

Command line btw /Cont 001

example
Command Line Options and Shortcuts

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 Decorator-Based vs. Precedence-Based Formats

Decorator-Based vs. Precedence-Based Formats

The Station Manager, Station Builder, and Basic TestWare applications
support two command-line formats. The System Loader application
supports the decorator-based format only.

• Decorator-Based Command Line Format

This command line format requires a prefix for each parameter in

the command line.

• Precedence-Based Command Line Format

This command line format does not require prefixes, but

parameters must be listed in a specific order.

Decorator-Based Command Line Format

The decorator-based command line format requires a prefix to identify
each station parameter.

When you are creating a decorator-based command line, keep in

Command Line Options and Shortcuts

mind:

• The order of the parameters is not important.

• Prefixes can be spelled out or abbreviated in the command line.

• The prefix and the parameter must be separated by a space.

• If the parameter name contains a space (for example, parameter

set 2), it must be enclosed in quotation marks.

Model 793.00 System Software 717

 Decorator-Based vs. Precedence-Based Formats

Decorator-based Use the following example as a reference when you create your
command line decorator-based command line.
example
Assume you want to start Station Manager with the following
command-line options:

• Configuration file name = test.cfg

• Parameter set name = parm set 1

• Interlock chain = 1

• Restore views = saved

• User level = tuning

• Password = Tuning (case-sensitive)

The decorator-based command line should look like this:

C:\tsiis\ntbin\Stmgr.exe /St test.cfg /Par “parm set 1” /I 1 /V saved /U tuning /Pas Tuning

Keep in mind:
Command Line Options and Shortcuts

• There must be a space between the original command line entry

and your first prefix.

• Each parameter must be preceded by the correct prefix.

• If the parameter name contains a space, the parameter name must

be enclosed in quotation marks.

• Password is the only parameter that is case-sensitive.

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 Decorator-Based vs. Precedence-Based Formats

Precedence-Based Command Line Format

The precedence-based command line format does not require prefixes.
This format is simpler, however, parameters must be listed in a specific
order.

When you are creating a precedence-based command line, keep in

mind:

• Parameters must be defined in the proper order (see “Command-

line parameter order” on page 719).

• The parameters must be separated by a space.

• You do not have to define all parameters, but if you want to

specify a parameter that is recognized later in the order, you have
to define all of the preceding parameters.

• If the parameter name contains a space (for example, parm set 2),
it must be enclosed in quotation marks.

Command-line In a shortcut command line, options are recognized in the following

parameter order order:

Command Line Options and Shortcuts

Station Manager

1. Configuration file name

2. Parameter set name

3. Interlock number

4. RSC name—optional, not available on some systems

5. Restore view option

6. User level

7. User-level password

8. .HWI file name

9. System name

10. Controller name

11. Import parameters file name

12. Application to launch

Model 793.00 System Software 719

 Decorator-Based vs. Precedence-Based Formats

Station Builder

1. Configuration file name

2. .HWI file name

3. Controller name

Basic TestWare

1. Test name

2. Station name

3. System name

4. Controller name

Precedence format Use the following example as a reference when you create your
example precedence-based command line.

Assume you want to start Station Manager with the following

command-line options:

• Configuration file = test.cfg

Command Line Options and Shortcuts

• Parameter set = parm set 1

• Interlock chain = 1

• RSC = rsc-1

• Restore views = no

• User level = tuning

• Password = Tuning (case-sensitive)

The precedence-based command line with these options should look

like this:

C:\tsiis\ntbin\Stmgr.exe test.cfg “parm set 1” 1 rsc-1 no tuning Tuning

Keep in mind:

• There must be a space between the original command line entry

and your first parameter.

• If the parameter name contains a space, the parameter name must

be enclosed in quotation marks.

720 Model 793.00 System Software

 Decorator-Based vs. Precedence-Based Formats

• Password is the only parameter that is case-sensitive.

Omitting parameters Since precedence-based parameters are recognized in a specific order,

the command line will not work if you omit parameters. However, you
can omit one or more parameters in your precedence-based command
line if you include prefixes for each parameter listed after the omitted
parameter.

For example, if you want to omit the interlock chain, RSC, and restore
view parameters in the above example, you must use the user level
and password prefixes (/U, /Pas) to complete the command line.

C:\tsiis\ntbin\Stmgr.exe test.cfg “parm set 1” /U Tuning /Pas Tuning

Command Line Options and Shortcuts

Model 793.00 System Software 721

 Creating a Shortcut

Creating a Shortcut
Before you can create the shortcut command line, you need to create a
shortcut.

