Magtrol DSP6000 User Manual

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Page 1

Model DSP6000Model DSP6000

Model DSP6000

Model DSP6000Model DSP6000

High Speed PHigh Speed P

High Speed P

High Speed PHigh Speed P

Dynamometer ControllerDynamometer Controller

Dynamometer Controller

Dynamometer ControllerDynamometer Controller

rogrammablerogrammable

rogrammable

rogrammablerogrammable

UserUser

User

UserUser

’s Manual’s Manual

’s Manual

’s Manual’s Manual

Page 2

MAGTROL, INC.MAGTROL, INC.

MAGTROL, INC.

MAGTROL, INC.MAGTROL, INC.

Sales and TSales and T

Sales and T

Sales and TSales and T

Buffalo, New York 14224 USA

Tel: (716) 668-5555 or 1-800-828-7844

wwww

Hysteresis Brakes and Clutches

While every precaution has been exercised in the compilation of this document, Magtrol, Inc. assumes no responsibility for errors or omissions. Additionally, no liability is assumed for any damages that may result from the use of the information contained within this publication.

echnical Assistanceechnical Assistance

echnical Assistance

echnical Assistanceechnical Assistance

70 Gardenville Parkway

Fax: (716) 668-8705

w.w.

Manufacturers of:

Motor Test Equipment

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agtr

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74M041 062200

LabVIEW National Instruments Corporation.

RadioShack the RadioShack Corporation.

is a registered trademark of

Page 3

Safety NotesSafety Notes

Safety Notes

Safety NotesSafety Notes

1. Make sure that all Magtrol dynamometers and electronic products are earthgrounded, to ensure personal safety and proper operation.

2. Check line voltage before operating the DSP6000.

3. Make sure that dynamometers and motors under test are equipped with appropriate safety guards.

iii

Page 4

This page intentionally left blank.

Page 5

able of Contentsable of Contents

able of Contents

able of Contentsable of Contents

SALES AND TECHNICAL ASSISTANCE .............................................................................................. ii

SAFETY NOTES..................................................................................................................................... iii

1 - INTRODUCTION ................................................................................................................................ 1

About This Manual ............................................................................................................................................. 1

Shipping .............................................................................................................................................................. 1

UNPACKING YOUR DSP6000 ............................................................................................................................................ 1

About the Model DSP6000 Dynamometer Controller ....................................................................................... 1

FEATURES ......................................................................................................................................................................... 1

SPECIFICATIONS ................................................................................................................................................................. 2

Front Panel .......................................................................................................................................................... 3

Figure 1. Front Panel .................................................................................................................................... 3

ENABLING SECONDARY FUNCTIONS ..................................................................................................................................... 3

FRONT PANEL CONTROLS AND BUTTONS ............................................................................................................................. 4

Vacuum Fluorescent Display (VFD) .................................................................................................................. 5

STATUS DISPLAY MESSAGES ..............................................................................................................................................5

DISPLAYING DESIRED INFORMATION .................................................................................................................................... 5

Rear Panel ........................................................................................................................................................... 6

Figure 2. Rear Panel ..................................................................................................................................... 6

Figure 3. Brake Connector ............................................................................................................................ 6

Figure 4. Accessory Torque/Speed Output.................................................................................................... 6

Figure 5. Dynamometer Connector ............................................................................................................... 6

REAR PANEL FUNCTIONS ....................................................................................................................................................7

2 - ABOUT THE PID LOOP..................................................................................................................... 8

P (Proportional Gain) ......................................................................................................................................... 8

I (Integral) .......................................................................................................................................................... 8

D (Derivative) .................................................................................................................................................... 8

Figure 6. PID Loop ....................................................................................................................................... 8

Setting The Correct PID'S For Your Motor ........................................................................................................ 8

3 - INSTALLATION................................................................................................................................ 10

Setting Unit for Line Voltage ........................................................................................................................... 10

Figure 7. Cover for Voltage Selector, Fuses ...............................................................................................10

Checking Your DSP6000 .................................................................................................................................. 10

4 - THE DSP6000 AS A STAND-ALONE UNIT (LOCAL CONTROL) ................................................. 12

Setting Desired Operating Parameters .............................................................................................................. 12

SET DISPLAY TO DESIRED POWER UNITS (WATTS OR HP) .................................................................................................. 12

SET DISPLAY TO DESIRED TORQUE UNITS .........................................................................................................................12

SET UP DISPLAY FOR DYNAMOMETER ............................................................................................................................... 12

SET UP COMMUNICATIONS WITH PC .................................................................................................................................12

SET UP AUXILIARY INPUT ................................................................................................................................................ 12

SET TORQUE CONTROL ....................................................................................................................................................12

SET SPEED CONTROL ....................................................................................................................................................... 13

SET OPEN LOOP CONTROL ...............................................................................................................................................13

SET UP I/O PARAMETERS ................................................................................................................................................ 13

Setting Dynamometer Load .............................................................................................................................. 14

Using Internal Memory..................................................................................................................................... 14

STORING DATA POINTS ....................................................................................................................................................14

RECALLING DATA POINTS ................................................................................................................................................ 14

Page 6

EXITING THE MEMORY MODE .......................................................................................................................................... 14

CLEARING THE MEMORY .................................................................................................................................................. 14

5 - THE DSP6000 WITH A PC (REMOTE CONTROL) ......................................................................... 15

About the GPIB Interface ................................................................................................................................. 15

Figure 8. GPIB (IEEE-488) Interface .........................................................................................................15

NSTALLING THE GPIB (IEEE-488) CONNECTOR CABLE ................................................................................................... 15

CHANGING THE GPIB PRIMARY ADDRESS .........................................................................................................................15

Checking the DSP6000-To-PC Connection...................................................................................................... 16

Programming .................................................................................................................................................... 16

CODES FOR CR - LF ....................................................................................................................................................... 16

DSP6000 Command Set ................................................................................................................................... 16

COMMAND SET FOR DSP6000.........................................................................................................................................17

Acquiring Speed-Torque Data .......................................................................................................................... 20

Selecting the Baud Rate for the RS-232 Interface ............................................................................................ 20

Figure 9. Connector Pin-Out ...................................................................................................................... 20

6 - CALIBRATION ................................................................................................................................. 21

Closed-Box Calibration .................................................................................................................................... 21

Calibration Schedule ......................................................................................................................................... 21

Basic Calibration Process ................................................................................................................................. 21

INITIAL CALIBRATION PROCEDURE .................................................................................................................................... 21

TORQUE OFFSET AND GAIN .............................................................................................................................................. 21

ACCESSORY TORQUE OFFSET AND GAIN ............................................................................................................................22

AUXILIARY INPUT OFFSET AND GAIN ................................................................................................................................22

ALTERNATE CALIBRATION PROCEDURE.............................................................................................................................. 22

Figure 10. Alternative Calibration ................................................................................................................ 23

7 - TROUBLESHOOTING ..................................................................................................................... 24

APPENDIX A: LABVIEW® PROGRAMMING EXAMPLES................................................................. 25

Simple Read ...................................................................................................................................................... 25

Torque Stabilized .............................................................................................................................................. 26

Speed Stabilized ................................................................................................................................................ 27

APPENDIX B: INERTIA CORRECTION .............................................................................................. 28

Inertial Effect on Motor Test Data.................................................................................................................... 28

Procedure for Inertia Correction ....................................................................................................................... 28

KEY CONDITIONS ............................................................................................................................................................ 28

APPENDIX C: FRONT PANEL/DISPLAY MENU FLOW CHARTS..................................................... 29

Dyno Setup Menu ............................................................................................................................................. 29

Com Setup Menu .............................................................................................................................................. 30

Aux Setup Menu ............................................................................................................................................... 31

Power Units Menu ............................................................................................................................................ 31

Torque Units Menu ........................................................................................................................................... 32

APPENDIX D: SCHEMATICS .............................................................................................................. 33

Encoder/Switch Board ...................................................................................................................................... 33

Power Supply .................................................................................................................................................... 33

DSP & Memory ................................................................................................................................................ 34

Analog I/O ........................................................................................................................................................ 35

GLOSSARY OF ABBREVIATIONS AND TERMS................................................................................ 36

MAGTROL LIMITED WARRANTY ....................................................................................................... 37

Page 7

1 - Introduction1 - Introduction

1 - Introduction

1 - Introduction1 - Introduction

ABOUT THIS MANUAL

This manual contains information about the DSP6000 Dynamometer Controller and procedures for optimal use. To obtain the best results from your unit, please follow the procedures for operation.

