GMW
USER’S MANUAL
MODEL: 5201
MODEL: 5201-MRD-MPS
PROJECTED FIELD ELECTROMAGNET
MOTORIZED ROTATING DRIVE
Date Sold:____________
THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION PROPRIETARY TO GMW ASSOCIATES. IT MUST
NOT BE REPRODUCED OR DISCLOSED TO OTHERS OR USED IN ANY WAY EXCECPT FOR THE INSTALLATION,
OPERATION OR MAINTENANCE OF GMW ASSOCIATES PRODUCTS.
File No: M5201a Projected Field Electromagnet.doc Revision Date: April 10, 2003
_____________________________________________________________________________________
GMW
955 Industrial Road, San Carlos, CA 94070 Tel: (650) 802-8292 Fax: (650) 802-8298
Email: sales@gmw.com Web site: http://www.gmw.com
PROPRIETARY
TABLE OF CONTENTS
SPECIFICATIONS Section 1
5201 Electromagnet Specifications
5201 Motorized Rotational Drive Specifications
WARNINGS [ Refer to this section before operation of Electromagnet System ] Section 2
INSTALLATION Section 3
Mounting Position
Electrical Connections
Electrical Interlocks
Water Cooling
Software
OPERATION Section 4
Software Description
Magnet System Software Operation
Electromagnet Operation
Motorized Rotating Drive Operation
Automatic Operation of Electromagnet System and Motorized Rotating Drive.
Logging of Electromagnet System, and Motorized Rotating Drive Parameters.
MAINTANENCE Section 5
Electromagnet
Motorized Rotational Drive
EXCITATION CURVES Section 6
Field versus Current
TEST DATA Section 7
Fiel d Uniformity
DRAWINGS Section 8
Drawing 11901960 Electromagnet/Motorized Rotation Drive General Assembly
Drawing 11901860 Electromagnet General Assembly
Drawing 11901950 Electromagnet Electrical Assembly
Drawing 13900420 Electromagnet Electrical Wiring.
Drawing 13900430 Electrical Wiring Kepco Programming Plug
Drawing 11901910 Electromagnet Terminal Block Assembly
Drawing 11902050 Motorized Rotation Drive General Assembly [no motor drive fitted]
Drawing 11902060 Motorized Rotation Drive General Assembly [with motor drive fitted]
Drawing 11902070 Motor Drive General Assembly
Drawing 13900350 Motorized Rotation Drive Electrical Wiring
Drawing 11902080 Service Panel Assembly
Drawing 11902090 Spool Assembly
Drawing 11902100 Belt Tensioner Assembly
Drawing 11902110 Stop Block Assembly
Drawing 11902120 Worm Mount Assembly
SOFTWARE REVISION LIST Section 9
Section 1
SPECIFICATIONS
Model: 5201 Electromagnet Specifications
Field: (at max current) Bx.= ±0.3T (3000G)
(X,Y,Z = 0, 0, 4mm)
Projected Field Region (for Bx) X = ± 2mm
Y = ± 5mm
Z = 0 to 12mm
Coil:
coil resistance (20°C) 0.85 Ohm
max resistance (hot)* 1.02 Ohm
max power 20A/20V (400W)
Self Inductance:
Cooling: 0.5 Litre/min 1.0 bar [14 psid]
Thermal Interlock: Open circuit above 75° C (167° F)
Dimensions: Drawing 11901860
70.0 mm W x 60.0 mm D x 120 mm H
2.8 inch W x 2.4 inch D x 4.7 inch H
Weight: 4 kg (9 lb)
*CAUTION - The value of maximum coil resistance given should not be exceeded.
At this resistance the coils are at maximum safe temperature for continuous operation.
1-1
SPECIFICATIONS
Table 1. Model 5201-MRD Specifications
Rotation Angle: [from zero point] +/- 200 deg max
Rotation Repeatability: +/- 0.2 deg max
Rotation Accuracy: +/- 0.5 deg max
Mechanical Stops: approx. +/- 210 deg max
Limit Switches: approx. +/- 200 deg max
Homing Switch : 0.0deg
Drive System:
Gear type Worm/Worm Gear
Mechanical reduction 100:1
Stepper Motor:
Motor type VS13B-SFRIO
Motor torque 0.5Nm (73 oz.in)
Motor frame size 17
Stepper Motor Controller:
Model Compumotor Zeta 6104
AC Power 115V AC only
Rotation Axis Scaling: approx. 6944 steps/deg
Dimensions: Drawing 11901960
200 mm W x 200 mm D x 193 mm H
7.9 inch W x 7.9 inch D x 7.6 inch H
Weight: 4 kg (9 lb)
1-2
Section 2
WARNINGS
REFER TO WARNINGS BELOW BEFORE OPERATING ELECTROMAGNET SYSTEM
ELECTROMAGNET
1. Safety
In operation the magnet fringing field in the vicinity of the pole gap is in excess of 0.5mT (5G). This can cause
mal functioning of sensitive electronic and magnetic components. We recommend that warning signs are posted
indicating that a magnetic field may be present.