How to Create a Shortcut

1. On any folder: Right-click, then select New/Shortcut.

2. Using the displayed Create Shortcut wizard, browse to the folder

where your system software is installed. The default location is
C:\ftiim (for FlexTest IIm), C:\tsiis (for TestStar IIs), or C:\ftgt
(for FlexTest GT).

3. Continue browsing to the ntbin folder, then click on the

application for which you are creating a shortcut (e.g., Stmgr).
Click OK.

4. Add the desired options to the command line displayed on the

wizard using the required syntax and format. Click Next.

5. If you want a shortcut name different than the one selected by the
Command Line Options and Shortcuts

wizard, enter it now, then click Finish.

722 Model 793.00 System Software

 Editing the Shortcut Command Line

Editing the Shortcut Command Line

Edit the shortcut command line to define your desired station settings.
For information on command line formats, see “Shortcut command
line” on page 710.

How to Edit the Shortcut Command Line

1. Right-click the shortcut icon you created, and then click
Properties.

2. In the Properties window, click the Shortcut tab.

3. In the Target box, type your command line.

Note There must be a space between the application file name (e.g.,
Stmgr.exe) and your command line addition.

4. Click OK.

Command Line Options and Shortcuts

Type your command line
here. Be sure to put a
space between
stmgr.exe and the start
of your command line.

Click OK.

Test your shortcut To test your shortcut command line, double-click the shortcut icon you
created.

Model 793.00 System Software 723

 Editing the Shortcut Command Line
Command Line Options and Shortcuts

724 Model 793.00 System Software

Appendix C
793.00 Aero Options
This section describes options unique to the Aero version of 793.00
System Software. These options include:

• A/B Compare— This option allows the user to link two signals
for comparison. The user can set a limit value on the difference of
these two linked signals (A and B).

• Group Detector Mode— Enabling this option puts all main

control mode input signals into four groups: Limits, Extended
Limits, A/B Compare, and Error. Limit actions can only be set for
each group of signals, not for individual signals within a group.

• Extended Limits— Enabling this option allows the user to set

both an upper and lower extended limit for each channel.

• Persistence— Enabling persistence allows the user to set a time

interval that an over limit condition can exist before the limit is
tripped.

• Import/Export Support— Allows import and export of system

settings via text files.

793.00 Aero Options

Model 793.00 System Software 725

 A/B Compare
The A/B Compare option allows you to link two signals for
comparison. The Station Builder interface provides this signal linking
capability.

Signal definition The optional A/B Compare signal is defined on the Control Modes
tab of the Station Builder Channels panel and can only be added on
non-calculated primary modes. The A/B Compare signal name
defaults to the “A” signal name appended with _B (e.g., Channel 2
Force_B), but this name can be edited. Signals A and B must have the
same dimension and default display units. The display units may be
changed in Station Manager and may differ.

.
793.00 Aero Options

726 Model 793.00 System Software

 A/B Compare limits With the A/B Compare option enabled you can set a limit value for the
difference of two linked signals (A and B).

For example, when using dual bridge load cells each bridge is
connected to a separate conditioner. The bridge “A” input is used for
control and bridge “B” input is a monitor. After linking these two
signals using Station Builder, you can set an A/B compare limit that
will trigger a specified action when the difference between the two
signals exceeds the set limit.

Enabling A/B Compare adds a B Inputs icon to the Station Setup

window of Station Manager. Clicking the B input icon opens the B
Inputs panel which displays tabs for calibrating the “B inputs” signal.

Click the A/B Compare tab to set the A/B Compare limit for a control
mode. Select a limit value as a percentage of full scale. If the full scale
range differs for signal A and B, the full scale range of signal A will be
used for the limit value.

Note If an A/B Compare signal is not defined for a control channel,

clicking the B Input icon displays the message: There are no Input
Signals for this Control Channel.

793.00 Aero Options

Model 793.00 System Software 727

 Group detector If the group detector option is enabled, the limit action displayed on
the B Inputs panel is common to all A/B compare signals, and cannot
be set on the A/B Compare tab. You can set the group mode limit
action on the Limit Detectors panel. See “Setting limit actions” on
page 732.

A/B Compare limit Persistence is the time interval that an over limit condition can exist
persistence before a limit is tripped. In this case, when the difference between the
two signals exceeds the set A/B Compare limit for a specified
persistence time, the limit is tripped.

If the persistence option is enabled, the Persistence Value slider is

displayed on the B Inputs panel. To disable persistence, set the
persistence value to zero.
793.00 Aero Options

728 Model 793.00 System Software

Extended Limits
Model 793.00 system software provides only one limit detector for
each input signal. This level of limit detection is not enough to meet
the safety and data acquisition needs of Aero testing. AeroPro software
needs at least two sets of limit detectors (inner and outer) to fire
actions when a limit is tripped.