SHIPPING

Your DSP6000 was packaged carefully for shipping. Please notify your carrier and Magtrol Customer Service if you believe your unit was damaged in shipping.

UNPACKING YOUR DSP6000

1. Save all shipping cartons and packaging material until you inspect the DSP6000.

2. Inspect the DSP6000 for any evidence of damage in shipping.

3. Make sure the carton contains the following:

• DSP6000 Dynamometer Controller

• Line cord

• User's Manual for the DSP6000

• Calibration certificate

ABOUT THE MODEL DSP6000 DYNAMOMETER CONTROLLER

Magtrol's Model DSP6000 Dynamometer Controller provides superior motor testing capabilities by using state-of-the-art digital signal processing technology. The DSP6000 both controls the dynamometer and provides digital readouts on the front panel. The DSP6000 is designed to work with all Magtrol load cell dynamometers, including the following dynamometer models:

001-DH 015-DH 008-DH 517-DE 601-DH007-DH508-DH518-DE 004-DH 507-DH 018-DH 001-DTH 005-DH017-DH518-DH002-DTH 505-DH 517-DH 528-DH 003-DTH

FEATURES

Fast, full curve data acquisition

Free-run to locked rotor in seconds.

High-speed data acquisition

120 torque and speed points per second via IEEE (GPIB) bus.

Speed and torque operating modes

Each mode provides independent PID settings for improved dynamometer control.

Programmable digital PID values

Controlled and stored either with Magtrol M-Test software or manually.

Single point or programmed load control

Single or multi-point torque and speed stabilized testing using Magtrol M-Test software.

Two standard computer interfaces

RS-232 and IEEE-488.

Additional analog input

Accepts any ± 5 VDC transducer.

Vacuum fluorescent display

Displays torque, speed, power, auxiliary input and PID values.

Many torque measurement options

Includes English, metric, and SI torque readings as standard.

Closed box calibration of torque and auxiliary input

Eliminates need to open box for adjustments.

The DSP6000 is designed to work with any personal computer using an IEEE-488 or an RS-232 interface, or as a stand-alone unit. In a computer-controlled environment, the DSP6000 provides the following motor testing capabilities:

• Proportional (P), plus Integral (I), plus Derivative (D) closed loop control (PID loop).

• Torque (Q) and Speed (N) data acquisition at a rate of up to 120 readings per second.

• Automatic progressive loading in either decreasing or increasing speed mode.

• Ability to remove the Effects of Inertia from dynamically obtained data. (See Appendix B)

• Complete curve capability for most motor types, including single/poly phase induction, AC/DC series, PMDC, brushless DC, air and internal combustion (if suitably coupled).

Page 8

SPECIFICATIONS

Magtrol Model DSP6000 Dynamometer ControllerChapter 1 - Introduction

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Page 9

Magtrol Model DSP6000 Dynamometer Controller Chapter 1 - Introduction

FRONT PANEL

Figure 1. Front Panel

MODEL DSP6000

DYNAMOMETER CONTROLLER

The front panel provides a power switch, eight control buttons, a Decrease/Increase Dial, and Vacuum Fluorescent Display (VFD). The front panel controls and buttons, from left to right, are:

• Power switch

• Six double-function control buttons:

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• Three single-function control buttons:

• SHIFT (to enable secondary functions printed

in blue above control buttons)

• Up/Left arrow

(scroll up, increase

magnitude)

• Down/Right arrow

(scroll down,

decrease magnitude)

• Decrease/Increase Dial

ENABLING SECONDARY FUNCTIONS

To enable the secondary function of the double-function control buttons:

1. Press the blue SHIFT button and release it. (The word SHIFT appears in the display.)

2. Press a control button to enable the function shown in blue letters above the control button:

POWER UNITS, TORQUE UNITS, AUX SETUP, COM SETUP or DYNO SETUP.

3. Press the SHIFT button again to exit the secondary function.

NOTE: Refer to the table, “Front Panel

Controls and Buttons” later in this chapter for further explanation of button features and use.

Page 10

FRONT PANEL CONTROLS AND BUTTONS

Magtrol Model DSP6000 Dynamometer ControllerChapter 1 - Introduction

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Page 11

Magtrol Model DSP6000 Dynamometer Controller

Chapter 1 - Introduction

VACUUM FLUORESCENT DISPLAY (VFD)

The VFD provides information about the control functions, the motor under test, and an auxiliary input device (if connected). The displays, from left to right, are:

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STATUS DISPLAY MESSAGES

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DISPLAYING DESIRED INFORMATION

Local control:

1. Press SHIFT and release; then press POWER UNITS to see UNITS displayed.

2. Press UP

or DOWN

available choices.

3. Press SHIFT to exit.

4. Press SHIFT and release; then press TORQUE UNITS to see UNITS displayed.

5. Press UP

or DOWN

options for units.

6. Press SHIFT to exit.

7. Press RECALL to view memory contents; last in = first out.

8. Press SHIFT to exit.

Remote control:

Refer to “DSP6000 Command Set” in Chapter 4 - The DSP6000 with a PC for a list of commands recognized

by the DSP6000.

Auxiliary Input:

1. Press SHIFT and release; then press AUX SETUP.

2. Rotate Decrease/Increase Dial to select scale.

3. Press SHIFT to exit.

to scroll through

Page 12

Magtrol Model DSP6000 Dynamometer ControllerChapter 1 - Introduction

1 2 3 4 5 6 7

9 10 11 12 13 14

COMMON D.P. TACH. SIGNAL N/C D.P. TORQUE COMMON TORQUE SIGNAL

N/C N/C

TACH. +5.0 VDC

ISOLATED

22 VDC

ISOLATED

22 VDC

CONNECTOR SHELL & CABLE SHIELD

REAR PANEL

The rear panel provides connectors and receptacles for connecting to appropriate equipment.

Figure 2. Rear Panel

Figure 3. Brake Connector

Figure 4. Accessory Torque/Speed Output

TACH.

COMMON

TACH.

SIGNAL

TORQUE

COMMON

D.P.

N/C

TORQUE OUTPUT

Figure 5. Dynamometer Connector

D.P.

For use with Magtrol Readouts only. Connecting another device to this output may cause equipment failure.

Page 13

Magtrol Model DSP6000 Dynamometer Controller Chapter 1 - Introduction

REAR PANEL FUNCTIONS

The rear panel, from left to right, provides the following functions:

Label Function

BRAKE Connect dynamometer brake cable here

Contains brake fuse (5 x 20mm)

BRAKE FUSE

CTRL OUT

ACCESSORY TORQUE-SPEED OUTPUT

UL/CSA 1.25A 250V SB IEC 1A 250V T

Connect to Model 5241 Power Amplifier when usin Dynamometer

Connect accessory output cable here (optional).

HD-825

For use with Ma this output may cause equipment failure.