2. Ferromagnetic Objects
During operation the magnet exerts magnetic attraction towards ferromagnetic objects in the near vicinity of its
pole gap. Keep ferromagnetic items clear!
3. Arcing
This magnet stores energy in its field during operation. Do not disconnect any current lead while under load or
the magnetic field energy will be discharged across the interruption causing arcing and possible damage to
electronic circuits.
4. Coil Hot Resistance
Do not exceed the maximum coil hot resistance given in the specifications or coil overheating and possible
damage may occur.
5. Watches, Credit Cards, and Magnetic Disks
Do not move magnetically sensitive items into the close vicinity of the magnet pole. Even some anti-magnetic
watches can be damaged when placed in close proximity to the pole gaps during operation. Credit cards, and
magnetic disks are affected by magnetic fields as low as 0.5mT (5G). Depending on the previous operating
field and the pole gap, the remanent field in the gap can be in excess of 0.5mT (5G) with the magnet power
supply off or disconnected.
---------------------------------------------------------------------------------------------------------
MOTORIZED ROTATIONAL DRIVE
1. Hand Operation
Do not rotate the Motorized Rotating Drive platen by hand. For hand operation the Motor Drive assembly
must be removed. See maintance section for instruction on how to remove the Motor Drive assembly.
2. Obstructions
Keep foreign objects and tools clear of the Motorized Rotation Drive. Ensure the Electromagnet and
Motorized Rotation Drive do not contact obstructions during rotation.
2-1
Section 3
INSTALLATION
HARDWARE
Mounting Position (Refer to drawing 11902050)
The magnet system can be mounting in any orientation, including being completely inverted. The motorized
rotating drive can be adjusted for height and also leveled by following the procedure below.
1. Loosen setscrew [item 19]
2. Screw –in/out foot assembly to adjust height and level as required
3. Retighen setcrew [item 19]
Four M5 mounting holes are provided on the bottom of the Motorized Rotating Drive for inverted mounting or
securing to test fixture etc.
Electrical Connections
The magnet system comes with integrated wiring for the magnet, and motorized rotating drive. Never connect
or remove cables from the magnet system with the AC power energized otherwise damage to the magnet
power supply or MRD stepper motor controller may occur. Follow instruction below for making electrical
connections.
Power Supply (Refer to drawing 11901950 & 13900420)
1. Plug in the magnet cable plug into the back of Kepco BOP power supply.
2. Secure the connecting plug with the two securing thumbscrews.
3. Connect the three sleeved wires to the output connector block on the rear of the Kepco BOP power
supply as detailed below.
• Black Wire with RED sleeve to Output
• Black Wire with BLUE sleeve to Common
• Green wire to Ground
4. Connect GPIB ribbon cable to edge connector on GPIB board.
5. Connect GPIB adaptor into the back of Kepco BOP power supply.
6. Secure GPIB adaptor with the two adaptor securing thumbscrews.
7. Connect GPIB cable to adaptor and secure with GPIB connector thumbscrews.
8. Connect the other end of the GPIB cable to the host computer.
9. Secure GPIB cable with the two GPIB connector securing thumbscrews.
10. Connect Kepco power supply to AC power source with cord set provided.
Motorized Rotating Drive (Refer to drawing 13900350)
1. Plug in the black 9 way plug on the MRD cable into the Motor connector on the Zeta 6104 controller.
2. Plug in the black 4 way plug on the MRD cable into the Limits connector on the Zeta 6104 controller.
3. Plug in the black 4 way plug on the serial communication cable into the Com 1 connector on the Zeta
6104 controller. Connect other end to host computer.
4. Connect Zeta 6104 controller to 115V AC power source with cord set provided.
3-1
Section 3
INSTALLATION
HARDWARE
Electrical Interlocks
The Model 5201 has two temperature switches, Selco part no 802L-075. They are located on the pole/coil
assembly heatsinks and wired in series. The temperature switches are normally closed, opening when the coil
heatsink temperature exceeds 75° C +/5° C.