The set of inner limits correspond to the Upper Limit and Lower Limit
provided with all 793.00 software. The set of outer limits are the
Extended Upper and Lower Limits available for Aero applications. The
Extended Limits option is selected automatically when installing 793
for Aero software.

Extended Upper Limit

1 cm Upper Limit

0 cm

-1 cm Lower Limit

Extended Lower Limit

With the Extended Limits option enabled, the Inputs panel Limits tab
will display Extended Upper Limit and Extended Lower Limits. Set
all limits and limit actions.

Note If A/B Compare is being used, the Limits tab will not be available on
the B Inputs panel.

Group detector If the group detector option is enabled, you cannot set any limit
actions on the Inputs panel Limits tab. You can set the group mode
limit action on the Limit Detectors panel. See “Setting limit actions”
on page 732.

Limit persistence Persistence is the time during which an over limit condition can exist
before a limit is tripped. 793.00 Aero Options
One common use of persistence is for static structure testing which can
produce spikes as test specimen and structure linkages “snap” into
place. Setting a persistence value allows the system to overlook these
short duration spikes and not shut down.

Model 793.00 System Software 729

 To disable persistence, set the persistence value to zero.

The set persistence value applies to all limit detectors displayed on the
Inputs panel.
793.00 Aero Options

730 Model 793.00 System Software

Group Detector Option
Limits When a configuration has the group detector option enabled, Station
Manager will put all main control mode input signals in four groups:
Limits, Extended Limits, A/B Compare, and Error groups.

In group mode, when limits are tripped, the group action will be fired
for each signal that exceeds its limit, but no more than once per clock
tick.

Limits Summary The Limits Summary tab on the Limit Detectors panel summarizes the
upper/lower limit values and status of the selected limit detectors. With
the extended limits option enabled for Aero applications, this tab also
displays extended upper/lower limits.

Use List to select the limit detectors you want to display. You can
choose to display the status of all system limit detectors (All
Detectors) or limit detectors on a selected system channel.

See “Limits Summary Tab” on page 375 for a description of this tab for
793.00 system software applications.

793.00 Aero Options

Model 793.00 System Software 731

 Setting limit actions When group detector mode is enabled, all of the individual channel
limit actions cannot be set on the Limits tab of the Inputs or B Inputs
panel. You can set a common limit action for a group using the Limit
Detectors panel as shown below. This example shows the Upper
Limit action setting for a group.
793.00 Aero Options

732 Model 793.00 System Software

Import/Export Support
AeroPro software can now import and export system settings via text
files. Some of the features of import/export support include:

• Calibration, PIDF tuning, and limits data can be imported into or

exported from Station Manager.

• Data is transferred via an ASCII file format that can be easily read
into Excel.

• Data import/export can be implemented for a few or all channels.

• Data import/export is not possible when system hydraulics are on.

Exporting Data
Use the Export Parameters window to complete the following data
export procedure:

1. Ensure that system hydraulics is off.

2. On the File menu in Station Manager, select Export

Parameters... to open the Export Parameters window.

793.00 Aero Options

Model 793.00 System Software 733

 3. Ensure that the Parameters File name is correct.

The default parameters file name is name of the station with a .txt
extension located in the default import/export directory (e.g.,
C:\ftgt\import_export\Aero1.txt).

To change the parameters file, click the Browse button, then use
the standard “file save” window to enter the required parameters
file name.

4. Select an export type.

Select channels, channel groups, or signals from the Export

type: list.

5. Select the items to export on the Select items to export list. List
items vary based on the export type selected.
Note If you choose to export signals, Select items to export lists all
signals that have “real“ hardware attached or that are calculated
inputs.

6. Select parameters to export from the Select parameters to

export list.

Parameters are grouped in categories (e.g., valve settings or tuning

parameters when exporting channel data).

7. Click the Export button to export the selected parameters to the

parameters file.

Export Parameters (part 1 of 2)

ITEM DESCRIPTION
Parameters File: Displays file name to which the selected information will be
exported. The default parameters file name is name of the station
with a .txt extension located in the default import/export directory
(e.g., E:\tsiim\import_export\Aero1.txt).
Browse This button allows you to change the parameters file. Click Browse
to open the standard “file save” window, and then select the
793.00 Aero Options

required parameters file name.

Export type: Allows selection of the type of data you need to export. Select
channels, channel groups, or signals from the displayed list.