DYNAMOMETER Connect dynamometer si AUX INPUT Connect auxiliary instrument cable here RS-232C Use this socket for RS-232 connector cable GPIB/IEEE-488 Use this socket for GPIB cable (meets IEEE-488 specifications) POWER Attach power cord here EARTH GROUND Attach earth

trol Readouts only. Connecting another device to

nal cable here

round here

Page 14

2 - About the PID L2 - About the PID L

2 - About the PID L

2 - About the PID L2 - About the PID L

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The DSP6000 has PID adjustment capability for both the speed and torque modes to provide you with the best system response. The PID Loop comprises the following three variables:

P = Proportional Gain

I = Integral

D = Derivative

The setpoint is the desired load or speed. Error is the difference between the setpoint and the actual measurement.

P (PROPORTIONAL GAIN)

With proportional gain, the controller output is proportional to the error or to a change in measurement. Deviation from the setpoint is usually present. Increasing proportional gain will make the PID loop unstable. Increasing integral value eliminates this instability. For best loop control, set the proportional gain as high as possible without causing the loop to become unstable.

I (INTEGRAL)

With integral, the controller output is proportional to the amount of time the error is present. Increasing the integral value eliminates the offset from the setpoint. If the response becomes oscillatory, increase the derivative value.

D (DERIVATIVE)

With derivative, the controller output is proportional to the rate of change of the measurement or error. Derivative can compensate for a changing measurement. Derivative takes action to inhibit more rapid changes of the measurement than proportional gain.

When a setpoint change occurs, the derivative causes the controller gain to go the "wrong" way when the measurement gets close to the setpoint. Derivative can be used to control overshoot. If derivative is used, higher gain and integral values are usually necessary.

Magtrol offers a comprehensive motor-test program which would satisfy most of your needs. Call Magtrol Sales at 1-800-828-7844 or 1-716-668-5555 to request your custom software.

NOTE: To set PID values, see Chapter 3

- Installation.

Figure 6. PID Loop

SETTING THE CORRECT PID'S FOR YOUR MOTOR

NOTE: Each type of motor may have it's

own optimum PID setting.

NOTE: The PID settings are scaled to the

maximum speed setting; therefore the maximum speed setting should be adjusted to just higher than the free-run speed of the motor being tested.

When testing a new motor where the optimal PID's are unknown:

1. Begin with the Proportional Gain (P) and the Integral (I) both set to a low value and the Derivative (D) set to zero. This will allow the best opportunity for finding the optimum in the lowest amount of steps.

2. Using the DSP6000 in the speed mode: Set the speed target at approximately 90% of the free-run speed.

Page 15

Magtrol Model DSP6000 Dynamometer Controller

Chapter 2 - About the PID Loop

3. Turn the brake to the ON position and observe how the actual speed moves toward the target speed.

4. If the speed moves slowly or not at all, increase the P until the target speed is achieved.

5. Turn the brake OFF.

6. Turn the brake ON and note how fast the free-run speed changes to the target speed.

7. If the speed conversion does not happen quickly, increase the I value.

8. Repeat steps 4-7 until the motor moves from the free-run to the target speed as quickly as possible without excessive overshoot.

Example:

Motor type: AC Free-Run speed: 1750

1. Set maximum speed to 1800

2. Set P = 5 I =5 D = 0

3. Set target speed to 1600

4. Turn brake ON—no response

5. Move P value to 10—still slow, not reaching 1600

The larger the I value the faster the DSP6000 will move to the target number, but an I value too large will cause instability (oscillation). Once the optimum values are found, these steps should be repeated at different percentages of speed to ensure that they are the best combination for the entire speed range.

NOTE: The PID values for a speed

stabilized test and a ramp test will vary. Therefore, PID adjustments may be needed when changing from a stabilized test to ramp testing with the same motor.

The D value has little or no effect on this type of testing, therefore the D value can remain at zero.

Note: Increasing the P more will not

increase the operating characteristics without first increasing the I value.

6. Turn brake OFF

7. Move I value to 10

8. Turn brake ON—Reaching 1600 very slowly

9. With the brake OFF, adjust the P to 15

10. Turn the brake ON—never reaching 1600

11. Turn the brake OFF. Decrease the P to 10 and increase the I to 15

12. Turn the brake ON—reaches 1600 Faster

13. Turn the brake OFF. Increase I to 20

14. Turn the brake ON—reaches 1600 Faster

15. Turn the brake OFF. Increase I to 25

16. Turn the brake ON—reaches 1600 Faster

17. Turn the brake OFF. Repeat

Page 16

3 - Installation3 - Installation

3 - Installation

3 - Installation3 - Installation

Before installing your DSP6000, you should become familiar with the front and rear panels, as outlined in Chapter 1-Introduction.

Make sure the DSP6000 is earth grounded before starting!

SETTING UNIT FOR LINE VOLTAGE

The DSP6000 will operate with either of the following power sources:

• 120V 50/60 Hz

• 240V 50/60 Hz

1. Find the line cord receptacle on rear panel. The line cord is a detachable NEMA Standard 3 wire.

2. Make sure the selector matches the power source (numbers should match the line voltage).

If not:

• Locate the power entry module.

• Remove the line cord.

• Insert a screwdriver into the slot and open the

cover.

• Slide the voltage selector so the desired line

voltage appears in the window.

• Install the appropriate fuses for that voltage.

CHECKING YOUR DSP6000

Do not overload or stall the motor. Prolonged overload can cause the motor to overheat.

NOTE: To ensure that the DSP6000 is

operational, a Magtrol Dynamometer with a test motor installed must be connected to the DSP6000. It is not required that the DSP6000 be connected to a computer.

1. Connect the DSP6000 to the dynamometer using the following cables:

• 14-pin signal cable

• 2-pin brake power cable

2. Turn on DSP6000 power. Desired results:

• The display panel will show all segments of

the VFD (series of rectangles), indicating that the DSP6000 is executing a self-test routine.

• Message "MAGTROL MODEL DSP6000"

appears.

• Next screen “INPUT UNITS/ENCODER”

appears.

Figure 7. Cover for Voltage Selector, Fuses

NOTE: The dynamometer torque units

and the speed encoder can be selected now, or after the normal display panel appears.

• Normal display panel appears.

3. Press P button and set to 20% with Decrease/ Increase Dial.

4. Press I button and set to 30% with Decrease/Increase Dial.

5. Press TORQUE SET button.

6. Adjust torque value so that it equals zero.

Page 17

Magtrol Model DSP6000 Dynamometer Controller

7. Start the test motor.

8. Allow the motor speed to stabilize at its no-load speed for a few seconds.

9. Press the BRAKE ON/OFF button to ON.

10. Press the TORQUE SET button.

11. Turn the Decrease/Increase Dial clockwise. Desired results:

• The torque reading will increase.

As brake power is applied, load is applied to the motor. The applied torque increases as the Decrease/Increase Dial is turned clockwise. For most motors, loading is indicated by motor speed reduction.

12. Reduce the torque load to zero by turning the Decrease/Increase Dial counterclockwise.

Desired results:

• The torque reading will decrease.

13. Press the BRAKE ON/OFF Button to OFF.

14. Use the SHIFT button to enable the MAX SPEED function.

15. Turn the Decrease/Increase Dial clockwise until the MAX speed reading is slightly greater than the motor’s free-run speed.

16. Press the SPEED SET button - Turn the DECREASE/INCREASE DIAL until speed setpoint no longer increases (max. speed setting).

17. Press P button and set to 10%.

18. Press I button and set to 15%.

19. Press the BRAKE ON/OFF button ON.

20. Press the SPEED SET button.

21. Turn the Decrease/Increase Dial counterclockwise. Desired results:

• The motor speed will decrease.