Water Cooling (Refer to drawing 11901960)
The Model 5201 can be operated to an average coil temperature of 70° C. Assuming an ambient laboratory
temperature of 20°C and a temperature coefficient of resistively for copper of 0.0039/°C, the hot resistance of
the coil should not exceed 20% more than the ambient temperature "cold" resistance. The coil thermostat will
open when either pole/coil heatsink temperature exceeds approximately 75° C. If either temperature switch
opens then the Magnet power supply circuit breaker will trip to the off position. Clean, cool (16°C - 20°C)
water at 0.5 l/min at 1.0 bar (14 psid) should be used to cool the 5201 magnet.
The cooling copper tubes are electrically isolated from the coils to avoid electrochemical corrosion. A 50
micron filter should be placed before the input to the magnet to trap particulates and avoid blockage of the
cooling circuits.
Water Cooling Connections
The magnet system has two water cooling connections provided on the rear of the motorized rotating drive.
Two barbed “push on” hose couplings are provided to suit 6 mm (1/4”) ID rubber hose.
• Water Inlet: Connect to a clean water source fitted with a suitable metering valve
(to control water flow).
• Water Outlet: Connect to drain.
Inlet Water Metering Valve Kit.
Metering Valve (brass) SWAGELOCK Cat No: B-4MG2 (1 required)
Hex Coupling (brass) 1/4” NPT female SWAGELOCK Cat No: B-4-HGC (2 required)
Hose Connectors (brass) 1/4” NPT to1/4”Hose SWAGELOCK Cat No: SB-PB4-PM4
(2 required)
Hose Push On (black) 1/4” ID SWAGELOCK: Cat No: PB-4-BK (as required)
3-2
Section 3
INSTALLATION
SOFTWARE
Software Requirements
• An IBM PC 486/Pentium or compatible.
• 8Mb RAM memory.
• SVGA monitor running 1024 x 768 pixels.
[Note1]
• CD Rom Drive.
• GPIB Board [National Instruments compatible].
• Windows 95/98/ME/XP Operating System software.
• LabVIEW for Windows 95/98/ME/XP.Ver 6.0 or higher.
Motorized Rotating Drive software can also be supplied as an executable file and run directly from the
Windows Operating System. In this case LabVIEW for Windows V6.0 is not required.
[Note 2]
Software Installation
The Motorized Rotating Drive LabVIEW driver and support files are all located in a directory called 5201
Magnet Control.
To install the driver follow the directions given below.
1. Insert CD rom into computer CD ROM drive
2. Copy the complete 5201 Magnet Control directory to the host computers hard drive.
3. Locate the Default.dat file in the Data directory.
4. Right mouse click on the file properties
5. Uncheck the Read Only attribute.
Before running the 5201 Magnet Control software set the Com Port control to match the Com Port being
used on the control computer. [Com 1 is the default.] The 5201 Magnet power supply is set to GPIB address
2 and is not changeable from the Setup Panel.
Note:
1. Using screen resolutions other than 1024 x 768 means all items on the LabVIEW front panels will have to
be resized by the end user.
2. The executable program file cannot be altered by the end user. Consult GMW if the 5201 Magnet
Control software is required as a executable file.
3-3
Section 4
OPERATION
SOFTWARE DESCRIPTION
MAIN CONTROL PANEL
Panel Control:. Makes either Setup or Automatic control panels visible.
Control Mode:. Selects either Manual or Automatic control mode of operation.
Key Focus Control:. When Key Focus is turned on the selected control is controlled by the Up an Down
arrows on the computer keyboard. A set value can also be directly entered from the
numeral keypad. By default the lowest significant digit is controlled and rolls over to
the next highest digit. Roll over occurs between the lowest to the most significant digit.
System Shutdown: Sets zero current on the magnet power supply, and stop rotation on the Motorized
Rotating Drive. Finally this LabVIEW application stops running, and a System
Shutdown message is displayed.
MAGNET FIELD CONTROL
Setpoint Control: Selects either a current setpoint in Amps or field input in Tesla.
Setpoint Mode Control: Selects either current control or field control of the magnet system..
Excitation File Control: Makes sub panel visible for the creating and loading of open loop characterization files.
Magnet Voltage Indicator: Display voltage from the magnet power supply.
Magnet Current Indicator: Display current from the magnet power supply.
Loaded Excitation File: Displays the current loaded excitation file.