734 Model 793.00 System Software

 Export Parameters (part 2 of 2)
ITEM DESCRIPTION
Select items to export Allows selection of data items to export from a list that varies with
the export type selected.
Select parameters to Allows selection of parameter categories to export from a list that
export varies with the export type selected.
When exporting channel or channel group data, select from the
following parameter categories: Valve Settings, Tuning Parameters,
Null Pacing Settings, APC Settings, PVP Settings, and Dual Comp
Settings.
When exporting signals, select from the following parameter
categories: Limits Settings, Fullscale Settings, Conditioner Settings,
and Shunt Information.
Export This button initiates export of the selected parameters to the
parameters file.
Cancel This button cancels the export parameter selection process.

793.00 Aero Options

Model 793.00 System Software 735

 Importing Data
Note Before importing data ensure that system hydraulics are off and
Calibration access level is selected.

Note When importing an input signal with multiple ranges, the name of
the range in the input file must match the currently selected range
on the input signal.

1. On the File menu in Station Manager, select Import

Parameters... to open a Parameters File window.

2. Select the input file from the Parameters File window. An Import
Parameters window will open which displays the type of
information to be imported (channels or signals) and list of
parameters found in the selected input file.
793.00 Aero Options

736 Model 793.00 System Software

 793.00 Aero Options

Model 793.00 System Software 737

 3. Ensure that the Parameters File name is correct.

The default parameters file name is name of the station with a .txt
extension located in the default import/export directory (e.g.,
C:\ftgt\import_export\Aero1.txt).

To change the parameters file, click the Browse button, then use
the Parameters File window to enter the required parameters file
name.

4. Select parameters to import from the Select parameters to

import list.

5. Click the Import button to import the selected parameters to the

parameters file.

Import Parameters
ITEM DESCRIPTION
Parameters File: Displays file name to which the selected information will be
imported. The default parameters file name is name of the station
with a .txt extension located in the default import/export directory
(e.g., C:\ftgt\import_export\Aero1.txt).
Browse This button allows you to change the parameters file. Click Browse
to open the Parameters File window, and then select the required
parameters file name.
Import type: Displays the type of information to be imported (channels or
signals).
Select parameters to Allows selection from a list of parameters found in the selected input
import file.
Import This button initiates import of the selected parameters from the
selected input file to the current system settings.
Cancel This button cancels the import parameter selection process.
793.00 Aero Options

738 Model 793.00 System Software

File Format
Each import or export file contains a single table. A typical table begins
with three comment and/or empty lines, followed by a line with table
type and version number. The next two lines contain table headings
that specify which parameters are stored in the file. The remaining
lines of the file contain the parameter data.

All channels, signals, or parameters are described using both their

display name and internal name. Channel, mode, and signal names
cannot be changed in an imported file.

A specific parameter may not have meaning for a particular channel or

signal. For example, Phase is not used for all signals. When a
parameter has no meaning for a channel or signal, the entry in the
export file is left blank. On import, the contents of unused parameters
should be empty.

Channel format The first four columns of a channel table are: Channel Name, Channel
Internal Name, Control Mode Name, and Control Mode Internal Name.

Each exported channel has one line with the channel name and any
channel-specific parameters. This is followed by lines with the channel
and mode names that contain mode-specific parameters. A typical
exported channel table is shown below.

793.00 Aero Options

Model 793.00 System Software 739

 Signal format The first two columns of a signal table are: Signal Name and Signal
Internal Name. The remaining columns display signal parameters. A
typical exported signal table is shown below.
793.00 Aero Options

740 Model 793.00 System Software

Index

Symbols Application Control panels 483

Applications menu 408
applying hydraulics when a channel is saturated 190
Arbitrary End-Level Compensation (ALC)
.cfg files. See station configuration files about 215
.hwi files. See hardware interface files configuring 217
arrays, in calculations 470
auto tuning 532
A auto-tuning 569
how to 570
Auto-Tuning control panel 495
Auxiliary Inputs
A/B Compare about 72
defining 726

Index
how to create 73
limit persistence 728 panel 105
limits 727 panel tabs 360, 361
acceleration compensation 705, 725 Summary panel 360
access level 277 Auxiliary Inputs panel 361
about 129
going to a higher level 129
setting 129
Action Lists tab 457
actions, to digital inputs 243
B
active feedback signal
saturated 186 Basic TestWare
actuator buffers 612
manually positioning with the Manual Command create a test 607
window 192 home control 622
manually positioning with the Remote Station launching 607
Controller 693 Options Editor 663
Adaptive Inverse Control (AIC) overview 604
about 204 Peak Detectors 619
configuring 206 print preview, toolbar 631
tuning 208 running a test 626
Adjustments tab shortcuts 715
channel limited channel (CLC) control modes 339 starting 607
PIDF control modes 337 test commands 608
Advanced Sensor Data window 446 Test Counters 624
Aero data test files 628
exporting 733 toolbar 644
importing 736 Begin/End times of tapered waveshapes 429
Aero options 725 buffers, Basic TestWare 612
A/B Compare 726
extended limits 729
group detector mode 731
import/export 733
setting group limit actions 732
C
AIC tab 350
ALC tab 353 cabling
Amplitude and Phase Control (APC) RSC to controller 686
about 201 calculated input signal
configuring 202 saturated 187
APC tab 348 saturation 187