Chapter 3 - Installation

NOTE: Adjust the motor’s stability by

adjusting the PID values. See Chapter 2 - About the PID Loop.

22. Turn off power to the test motor.

NOTE: If the desired results did not

occur, please see Chapter 7 - Troubleshooting.

Page 18

4 - The DSP6000 as a Stand-4 - The DSP6000 as a Stand-

4 - The DSP6000 as a Stand-

4 - The DSP6000 as a Stand-4 - The DSP6000 as a Stand-

Alone Unit (LAlone Unit (L

Alone Unit (L

Alone Unit (LAlone Unit (L

ocal Control)ocal Control)

ocal Control)

ocal Control)ocal Control)

NOTE: Although the DSP6000 can be

used without a computer, it will only perform at a fraction of its capability.

SETTING DESIRED OPERATING PARAMETERS

NOTE: See Appendix C: Front Panel/

Display Menu Flow Charts.

SET DISPLAY TO DESIRED POWER UNITS (WATTS

HP)

1. Press and release SHIFT.

2. Press POWER UNITS.

SET DISPLAY TO DESIRED TORQUE UNITS

1. Press and release SHIFT.

2. Press TORQUE UNITS.

3. Continue pressing TORQUE UNITS until the desired unit of measure is displayed.

4. Press SHIFT to exit.

SET UP DISPLAY FOR DYNAMOMETER

1. Press and release SHIFT.

2. Press DYNO SETUP.

3. Press TORQUE UNITS until input unit matches dynamometer.

4. Press ENCODER until selection matches encoder installed on dynamometer (60 bit = standard).

5. Press SHIFT to exit.

SET UP COMMUNICATIONS WITH PC

(If necessary)

1. Press and release SHIFT.

2. Then press COM SETUP.

3. Select GPIB ADDRESS. Press GPIB ADDRS until appropriate address appears. (See “Changing the GPIB Primary Address” in Chapter 5 - The

DSP6000 with a PC (Remote Control.)

4. Select baud rate. Press RS-232 BAUD until appropriate baud rate appears.

5. Press SHIFT to exit.

SET UP AUXILIARY INPUT

(If necessary)

See “Displaying Desired Information” in Chapter 1 - Introduction.

SET TORQUE CONTROL

NOTE: See Chapter 2 - About the PID

Loop.

1. Press the TORQUE SET button.

2. Use the UP Decrease/Increase Dial to adjust the setpoint to zero.

3. Press the P button.

4. Use the Decrease/Increase Dial to preset an initial value of 20.

5. Press the I button.

6. Use the Decrease/Increase Dial to preset an initial value of 30.

7. Press the D button.

8. Use the Decrease/Increase Dial to preset an initial value of 0.

9. Use the BRAKE ON/OFF button to turn the brake ON.

10. Start your motor under test.

11. Press the TORQUE SET button and adjust the setpoint to the desired load.

12. Check the torque display to make sure that the dynamometer loads the motor under test to that torque load.

NOTE: If the response is too slow or

and DOWN " buttons and the

oscillatory, adjust the values for P, I, and D.

Page 19

Magtrol Model DSP6000 Dynamometer Controller

Chapter 4 - The DSP6000 as a Stand-Alone Unit (Local Control)

Desired results:

• The dynamometer should load the motor under test to the load point quickly with little or no overshoot when the BRAKE function cycles ON or OFF.

Do not exceed the capabilities of the dynamometer or the power source in use.

Motors draw very large currents when held at locked rotor, and overheating may result.

When using torque control, you cannot test induction motors beyond breakdown, except at locked rotor.

SET SPEED CONTROL

When using speed control, motors between 0 and 100 RPM cannot be tested unless the dynamometer is equipped with an optional speed encoder.

1. Use the SHIFT button to enable the MAX SPEED function.

2. Use the UP Decrease/Increase Dial to set a value equal to or slightly greater than the free-run speed of the motor under test.

3. Press the SHIFT button to exit the MAX SPEED function.

4. Press the SPEED SET button.

5. Use the UP Decrease/Increase Dial to set a speed equal to the max. speed.

6. Press the P button.

7. Use the Decrease/Increase Dial to preset a value of

10.

8. Press the I button.

9. Use the Decrease/Increase Dial to preset a value of

15.

10. Press the D button.

11. Use the Decrease/Increase Dial to preset a value of

and DOWN " buttons and the

12. Use the BRAKE ON/OFF button to turn the brake ON.

13. Start your motor under test.

14. Press the SPEED SET button and adjust the setpoint to the desired speed.

Desired results:

• The dynamometer should load the motor under test to the desired speed quickly with little or no overshoot when the BRAKE button is cycled ON or OFF.

NOTE: If the response is too slow or

oscillatory, adjust the values for P, I and D.

SET OPEN LOOP CONTROL

1. Use the BRAKE ON/OFF button to turn the brake ON.

2. Press and hold the TORQUE SET button until you hear a second beep.

3. The TORQUE SET POINT display will now indicate 0.00%.

4. Use the UP

and DOWN " buttons and the Decrease/Increase Dial to set a value of current equal to the percent of full scale output (1 Amp).

5. To exit the Open Loop Control mode, press any of the PID buttons or the SPEED SET button.

Desired results:

• The dynamometer should load the motor under test. Because the mode is open loop, the controller will not stabilize on speed or torque, but will apply a constant current to the dynamometer brake. The actual loading will change as the brake heats up or as other external factors change. The PID's have no effect in this mode.

SET UP I/O PARAMETERS

1. Press and release SHIFT.

2. Press SETUP.

3. Press the DOWN

4. Press SHIFT.

5. Press UP ! or DOWN " until you see the desired contrast level.

button twice.

Page 20

Chapter 4 - The DSP6000 as a Stand-Alone Unit (Local Control)

Magtrol Model DSP6000 Dynamometer Controller

6. Press SHIFT.

7. Press UP desired GPIB address.

8. Press SHIFT.

9. Press UP ! or DOWN " until you see the desired RS-232 baud rate.

10. Press SHIFT to exit.

or DOWN " until you see the

SETTING DYNAMOMETER LOAD

1. Press the UNITS DISPLAY button.

2. Use the Decrease/Increase Dial to adjust the current output to 0%.

3. Use the BRAKE ON/OFF button to turn the brake ON.

4. Start the motor under test.

5. Use the UP Decrease/Increase Dial to adjust the loading on the motor.

and DOWN " buttons and the

RECALLING DATA POINTS

1. Press and release RECALL. The VFD will indicate RECALL followed by a number. This number indicates the memory location that is being displayed. The order of recalled data is LAST IN = FIRST OUT (LIFO). A "M" also appears to the right of the SPEED display to let the user know that the displayed data is from memory and not real time data.

2. Continue pressing RECALL until all the desired data is retrieved. Once data has been recalled, it is lost from internal memory.

EXITING THE MEMORY MODE

1. Press and release SHIFT.

CLEARING THE MEMORY

1. Press and release SHIFT.

2. Then press CLR MEM.

Do not exceed the capabilities of the dynamometer or the power source in use. Motors draw very large currents when held at locked rotor, and overheating may result. When using open loop current control, induction motors cannot be tested beyond breakdown, except at locked rotor.

USING INTERNAL MEMORY

STORING DATA POINTS

1. Press and release STORE. The VFD will indicate STORE followed by a number. This indicates the memory location that contains the data.

2. Continue pressing STORE at each desired point.

Page 21

5 - The DSP6000 with a PC (R5 - The DSP6000 with a PC (R

5 - The DSP6000 with a PC (R

5 - The DSP6000 with a PC (R5 - The DSP6000 with a PC (R

emote Control)emote Control)

emote Control)

emote Control)emote Control)

The DSP6000 can be used with a computer to control a dynamometer and to transmit data from motor testing directly to the computer. Using the DSP6000 with a computer enables the unit to perform at its full capacity.