MAGNET ROTATION CONTROL PANEL
Home CW Control: Makes the motorized rotating Drive rotate in a clockwise direction until it finds the
homing position at 0.0 deg and resets the current position counter to 0.0 deg.
Home CCW Control: Makes the motorized rotating Drive rotate in a counterclockwise direction until it finds
the homing position at 0.0 deg and resets the current position counter to 0.0 deg.
Counter Reset Control: Resets the current position counter to 0.0 deg.
Velocity Control: Sets the velocity of the stepper motor.
Set Position Control: Sets the MRD platen to the desired position.
Immediate Control: Starts the MRD in motion as soon as set position input value is entered.
Go Control: If immediate control is turned off, no motion occurs on the MRD until the Go button is pressed.
Start Motion CCW Control: Starts the motorized rotating drive rotating in a counterclockwise direction until
a soft limit is reached, or the Stop Motion button in pushed.
Start Motion CW Control: Starts the motorized rotating drive rotating in a clockwise direction until a soft
limit is reached, or the Stop Motion button in pushed.
Stop Motion Control: Stops the motorized rotating drive rotating at any time.
Emergency Stop Control: Stops the motorized rotating drive rotating INSTANTLY.
FOR EMERGENCY USE ONLY.
4-1
Section 4
OPERATION
SOFTWARE DESCRIPTION
MAGNET ROTATION CONTROL PANEL (Continued)
CCW Limit Control: Stops the motorized rotation drive from rotating in thecounterclockwise direction when
the current position counter equals the CCW limit setting.[A red indicator shows when
limit is reached.]
CW Limit Control: Stops the motorized rotation drive from rotating in theclockwise direction when the
current posit ion counter equals the CW limit setting. [A red indicator shows when limit
is reached.]
Current Position Indicator: Shows the motorized rotation drive current position on a digital display. Units
are in degrees from the initialized zero position, [normally 0.0 deg.]
Ramp Indicator: Shows velocity ramp up and down as set position is approached.
SETUP PANEL (Visible only when selected with the Panel Control)
Com Port Control: Selects the computer serial port to use to communicate with the stepper motor controller.
[Set to Com 1 as default.]
Motor Controls: Sets the acceleration, start of speed ramp down, ramp rate and axis scaling of the stepper
motor. Ramp feature can be turn On or Off by the Ramp control switch
Home Motion Controls: Sets the acceleration, deceleration and velocity of the stepper motor when homing
to the 0.0 deg position.
Soft Limits Range: Sets the maximum, minimum and increment on the soft limits scale. Soft Limit feature can
be turned On or Off by the Soft Limits control switch.
Velocity Chart Indicator: Shows the current acceleration, deceleration and velocity of the stepper motor.
Reset Controller on Start Up: Sends a Reset command to the stepper motor controller. This command is
only sent once when the program starts.
AUTOMATIC CONTROL/LOGGING PANEL (Visible only when selected with the Panel Control).
Date Indicator: Shows the data from the computers clock.
Time Indicator: Shows time from the computers clock.
Step in Progress: Shows the current row of data being used for automatic control.
Automatic Control: Turns On and Off the automatic operation from the table setting control.
Logging Control: Turns On and Off logging of system data to log file.
Table Settings Control: The table setting control has five columns of data. Step is the row of Data in use.
Current or Field settings are sent to the magnet power supply. Rotation settings
are sent to the Motorized Rotating Drive. Time in seconds is the interval between
steps.
Step Control: Single steps the table control through steps 1,2,3,4 etc.
Zero Control: Returns the table control to step 1.
4-2
Section 4
OPERATION
SOFTWARE DESCRIPTION
Auto Log Indicator: Flash’s yellow when data is being written to log file.
Data to File Indicator: Shows data that will be written to log file.
Log File Indicator: Reads the data from the current log file.
Log File Name Indicator: Shows the current log file name.
New Data File Control: This control makes the Log File Setup Panel visible.
Open File Control: Reads data from the current log file and displays data in the log file indicator.
Press to Log Control: Logs one line of data to the current log file. Auto log indicator will flash yellow.
CREATE DATA FILE PANEL (Visible only when the new data file control is pressed).
Data File Header Control: Provides inputs for test engineer, magnet model, magnet serial no andtest notes.
The computer date is automatically inserted into the data file.
Data File Name Control: Provides input for new file name.
Create New Data File Contro l: Creates a new data file and writes all the data file header information to the
file. Note: If a file with the same name exists a warning will be given.