Model 793.00 System Software 741

 Calculated Inputs Channels panel 97
about 61, 66 Control Modes tab 100
how to create 68 External Command tab 104
Calculated Outputs General tab 99
about 42, 67 command lines
Drive tab 388 how to edit shortcut 723
how to create 67 Command Options
panel 384, 385, 386 Begin/End times 429
calculated resources Ramp Times 428, 429
about 66 Taper Times 429
Calculation Definition panels 461 Command Options tab 423
Calculation Editor window 459 Command Plus Error channels
calculation grammar about 41
arrays 470 how to create 52
built-in functions 468 command sources 522
error handling 475 compensation
literal numbers and expressions 466 about 194
simple expression acceleration 705, 725
about 465 Adaptive Inverse Control (AIC)
built-in functions 468, 469, 470 about 204
Index

comments 465 configuring 206, 305

data types 466 tuning 208
operators, in calculations 467 Amplitude and Phase Control (APC)
user-defined functions 473, 475 about 201
variables 469 configuring 202, 304
Calculation Parameters panel 389 Arbitrary End-Level (ALC)
Calculation tab 387 about 215
calibration configuring 217, 306
parameter display 308 Compensators tab 302
shunt 250 Null Pacing
shunt, performing 251 about 195
calibration file configuring 196, 302
range definition 136 Peak/Valley Compensation (PVC)
Calibration tab 313, 318 about 198
Station Signals panel 366 configuring 199, 303
Channel Groups Peak/Valley Phase (PVP)
about 259 about 219
Master Command 261 configuring 220, 307
Channel Limited Channel (CLC) control modes 60 conditioner
about 590 polarity 543
how to create 63 Conditioner tab, 3-stage valve drivers 334, 336
tuning 592 conditioners 239
Channel Options window 418 full-range 239
Channel Status Panel configuration files. See station configuration files
Channel Summary tab 295 configuring signals for external readout 179
Compensators tab 302 control modes
AIC 305 about 60
ALC 306 characteristics 522
APC 304 CLC 60
null pacing 302 creating 60
PVC 303 displacement 523
PVP 307 Dual Compensation 61
Drive tab 299 force 523
3-stage valve driver 300 PIDF 60
dual valve driver 299 strain 523
Channel Status panel 295 Control Modes tab 100
Calibration tab 308 controller scope
Full Scale tab 297 tuning use 539
Fullscale tab 297 counters (Basic TestWare) 624
Tuning tab 298

742 Model 793.00 System Software

custom actions digital outputs
configuring 245 about 71
defining 247 how to create 71
cyclic function(Basic TestWare) Digital Outputs Summary tab 368
how to define 609 dimensions, for calculations 466
Directories tab 414
displacement
control modes 523
D displacement tuning
adjusting integral gain 582
prerequisites 577
data acquisition (Basic TestWare) procedure 577
about 611 when to tune 577
level crossing 618, 654 Display menu
peak/valley 616, 651 Station Manager 289
running max/min 617, 653 displaying hidden windows with the SDO 675
test setup 649 dither
timed 614, 649 about 563
Data file format adjusting 564
Excel 657 Drive panel

Index
import/export (Aero) 739 three stage valves 329
Lotus 657 two stage valves 327
Microsoft Excel 657 Drive tab
data file header (Basic TestWare) 613 Calculated Outputs 388
data types, for calculation 466 Dual Compensation mode 61
decorator-based command line format 717 about 594
Define Actions tab 448 editing 102
action group panel 455, 456 gain settings, about 595
digital output panel 454 how to create 64
hydraulics/powers panel 453 tuning 597
message panel 450 dual valve tuning 559
ramp to panel 451
stop at level panel 452
Delta P stabilization 529
Derivative gain 527 E
Detectors
panel tabs 373
window 504 electrical zero offset 152
detectors auto zeroing 155
about 223 manual zeroing 155
errors Emergency Stop (RSC) 691
about 235 emergency stop on the RSC 691
monitoring 238 enabling limit detectors 241
setting 236 Error messages on the RSC 701
limits error signal 537
about 226, 231 Error Summary tab 378
group mode (Aero) 732 errors
setting 227, 231 about 235
monitoring 230, 234 in calculations 475
Digital I/Os window 508 monitoring 238
digital inputs setting 236
about 70 Event-Action Editor
how to create 70 about 246
Digital Inputs panel 369, 372 window 448
Digital Inputs Summary tab 367 Excel
digital inputs/outputs Data file format 657
about 243 export
actions 243 Aero data 733
manually triggering outputs 248 expressions, in calculations 465
responses, configuring 245 extended limits 729