ABOUT THE GPIB INTERFACE

(General Purpose Interface Bus)

Magtrol instruments use the GPIB (IEEE-488 Standard) for computer-to-instrument interfacing because:

• The GPIB parallel interface is faster than serial

interfaces.

• The GPIB enables testers to access up to 15

instruments on one port. Because typical motor testing requires that at least five separate parameters be synchronized, a system of easy, fast access to more than one instrument is essential.

• The GPIB has rigid data formatting and

hardware standards. These standards help to ensure that all functions will work properly when the hardware and software are installed.

Figure 8. GPIB (IEEE-488) Interface

D1 D2 D3

D4 EO1 DAV

NFRD NDAC

IFC

SRQ

AT N

SHIELD

113 214 315 416 517 618 719 820 921 10 22 11 23 12 24

D5 D6 D7 D8 REN DAV-COM NFRD-COM NDAC-COM IFC-COM SRQ-COM ATN-COM SIGNAL GROUND

INSTALLING THE GPIB (IEEE-488) CONNECTOR CABLE

NOTE: The GPIB interface is not

standard on most computers. An interface card and driver software must be installed. Magtrol recommends National Instruments Corporation hardware and software.

• An IEEE-488 cable must also be installed between the computer and the DSP6000.

Make sure both the computer and the DSP6000 are turned OFF before installing the GPIB connector cable.

1. Connect one end of a high-quality, double-shielded cable to the DSP6000 GPIB connector.

2. Connect the other end to the GPIB interface in your PC.

CHANGING THE GPIB PRIMARY ADDRESS

Each instrument serviced by the GPIB has its own Primary Address code, which enables the computer to obtain readings from the instrument. The factory default setting on the DSP6000 is 09.

Page 22

Chapter 5 - The DSP6000 with a PC (Remote Control)

Magtrol Model DSP6000 Dynamometer Controller

Some PC interfaces can access from one to fifteen 4-bit primary addresses. Other interfaces can access as many as thirty-one 5-bit primary addresses. The DSP6000 uses the 4-bit format.

1. Press the SHIFT button and release.

2. Press the COM SETUP button to set the primary address.

3. Press the button below the GPIB address display to increase by 1 (range 0–15).

6. Press SHIFT to input the address.

CHECKING THE DSP6000-TO-PC CONNECTION

NOTE: Make sure that the DSP6000 and

its host computer are communicating before acquiring data.

1. Make sure the primary address is set correctly for the DSP6000 (see above).

2. Set the input variable to 15 characters (13 variable characters and the two required data termination characters CR and LF. (See “Programming” later in this chapter.)

3. Issue output data command "OD" and read 15 characters according to the instructions for your GPIB interface.

Desired results:

• Torque/speed data will be returned

• The error message I/O ERROR does not appear on

the display panel.

NOTE: If the desired results did not

occur, please see Chapter 7 - Troubleshooting.

PROGRAMMING

NOTE: Check the manual provided with

your software for full instructions.

1. Use the following information to answer the formatting questions asked when installing your GPIB software.

• All GPIB data acquisition systems require the

use of data termination characters. The DSP6000 uses the GPIB standard termination characters "Carriage Return (CR)-Line Feed (LF)." Provide them in that order.

CODES FOR CR - LF

CISABXEHCED

=RC )31($RHCD031

=FL )01($RHCA001

2. Set the timeout for at least one second if asked to set a communication fault delay timeout.

• If the communication fault delay timeout is too

short, or if the computer resets the interface too quickly, the host instrument may stop responding.

DSP6000 COMMAND SET

When entering a command code:

1. Type all characters in uppercase ASCII format.

2. End all commands with a CR-LF (hex 0D-0A).

3. Do not string multiple commands together in one line.

The character # represents a floating point numerical value following the command. Leading zeroes are not required.

NOTE: If a command is not recognized,

the I/O ERROR message will appear in the Status Display.

Page 23

Magtrol Model DSP6000 Dynamometer Controller Chapter 5 - The DSP6000 with a PC (Remote Control)

COMMAND SET FOR DSP6000

Command

ACQUIRING SPEED-TORQUE DATA

Speed-torque data is a fixed-length string in ASCII format with a floating point decimal. Use the following string format:

SdddddTdddd.R[cr][lf]

SdddddTdddd.L[cr][lf]

where . . . S = Speed in RPM. No leading zeroes are used. d = Decimal digit 0 through 9 T = Torque in units selected during setup. The torque

value always contains a decimal point. L = Counterclockwise dynamometer shaft rotation (left) R =Clockwise dynamometer shaft rotation (right) . = Decimal point. The decimal point location depends

on the specific dynamometer and torque range in

use.

NOTE: The [cr] and [lf] characters will

not display.

Figure 9. Connector Pin-Out

DTR

GND

12345

6789

The DSP6000 is equipped with an RS-232 (serial) interface. To select the baud rate:

1. Press SHIFT and release.

2. Press the COM SETUP button.

3. Press the button under the RS-232 display to cycle through the following available baud rates:

300 2400 9600 600 4800 19200 1200

Other important communication parameters are:

• No Parity

• 8 Data Bits

• 1 Stop Bit

Example:

If a motor is running at 1725 RPM clockwise, with the dynamometer loading the motor to 22.6 oz.in., the DSP6000 will return:

S 1725T22.60R

By manipulating the string, the speed-torque and shaft direction (if required) can be extracted. Then separate numerical variables can be assigned to them for data processing.

SELECTING THE BAUD RATE FOR THE RS-232 INTERFACE

The DSP6000 communicates with the host computer through a DB-9 interface connector. The connector pinout is: 2-RX, 3-TX, 4-DTR, 5-GND. No other pins are connected.

To wire your own serial communications cable, use the following wiring diagram:

9 Pin (DSP6000)

9 Pin (Computer)

2345

3265

A cable may also be purchased from your local electronics store. A RadioShack #26-152 cable and #26264 null modem adapter are known to work. The null modem adapter must be used on the computer end of the cable.

Page 27

6 - Calibration6 - Calibration

6 - Calibration

6 - Calibration6 - Calibration

CLOSED-BOX CALIBRATION

The DSP6000 features closed-box calibration. The advantage of closed-box calibration is that the user does not have to disassemble the case or make mechanical adjustments. However, the calibration of the Accessory Torque Output must be done internally with Offset and Gain trim pots.

The Torque readout and Auxiliary Input can be calibrated using external reference sources. Correction factors for Offset and Gain are stored in nonvolatile memory. They remain in effect until the user or the calibration house updates them.

The front panel displays the actual correction factors above the ZERO and GAIN readouts. Record these values before calibration. In the unlikely event of a Controller failure, it can re-initialized by pressing and holding the P, I nad D buttons while turning the power on. All internal memory and setups will be lost. After re-initializing, reprogram the GAIN and ZERO values into memory.

CALIBRATION SCHEDULE

Calibrate your DSP6000:

• After any repairs are performed

• At least once a year; more frequently to ensure

required accuracy

INITIAL CALIBRATION PROCEDURE

NOTE: Record the actual correction

factors displayed before proceeding with calibration.

1. Allow the DSP6000 to stabilize in an environment with:

• An ambient temperature of 18°C to 25°C

• Relative humidity less than 80%

2. Turn on the DSP6000.

3. Allow the DSP6000 to warm up for at least 30 minutes.

4. Enable the calibration mode as follows:

• Turn instrument power OFF

• Press in and hold the UP

arrow buttons simultaneously

• Turn instrument power ON

5. Continue pressing the UP

arrow buttons until the display shows the

software revision date.