Options are replace the existing file data or cancel the operation. Clicking
the replace control will make a new data file with new header information.
Close Panel Control: Closes the create data file panel.
4-3
Section 4
OPERATION
To Start the Magnet System Software
Click the LabVIEW Run button.
To Stop the Magnet System Software
Click the red System Shutdown button located at the lower LH corner of the screen.
Magnet System Software Default Settings
The Magnet Control System software will open with all parameters set to the default settings. To change the
default of a control follow the instructions listed below.
1. First stop the software by clicking on the SYSTEM SHUTDOWN button.
2. Then set the control to the desired default value.
3. Right mouse click on the control and select Data Operation.
4. Click on the selection Make Current Value Default.
5. Restart the Motorized Rotating Drive Software by clicking on the LabVIEW run arrow at the top left
screen.
Magnet System Software Help
On screen help is available. To use the on line help use a CTRL + H from the keyboard to open the help
window, and then move the cursor over the control or indicator on the front panel. A description of the control
or indicator function will appear in the help window.
ELECTROMAGNET OPERATION (Current Control)
1. Select current control mode (default).
2. Select Setpoint on the key focus control.
3. Enter desired current from the keyboard and press the enter key.
The setpoint control pointer should move to the desired current and the correct current will be displayed in the
magnet current indicator.
ELECTROMAGNET OPERATION (Field Control)
1. Select field control mode.
2. Press the create/load excitation file button.
(The open loop file charactization sub panel will appear).
3. Press the load button.
4. Select the directory where the open charactization files as located.
5. Select the desired file for the correct height above the magnet.
6. (Note for operation 4.0 mm above the magnet the correct file will be 5201-Z04.olc.)
7. Click the done button (The open loop file charactization sub panel will close).
8. The loaded file name will appear in the loaded excitation file indicator.
9. Select Setpoint on the key focus control.
10. Enter desired current from the keyboard and press the enter key.
4-4
Section 4
OPERATION
MOTORIZED ROTATING DRIVE
Setup Operation:
1. Firstly power up the Zeta 6104 stepper motor controller.
2. Start the 5201 magnet contol software.
3. Click either the CW or CCW home button.
4. After the platen stops at the approximate zero point reduce the velocity setting to 0.1.
5. Use the CW or CCW motion to approach the zero mark.
6. Use the stop motion button when the zero mark is reached.
7. Press the counter reset button to set the position counter to zero.
8. Return the velocity control to the desired setting 0.5 to 2.0.
Note: Do the above operation on power up only. Do not use the home control to go accurately to 0.0 deg, use
the set position control as detailed below.
Set Position Operation:
Type in the desired position into the set position control and press the enter key on the keyboard.
Note: If immediate control is turned on, the MRD will start to rotate as soon as new input value has entered
and enter key pressed. If immediate control is turned off then press the GO button to start the MRD rotating to
the new position.
Soft Limits Operation
1. Set the soft limits control to enable.
2. Set the CCW limit by clicking on the blue pointer with the mouse and dragging to the desired location on
the status indicator.
3. Set the CW limit by clicking on the blue pointer with the mouse and dragging to the desired location on the
status indicator.
4. Click on either the CCW or CW Start Motion button.
The motorized rotating drive will rotate in the desired direction until the soft limit is reached. The soft limit digital
control will flash red when the soft limit is reached. Further rotation in the same direction will not occur.
Clicking on the opposite direction Start Motion button will rotate the motorized rotation drive in the opposite
direction until its soft limit is reached.
Hardware Limits
The hardware CCW and CW limit switches operate at approximately -200deg and +200deg respectively.
After the limit switch has operated the rotation of the motorized rotating drive will decelerate at the same rate as
set by the software acceleration control setting and then stop. A 5 deg overrun has been allowed for before the
mechanical stops operate.
Mechanical Stops
The mechanical stops operate at -200 deg and +200 deg stopping any rotation beyond these positions.
4-5
Section 5
MAINTANCE
Electromagnet
Electrical Connections on the magnet terminal block should be checked annually. The electrical connections
should be clean and tight. Discoloration is a sign that the connection is overheating and must be rectified before
further use of the magnet.
Water Hoses should be checked regularly for water leaks. Any leaks should be rectified before further use of
the magnet.
Motorized Rotating Drive
Rotating Platen contains nylon ball bearings and does not require periodic lubrication.
Worm Gear should be lubricated annually by smearing the worm gear with a coating of a graphite based
grease.
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