Model 793.00 System Software 743

 External Command Control Panel 493
External Command Inputs G
about 74
how to enable 74
External Command tab 420 gain
Derivative 527
Dual Compensation mode 595
Feed Forward 528
F Integral gain, about 525
Proportional, about 525
Stabilization 529
Feed Forward gain 528 Graph Settings tab for the Scope 398
feedback group detector mode
configuring external 148 setting limit actions 732
invalid active
about 187
correcting 189
offsetting 150 H
out of range 186
saturated 186
Index

file format hardware interface files (.hwi)

Aero import/export 739 about 37
File menu 279 defining RSC parameters 685
Station Builder 84 hardware resources
Station Manager 279 about 37
Filter tab (Station Manager) 341 how to allocate with Station Builder 38
filters Hardware tab
enabling 600 Station Signals panel 364
tuning 600 Help menu
force tuning Station Builder 92
integral gain adjust 589 Station Manager 482
prerequisites 584 hiding windows with the SDO 675
procedure 584 home control
Forward Loop Filter Types about 622
Band-stop 341 defining home position 623
Forward Loop Filter types how to use 623
Band-stop 341 how to quit the Station Desktop Organizer 676
Low Pass 341 HPS controls (RSC) 691
Low-pass 341 HSM
forward loop filter, about 531 RSC controls 690
Frequency Mode tab, Setup for Scope window 401 HSM controls (RSC) 690
Full Scale tab HSM power control 44
Station Signals panel 365 FlexTest IIm/CTC controllers 44
full-range conditioners 239 TestStar IIs controllers 44
function generation in Basic TestWare 608 Hydraulics
Function Generator about 183
programming 255 applying 185
random function 492 hydraulics
function generator warm-up 546
random 534
Function Generator Control Panel 485
functions
for calculations, built-in 468 I
user-defined, in calculations 473
475
import
Aero data 736
import/export
Aero system settings 733
file format (Aero) 739

744 Model 793.00 System Software

initial limit detectors 241 menu
Inner Error tab 380 Station Builder
Inner Loop tab for 3-stage valve drivers 333 File 84
inner loop, tuning three stage valves 549 Help 92
innerloop main 83
tuning 549 Window 91
input signal Station Desktop Organizer
saturated 186 main 678
Inputs tab 508 Station Manager
integral gain Applications 408
tuning adjust 582 Display 289
Integral gain, about 525 File 279
Interlock indicator (RSC) 690 Help 482
interlocks 186 main 274
invalid active feedback 187 Tools 409
Message Log Add window 406
Message Log Print window 407
message logs
L Basic TestWare
using 632

Index
window description 664
launching Station Manager
Basic TestWare 607 about 266
Station Builder 36 archiving 272
Station Desktop Organizer 669 printing 268
Station Manager 121 setting what gets logged 271
level crossing data acquisition 618, 654 user entry
limit actions adding 269
setting, group detector 732 deleting 270
limit persistence 729 Message Logs window 403
A/B Compare 728 Message window displays on the RSC 701
limits Meters
A/B Compare 727 about 172
about 226, 231 configuring 173
extended, for Aero 729 deleting 175
monitoring 230, 234 Setup window 394
setting 227, 231 window 392
Limits Summary tab 375 Microsoft Excel
Limits tab 323 Data file format 657
Lotus monitoring waveforms 536
Data file format 657 areas of interest 536
low rate, about 43 error signal 537
Lower Limits tab 376, 382 using controller scope 539
using oscilloscope 539
monotonic function (Basic TestWare)
M how to define 610
moving the Station Desktop Organizer taskbar 671
MultiPurpose TestWare page (RSC) 700
function key descriptions 700
Manual Command window 510 MultiPurpose TestWare Page of the RSC 684
using Park/Ride buttons 512 multi-station testing 79
manually positioning the actuator creating multiple stations 80
using the Manual Command window 192
using the Remote Station Controller 693
Master Command Groups
creating channel groups 261
selecting channel groups 262
Master Command tab 421, 440
Master Span Group 263
Master Span tab 418