6. Press the SHIFT button once.

NOTE: To exit CALIBRATE mode

without making any changes, press the SHIFT button six times.

and DOWN

BASIC CALIBRATION PROCESS

The basic calibration process consists of four procedures which must be performed in the following order:

1. Initial Procedure

2. Torque Offset and Gain

3. Accessory Torque Output Offset and Gain

4. Auxiliary Input Offset and Gain

To calibrate the DSP6000, you will need:

• External voltage reference of 0 to 5 volts DC

• Digital multimeter (DMM) with VDC accuracy

of 0.05% or better

TORQUE OFFSET AND GAIN

1. Connect the external voltage reference common to Pin 13 of the dynamometer input connector.

2. Connect the external voltage reference high to Pin 14 of the dynamometer input connector.

3. Apply +2.000 VDC.

4. Press the GAIN button.

5. Adjust the gain by turning the Decrease/Increase Dial until the displayed voltage equals the reference voltage.

Page 28

Chapter 6 - Calibration

Magtrol Model DSP6000 Dynamometer Controller

NOTE: The magnitude of change per

revolution can be increased by

pressing the UP

button or decreased by pressing the DOWN " button.

6. Apply 0.000 VDC.

7. Press the ZERO button.

8. Adjust the Decrease/Increase Dial until the display indicates 0 mVDC.

9. Repeat steps 3 through 8 to complete this procedure.

10. Record the correction factors displayed above the ZERO and GAIN readouts for future reference.

ACCESSORY TORQUE OFFSET AND GAIN

1. Connect the DMM common to Pin 4 of the Accessory Torque-Speed Output connector.

2. Connect the DMM high to Pin 2 of the Accessory Torque-Speed Output connector

3. Apply 0.000 VDC

4. Adjust R24 (OFFSET) on the circuit board for 0 mVDC on the DMM.

5. Apply +2.000 VDC.

6. Adjust R25 (GAIN) on the circuit board for +2.000 VDC on the DMM.

AUXILIARY INPUT OFFSET AND GAIN

1. Press the SHIFT button once. Display indicates AUX INPUT calibration.

2. Connect the external voltage reference to the Auxiliary Input BNC connector.

3. Apply +5.000 VDC.

4. Press the GAIN button.

5. Adjust the gain by turning the Decrease/Increase Dial until the displayed voltage equals the reference voltage.

NOTE: The magnitude of change per

revolution can be increased by pressing the UP ! button or decreased by pressing the DOWN " button.

6. Apply 0.000 VDC.

7. Press the ZERO button.

8. Adjust the Decrease/Increase Dial until the display indicates 0 mVDC.

9. Repeat steps 3 through 8 to complete this procedure.

10. Record the correction factors above the ZERO and GAIN readouts for future reference.

11. Press the SHIFT button once to return to default display.

ALTERNATE CALIBRATION PROCEDURE

The DSP6000 can also be calibrated by using a certified dynamometer, calibration beam, and weight instead of an external voltage reference.

NOTE: Magtrol suggests you do NOT

use this method. By using the alternate calibration procedure, you are calibrating the DSP6000 to a specific dynamometer, not to a reference standard. If you connect the DSP6000 to a different dynamometer, the resulting torque reading may be incorrect.

1. Connect the chosen dynamometer to the DSP6000 using the 14-pin signal cable and the 2-pin brake cable.

2. Attach the calibration beam to the dynamometer shaft.

3. Enter the calibration mode.

4. Press the BRAKE ON/OFF button ON to apply full loading to the dynamometer.

5. Hang the weight on the calibration beam pin and level the beam.

6. Press the GAIN button.

7. Adjust the gain by turning the Decrease/Increase Dial until the displayed voltage equals the reference voltage.

NOTE: The magnitude of change per

revolution can be increased by pressing the UP ! button or decreased by pressing the DOWN " button.

Page 29

Magtrol Model DSP6000 Dynamometer Controller

Chapter 6 - Calibration

8. Remove the weight for ZERO adjustment.

9. Press the ZERO button.

10. Adjust the Increase/Decrease Dial until the display indicates 0 mVDC.

NOTE: The mV output of the

dynamometer will be equivalent to the Full Scale Torque Rating, disregarding any decimal point.

Example:

Magtrol’s HD-400-6 Dynamometer has a fullscale torque of 40.0 oz.in. The distance from the center of the dynamometer shaft to the pin on the calibration beam is 5 inches. Placing an 8 oz. weight on the pin will produce a torque of

40.0 oz.in. The mV output of the dynamometer will be 40.0 minus decimal point or 400.

11. Repeat steps 5 through 10.

12. After completing calibration:

• Press the BRAKE ON/OFF button OFF to

remove loading from the dynamometer.

13. Remove the calibration beam from the dynamometer shaft.

14. Proceed with your desired motor testing.

Figure 10. Alternative Calibration

Torque = Weight (W) x Distance (D)

Weight (W) = Torque / Distance (D)

Be sure the shaft flat is facing down, tighten the cal-beam screw against the

shaft flat only.

Page 30

7 - T7 - T

7 - T

7 - T7 - T

PROBLEM REASON SOLUTION

Command does not match the

Display indicates I/O ERROR

Speed command sent, but Controller does not respond.

Mechanical power reads much hi

her or lower than expected.

No GPIB communication Setup error and/or hardware fault.

No RS-232 communication Setup error and/or hardware fault.

Dynamometer shaft does not turn smoothly when BRAKE is OFF.

unit's pro instructions.

Communication occured but the Controller is not loadin

Torque units are incorrect.

Salient poles were set up on the rotor by havin applied with no shaft rotation.

roubleshootingroubleshooting

roubleshooting

roubleshootingroubleshooting

rammed set of

the motor.

brake current

Use correct command and format.

Adjust PID values.

Set torque input units to match the specifications on dynamometer nameplate.

Check:

• GPIB address of Controller

• GPIB cable: should be functionin

attached to Controller and computer interface card.

Check:

• Baud rate of Controller

• Pinout of serial cable

• Cable attachment to Controller and serial

interface port of computer. Start the motor and brin

Press BRAKE button ON. Adjust output current up to a value at least 25% of the maximum torque ratin in use (if possible). Reduce output current

to 0.

and

up to speed.

of the dynamometer

If you require additional assistance, please contact

Magtrol Customer Service at 1-800-828-7844 or 1-716-668-5555

Page 31

®®

Appendix AAppendix A

Appendix A

Appendix AAppendix A

Magtrol offers a comprehensive motor-test software program to satisfy most of your programming needs. To order your software, call Magtrol Sales at 1-800-828-7844 or 1-716-668-5555.

SIMPLE READ

: L: L

: L

: L: L

abVIEWabVIEW

abVIEW

abVIEWabVIEW

®®

P P

rogramming Examplesrogramming Examples

rogramming Examples

P P

rogramming Examplesrogramming Examples

Page 32

TORQUE STABILIZED

Magtrol Model DSP6000 Dynamometer ControllerAppendix A: LabVIEW Programming Examples

Page 33

Magtrol Model DSP6000 Dynamometer Controller Appendix A: LabVIEW Programming Examples

SPEED STABILIZED

Page 34

Appendix BAppendix B

Appendix B

Appendix BAppendix B

: Inertia Correction: Inertia Correction

: Inertia Correction

: Inertia Correction: Inertia Correction

INERTIAL EFFECT ON MOTOR TEST DATA

A major advantage of the DSP6000 is its ability to obtain full motor performance data (free run to locked rotor) by continuous load application with an absorption dynamometer. Data acquisition is fast, resulting in minimal motor I2R losses, and loading characteristics simulate actual end-use applications.