Model 793.00 System Software 745

 N Peak Detectors (Basic TestWare)
about 619
how to configure 620
Peak/Valley Compensation (PVC)
Navigation pane about 198
in Station Builder 95 configuring 199
in the Station Setup window 294 peak/valley data acquisition 616, 651
Null Pacing compensation Peak/Valley Phase (PVP) Compensation
about 195 about 219
configuring 196 configuring 220
Null Pacing tab 343 persistence 729
numbers, for calculations 466 A/B Compare limits 728
PIDF control modes 60
how to create 62
O manual tuning 576
tuning, about 575
polarity
conditioner 543
offset servovalve 543
about 149 positioning the Station Desktop Organizer 671
Index

auto 150 precedence-based command line format 719

electrical zero 152 preview
manual 150 station configuration file 78
signals, scope 165 Print
Offset/Zero tab 321 Parameters to File dialog box 288
Open Parameter Set window 283 Preview window 286
Open Station window 281 preview window toolbar 287
Options Editor preview window toolbar (BTW) 631
Basic TestWare 663 preview window toolbar (Station Builder) 88
options, Aero software 725 program and control channels
oscilloscope about 40
tuning use 539 how to create 44
out of range feedback 186 program channels
Outer Error tab 380 about 40
outer loop, tuning, about 568 program only channels
Outputs tab 509 about 42
overview how to create 55
Basic TestWare 604 program outputs
Station Builder 32 about 253
Station Desktop Organizer 668 adjusting 253
Station Manager 119 program with feedback channels
about 41
how to create 48
P Proportional gain, about 525
PVC tab 346
PVP tab 355
parameter set
about 123
deleting 126
opening 127
R
previewing 128
saving, new name 126 Ramp tapered wave shape 491
Parameters Definition panel 477 Ramp Times
Park/Ride Command Options 428
setting values 264 Ramp wave shape 490
setting values as group 265 random functions 534
using 264 Random functions, Function Generator 492
range example 240
ranged 239

746 Model 793.00 System Software

ranged conditioners 239 save
ranges in sensors 239 station parameter set 582
ranges, sensor 239 tuning parameters 519
Readout Adjust panel 359 Save Parameters As Dialog Box 284
Readout Summary panel 358 scaling, scope 162
readouts scope
about 69 about 159
how to create 69 auto scaling 162
Readouts Summary panel 358 offsetting signals 165
reconfigurable signals 72, 362 plot
refreshing the Station List frequency, setting up 160
Station Desktop Organizer 676 time, setting up 159
Remote Setpoint Adjust x-y, setting up 161
about 75, 258 setting up 159
configuring 258 sync current channel setup 169
how to set up 75 time scale, adjusting 166
Knob panel 391 time signals, viewing 167
window 515 Scope window 395
Remote Station Controller selecting ranges 240
changing control modes 698 sensor

Index
controller connections 686 ranges 239
creating Signal Pages 704 Sensor File Editor window 442
defining in .hwi file 685 Sensor tab 310
display controls 694 sensors
Emergency Stop 691 about 131
emergency stop 691 assigning a file 141
how to enable 687 calibration files 131
HPS controls 691 creating a file 135
HSM controls 690 ranges 239
Interlock indicator 690 Transducer ID 146
Interlock reset 690 Transducer ID, saving data to 147
manually positioning the actuator 693 serial connections, update rates on 43
MultiPurpose TestWare page 700 servovalve
Reset button 690 polarity check 545
Station Manager page 697 setting polarity 542
Station Stop 691 Setpoint
Test controls 691 adjusting 257
test controls 691 setting time 431
zeroing a sensor signal 698 Setpoint and Span window 513
Reset button (RSC) 690 Setup for Scope window 398
Rig Command shortcuts
setting values 264 Basic TestWare 715
setting values as group 265 creating 722
using 264 Station Builder 712
Rig Commands tab 438 Station Manager 710
RSC tab 434, 436 system loader 713
running max/min data acquisition 617, 653 shunt calibration 250
about 250
performing 251
Shunt tab 319
S Signal Auto Offset window 503
Signal Lists
displaying 177
saturated active feedback signal 186 editing 178
saturated calculated input signal 187 Signal Lists on the RSC 703
saturated feedback 186 Signal Lists tab 432
applying hydraulics 190 Signal Pages on the RSC 704
saturation of calculated input signal 187 signal polarity 133
Sine tapered wave shape 491
Sine wave shape 490

Model 793.00 System Software 747

 Span Station Desktop Organizer
adjusting 257 displaying hidden windows 675
setting time 431 hiding windows 675
specimens 535 how to quit 676
changing 518 launching 669
tuning with 535 menu 672
tuning without 536 moving taskbar 671
Square tapered wave shape 491 moving the taskbar 671
Square wave shape 490 positioning 671
square wave shape 533 refresh station list 676
Stabilization Filter types starting 669
1 Hz High-pass 342 starting an application 675
Band-pass 342 starting manually 669
Stabilization gain 529 Status Indicators 681
stabilization, signal 65 Stop Button 680
how to create 65 Station Log tab 410
starting Station Manager
Basic TestWare 607 controls and displays 273
Station Builder 36 demonstration mode 122
Station Desktop Organizer 669 launching 121
Index

Station Manager 121 main menu 273

starting applications with the SDO 675 overview 119
Station 710 print preview toolbar 287
Station Builder 31 print preview window 286
controls and displays 81 shortcuts 710
defining A/B Compare 726 starting 121
file menu 84 toolbar 275
help menu 92 Station Manager page (RSC)
launching 36 changing control modes 698
main menus 83 function key descriptions 697
navigation pane 95 zeroing a sensor 698
overview 32 Station Options window 410
print preview, toolbar 88 Station Setup window 290
reconfigurable signals 72 Station Signals panel 363
shortcuts 712 Calibration tab 366
starting 36 Full Scale tab 365
window menu 91 Hardware tab 364
station configuration files 34 using 176
about 123 Values tab 363
creating multiple stations 80 Station Stop (RSC) 691
file setup 34 Station View Options tab 416
how to create 36 Station Views
how to open (Station Builder) 76 about 130
how to preview (Station Builder) 78 saving and restoring 130
how to save (Station Builder) 77 Status Indicators
opening 124 Station Desktop Organizer 681
Station Configuration window 94 Stop Button
expanding channel lists 96 Station Desktop Organizer 680
navigation pane 95 strain
Station Controls panel 498 control modes 523
toolbar 498 Sync Current Channel
Station Controls panel toolbar 501 using 169, 357
Sync Station Channel
using 169, 357
system hydraulics, warm-up 546
system loader shortcuts 713
system rate, about 43
System Resources window 90
system warm-up 133

748 Model 793.00 System Software

T tuning
about 540
acceleration stabilization 530
auto-tuning 569, 570
tapered wave shapes Channel Limited Channel (CLC) control modes 590,
ramp 491 592
sine 491 checklist 520
square 491 compensation 518
temperature controllers control modes 522
how to program (TSIIs) 58 control range adjust 524
test commands (Basic TestWare) controls 524
about 608 creating a program 532
defining cyclic 609 Delta P stabilization 529
defining monotonic 610 Derivative gain, about 527
Test controls (RSC) 691 displacement 577
Test Counters (Basic TestWare) dither
about 624 about 563
how to configure 625 adjusting 564
test files (Basic TestWare) Dual Compensation mode
opening 629, 645 about 594

Index
previewing 630 gain 595
printing 631 tuning 597
saving 629, 645 dual valve 559
test setup (Basic TestWare) Feed Forward gain, about 528
Command tab 647 filters
Data Acquisition tab 649 about 600
Data File tab 656 enabling 600
Detectors Setup tab 659 force control modes 584
Detectors Summary tab 661 forward loop filter, about 531
Home tab 658 guidelines 519
Test Log tab 662 inner loop 549
window 647 innerloop 549
timed data acquisition 614, 649 Integral gain, about 525
toolbar manual
Basic TestWare 644 about 575
Station Builder 81 how to 576
Station Controls panel 498, 501 monitoring waveforms 536
Station Manager 275 outer loop, about 568
Tools menu prerequisites 521
Station Manager 409 Proportional gain, about 525
Trace Settings tab in the Scope window 400 selecting amplitude 534
Transducer ID selecting frequency 534
about 145 specimens
assigning 146 changing 518
saving data to module 147 tuning with 535
transitions times between run, stop, and hold 426 tuning without 536
Stabilization gain, about 529
three stage valves 549
valve balance 557
waveforms 532
when to tune 520

U
Unit Assignment Set (UAS) window 479
Unit Selection tab 412

Model 793.00 System Software 749

 update rates
about 42
using serial connections 43
Upper Limits tab 376, 382

V
valve balance, adjusting 557
valve polarity 542
Valve tab for 3-stage valve drivers 329
valves
polarity check 545
variables, in calculations 469

W
Index

warm-up procedure 546

Warning messages on the RSC 701
Wave shapes
ramp 490
ramp tapered 491
random function 492
sine 490
sine tapered 491
square 490
square tapered 491
waveforms 532, 536
areas of interest 536
error signal 537
monitoring 536
Window menu
Station Builder 91

Z
zeroing a sensor
using the RSC 698

750 Model 793.00 System Software