When a motor is accelerating or decelerating, the measured torque is the sum of the true motor torque ± the inertial torque, or stored energy, of the system. Unless inertial torque is excluded, motor performance will vary in proportion to the rate of acceleration or deceleration.

This type of error can produce problematic test results. For example, during rapid deceleration, system inertia can produce apparent efficiency greater than 1.0. This error may occur if output power is divided by input power without extracting the stored energy in the system.

4. Immediately program your DSP6000 (Nddddd) to a speed equal to the dynamic speed value. When the speed stabilizes, use this as the static torque value.

CF = Dynamic Torque - Static Torque

To correct your data, subtract the CF from each torque point obtained during the ramp.

Example:

SPEED VS TORQUE

CURVE WITH CONSTANT DECELERATION

S P E E D

STATIC TORQUE

CF = DIFFERENCE IN TORQUE

VALUE

TORQUE

DYNAMIC

TORQUE VALUE

.78 OF FR

DIFFERENCE IN TORQUE

Since "inertial effect" is only a factor when speed is changing, and because inertial torque is proportional to the rate of change, inertial value may be expressed as a unit of torque per change in RPM in a given period of time. With the DSP6000, properly adjusted PID values yield constant change in RPM so that the inertial torque can be expressed as a constant.

PROCEDURE FOR INERTIA CORRECTION

1. Determine the torque Correction Factor (CF) as follows:

• Adjust the PID loop properly

• Establish a torque value equal to the inertial

torque.

2. Use the "Program Down" command (PD#) to ramp to 75% of the free-run speed.

3. Select a data point on the performance curve where speed will be approximately 78% of the free-run speed. Let this represent the dynamic speed-torque value.

KEY CONDITIONS

• Select appropriate value. The test point selection of 78% is typical for an induction motor. Use a value in the linear portion of the motor curve where there is a substantial torque change with speed.

• Acquire data rapidly. Rapid data acquisition is necessary so that motor heating does not degrade performance by adding a false difference between the static and dynamic torque values.

• Use a regulated power source. The input line voltage must be stable for the time necessary to perform the test. Torque varies by the square of the change in line voltage.

• Obtain new CF value for various deceleration/ acceleration rates. The CF is

only valid for its specific ramp rate. To calculate other CF rates, use the following equation:

= (CF

new

/ramp rate) X new ramp rate

old

Page 35

Appendix CAppendix C

Appendix C

Appendix CAppendix C

DYNO SETUP MENU

: F: F

: F

: F: F

ront Pront P

ront P

ront Pront P

anel/Display Menu Flow Chartsanel/Display Menu Flow Charts

anel/Display Menu Flow Charts

anel/Display Menu Flow Chartsanel/Display Menu Flow Charts

6000 bit

ENCODER:

600 bit

60 bit

N.m

N.cm

N.mm

kg.cm

DYNO

SETUP:

INPUT

UNITS:

g.cm

lb.ft.

lb.in.

oz.ft.

oz.in.

Page 36

COM SETUP MENU

Magtrol Model DSP6000 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow Charts

19200

9600

4800

COM SETUP:

RS-232

BAUD:

GPIB

ADDRESS:

2400

1200

600

300

0 - 15

CONTRAST:

0 - 3

Page 37

Magtrol Model DSP6000 Dynamometer Controller Appendix C: Front Panel/Display Menu Flow Charts

AUX SETUP MENU

POWER UNITS MENU

SCALE:

AUX SETUP: DISPLAY: OFF

0 - 10000

UNITS/VOLT

POWER UNITS:

Page 38

TORQUE UNITS MENU

Magtrol Model DSP6000 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow Charts

N.m

N.cm

N.mm

TORQUE

UNITS:

kg.cm

g.cm

lb.ft.

lb.in.

oz.ft.

oz.in.

Page 39

Appendix DAppendix D

Appendix D

Appendix DAppendix D

ENCODER/SWITCH BOARD

: Schematics: Schematics

: Schematics

: Schematics: Schematics

(PB0)

(PB1)

(PB2)

(PB3)

(PB4)

(PB5)

(PB6)

(PB7)

(PB8)

(PB9)

(PB10)

(AUDIO)

(+ 5V)

(GND)

12 13 14

POWER SUPPLY

1 2 3 4 5

22K 22K 22K 22K 22K 22K 22K 22K 22K 22K 22K

SW1

TX1

14A-30-515

SW2

SW3

PD05

SW4

SW5

BR1

BR2

SW6

SPKR1

C19 4700

C17 1000

R7R6R5R4R3R2R1 R8 R9 R10 R11

SW7

SW8

C23

0.1

C22

0.1

SW9

LM340T5

IN OUT

COM

+25V

R21

5.1K

A B

SW10

C23

0.1

(ROTARY ENCODER)

+5VD +5VA

1uH

1.0

1uH

TX2

14A-56-28

PE05

BR3

C18 1000

C25 4700

+35V

COM

C21

0.1

R23

3.3K

-25V

R22

5.1K

LM320T5

IN OUT

COM

C24

0.1

-5VA

C20 1

Page 40

Magtrol Model DSP6000 Dynamometer ControllerAppendix D: Schematics

+5VD

RESET~

DIO8

RESET

U13

6717161819

D1D2D0

10911

I/O0

D21

D23 12

DQ0A0

243

D15

D13 12

243

DQ0 DQ0

A0A1A3

U12 U10U11 U7

A15

DSP56002FC40

EXTAL

VDD1OUT

GND

NC/OE

14 2

80777471918988

DIO6

DIO7

DIO5

ADDR3

ADDR4

131211

O4O6O5

O2O1O3

A37A5

A2A1A0

D3D2D1D0D6D4D5 13

I/O3

I/O2

I/O1

D19

D22 131511

DQ2

DQ3

DQ1A1

D14 131511

DQ3

DQ2

DQ1

D5D7D1 131512

DQ1

DQ32MHz

A2 DQ2

A12

A13

A14

XTAL

132

XTAL_OSC d

1618171315 46513

DIO3

DIO2

DIO4

ADDR2

ADDR0

ADDR1

D6D7D3D5D4

171618

A6A7A9

598

161517

I/O4

I/O5A6I/O6

3A25

D16

D18

D17

DQ5A5

DQ6

A4 DQ4

A6DQ6

25524

D11

D10

D9 16

DQ4A3DQ5A5

A4DQ4

A6A7A8

25524

D2D0D6

D417

181916

DQ6

A5 DQ5

452

7782788083

766171

A11

A10

DIO1

DATA15

253232421

I/O7

A8A9OE

+5VD

D20 191817

DQ7A7

D12 191817

DQ7

A8A7A9

CKOUT

123

40MHz

10121178

819576

IFC

REN

DATA13

DATA14

67954947501011

3215

A10

A11

A10

211918

22K

R43

A10

7236

A10

7236

A10

126

+5VD

2324201922

IEEE488

DAV

NRFD

NDAC

DATA10

DATA12

DATA11

A13CEA12

A14

26222

R20

+5VDW

AT28C16E-20SC

272220

A13

A1127

A12

21910

A11

A12

A13

21910

A13

A11

A12

967

211023

A4A7A1

PCAP

PLOCK

CKP

128

130

131

0.012

C10

R17

+5VD

EOI

ATN

SRQ

DATA7

DATA6

DATA9

DATA8

OE/VPP

A15

MBM27C512

22K

PAGE

A14

MCM6206BAEJ25

A14

MCM6206BAEJ25

RD~

A14

MCM6206BAEJ25

A15

118

117

D22

D23

PINIT

125

RESET~

2.2K INPUT

40MHz

XTAL1

XTAL0

DATA5

DATA4

WR~

115

D21

RESET

RES

GND

C81

KEYCLK

DATA2

DATA3

434439

74HC00

DS~

114

112

D20

D19

R19

+5VD

0.01

MC34064D 4

0.1

99989666100

KEYDQ

KEYRST

DATA0

DATA1

424664

U20a

131215

Y1B

U19

AY0

A12

A14

A13

111

109

107

108

D16

D17

D18

IRQB

NMI

IRQAMODA/

MODC/

MODB/

119

121

120

22K

+5VD

TADCS

LADCS

A15

106

D15

D14

R15

R18

REM

TRIG

ABUS

RDWRCS

623414

+5VD

9711

Y6Y5Y74Y4G2A

G2B

DS~

103

104D996

100

101

D12

D13

D11

DSO

DSI/OS0

22K

DSP & MEMORY

20511

DCAS

ABUS_OE

BBUS_OE

CPUACC

BBUS

74HC138

D10

DSCK/OS1

515052

DACK

DRQ

323322

D2D3D1D5D4

RDDRBN

RD~

WR~

+5VD

HEADER_8

85888790915584

4247444146

+5VD

WTBGBR

434054

R72

PAGED

22K

RDY1

INTR

BURST_RD

FIFO_RDY

SWAP

DS~

57138

X/Y

MODE

532952

PAGE

HACK/PB14

TIO

TNT4882

BUSY

PB10

PB11

12106D64

HA2/PB10

HEN/PB12

HR/W/PB11

HREQ/PB13

nc1

nc2

PB8

PB9

141715

H7/PB7

HA0/PB8

HA1/PB9

PB7

PB5

PB6

H5/PB5

H6/PB6

PB4

H4/PB4

D2D0D6

D3D5D1

PB2

PB3

H3/PB3

H2/PB2

862 751

PB1

PB0

242119

H1/PB1

H0/PB0

BUSY

+5VD

1211

13159

+5VD

STD

STD/PC8

161410

DISPLAY

HEADER_16

FSI

SRD

SCK

SC2/PC5

SCK/PC6

SRD/PC7

DPB

L/R

353228

SC0/PC3

SC1/PC4

0.1

C76

+5VD

0.1

C69

DPA

263325

TXD/PC1

RXD/PC0

SCLK/PC2

U21

74HC00

V+

VCC

C1+

+5VD

U20b

C53

C77

0.1

V-

C1-

0.1

22K

R13

22K

R12

22K

R11

22K

R10

22K

74HC00

C2+

4115

U20c

J10

C68

74HC00

PB1

PB0

C2-

0.1

PB3

468

PB2

45213

TX1OUT

TX2OUT

TX1IN

TX2IN

PB7

PB5

531

PB6

PB4

U20d

PB9

PB8

896

RS232

RX1IN

RX2IN

MAX232CSE

GND

RX1OUT9RX2OUT

PB11

0.001

3.3K

R16

+5VD

MMBT2222

1.0

C79

R14

141210

11139

KEYPAD

HEADER_14

0.001 d

PB10

C39

0.1

+5VD

C38

0.1

C35

0.1

C29

0.01

C30

0.01

3 x MCM6206BAEJ25

C32

0.01

0.1

+5VD

0.1

C14

0.01

C15

0.01

DSP56002FC40

C12

0.01

0.1

330

+5VD

C13

C72

XTAL_OSC

C71

74HC138

C16

C11

C48

+5VD

C45

C37

C58

C36

TNT4882 27C512

C73

C75

C74

0.1

74HC00

0.1

AT28C16

0.1

0.1 d

0.1

Page 41

Magtrol Model DSP6000 Dynamometer Controller Appendix D: Schematics

ANALOG I/O

Page 42

GlossarGlossar

Glossar

GlossarGlossar

BNC ............................................................................. bayonet, locking-type connector

CCW ............................................................................counterclockwise (turn to left)

CF ................................................................................ correction factor (inertia correction factor)

CR ................................................................................ carriage return

CW ............................................................................... clockwise (turn to right)

D .................................................................................. derivative

D/A .............................................................................. digital to analog converter

DMM ........................................................................... digital multimeter

FR ................................................................................ free-run speed

GPIB (General Purpose Interface Bus) ....................... parallel interface port; interchangeable with IEEE-488

Hp ................................................................................ horsepower; measure of mechanical power

Hz ................................................................................ hertz; frequency

I .................................................................................... integral

y of Abbreviations and Ty of Abbreviations and T

y of Abbreviations and T

y of Abbreviations and Ty of Abbreviations and T

ermserms

erms

ermserms

I/O ................................................................................ input/output

LF ................................................................................ line feed

local ............................................................................. manual control (use front panel controls)

mVDC.......................................................................... millivolts DC

N .................................................................................. speed

NEMA ......................................................................... National Electrical Manufacturers Association

P ................................................................................... proportional; proportional gain

PID ............................................................................... proportional, integral, derivative

PMDC .......................................................................... permanent magnet DC

Q .................................................................................. torque

remote .......................................................................... computer control (uses programmed controls from computer)

RPM............................................................................. revolutions per minute

SI.................................................................................. Systeme Internationale units of measure

S/s ................................................................................ samples per second

V .................................................................................. volts; typically AC

VDC............................................................................. volts DC

Page 43

Magtrol Limited WMagtrol Limited W

Magtrol Limited W

Magtrol Limited WMagtrol Limited W

Magtrol, Inc. warrants its products to be free from defects in material and workmanship under normal use and service for a period of one (1) year from the date of shipment. Software is warranted to operate in accordance with its programmed instructions on appropriate Magtrol instruments. This warranty extends only to the original purchaser and shall not apply to fuses, computer media, or any other product which, in Magtrol’s sole opinion, has been subject to misuse, alteration, abuse or abnormal conditions of operation or shipping.

Magtrol’s obligation under this warranty is limited to repair or replacement of a product which is returned to the factory within the warranty period and is determined, upon examination by Magtrol, to be defective. If Magtrol determines that the defect or malfunction has been caused by misuse, alteration, abuse or abnormal conditions of operation or shipping, Magtrol will repair the product and bill the purchaser for the reasonable cost of repair. If the product is not covered by this warranty, Magtrol will, if requested by purchaser, submit an estimate of the repair costs before work is started.

To obtain repair service under this warranty, purchaser must forward the product (transportation prepaid) and a description of the malfunction to the factory. The instrument shall be repaired at the factory and returned to purchaser, transportation prepaid. MAGTROL ASSUMES NO RISK FOR IN-TRANSIT DAMAGE.

THE FOREGOING WARRANTY IS PURCHASER’S SOLE AND EXCLUSIVE REMEDY AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY, OR FITNESS FOR ANY PARTICULAR PURPOSE OR USE. MAGTROL SHALL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OR LOSS WHETHER IN CONTRACT, TORT, OR OTHERWISE.

arrantyarranty

arranty

arrantyarranty

CLAIMS

Immediately upon arrival, purchaser shall check the packing container against the enclosed packing list and shall, within thirty (30) days of arrival, give Magtrol notice of shortages or any nonconformity with the terms of the order. If purchaser fails to give notice, the delivery shall be deemed to conform with the terms of the order.

The purchaser assumes all risk of loss or damage to products upon delivery by Magtrol to the carrier. If a product is damaged in transit, PURCHASER MUST FILE ALL CLAIMS FOR DAMAGE WITH THE CARRIER to obtain compensation. Upon request by purchaser, Magtrol will submit an estimate of the cost to repair shipment damage.

Page 44

70 Gardenville Parkway ! Buffalo, New York 14224

Phone: (716) 668-5555 ! (800) 828-7844 Fax: (716) 668-8705

Web site: www.magtrol.com ! E-mail: [email protected]

MOTOR TESTING EQUIPMENT ! HYSTERESIS BRAKES AND CLUTCHES