Magtrol DSP6001 User Manual

Model DSP6001

Via Paolo Uccello 4 - 20148 Milano Tel +39 02 48 009 757 Fax +39 02 48 002 070 info@dspmindustria.it www.dspmindustria.it

High Speed Programmable

Dynamometer Controller

User’s Manual

Purchase Record

Please record all model numbers and serial numbers of your Magtrol equipment, along with the general purchase information. The model number and serial number can be found on either a silver identiﬁcation plate or white label afﬁxed to each unit. Refer to these numbers whenever you communicate with a Magtrol representative about this equipment.

Model Number: _____________________________

Serial Number: _____________________________

Purchase Date: _____________________________

Purchased From: _____________________________

While every precaution has been exercised in the compilation of this document to ensure the accuracy of its contents, 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.

TRADEMARKS

LabVIEW™ is a trademark of National Instruments Corporation. Microsoft® is a registered trademark of Microsoft Corporation. National Instruments™ is a trademark of National Instruments Corporation. Windows® is a registered trademark of Microsoft Corporation.

1st Edition, revision J – March 2010

Safety Precautions

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

2. Check line voltage before operating the DSP6001.

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

Revisions To This Manual

The contents of this manual are subject to change without prior notice.

REVISION DATE

1st Edition, revision J – March 2010

TABLE OF REVISIONS

Date Edition Change Section(s)

03/01/10 1st Edition - rev. J Added 60 bit encoder to chart for torque transducers 3.3.1 04/16/09 1st Edition - rev. I Added UE commands 5 = 1-bit, 6 = 2-bit and 7 = 6-bit. 8.6.4 05/18/05 1st Edition - rev. H

06/28/04 1st Edition - rev. G Removed DSP6001 resetting procedure 9.4 05/24/04 1st Edition - rev. F Added DIR#, OH1 and IOXX.XX Misc. Command codes 8.6.7, D.6 08/05/03 1st Edition - rev. E Ratings changes for: Operating Temperature, Accuracy,

08/05/03 1st Edition - rev. E Auxiliary Input rating replaced with Input Voltage Range 1.3 08/05/03 1st Edition - rev. E Screen Saver function removed 2.3.2 08/05/03 1st Edition - rev. E Added Power Alarm to priority table 6.1.3 08/05/03 1st Edition - rev. E Deleted DDLXX.XX Ramp Command code 8.6.3, D.3 08/05/03 1st Edition - rev. E Deleted A,B,C,D and E Speed Command codes 8.6.3, 8.6.5, D.3 08/05/03 1st Edition - rev. E Deleted C# Misc. Command code 8.6.7, D.6 05/06/02 1st Edition - rev. D Speed check and decimal point check added to calibration

12/20/01 1st Edition - rev. C Added values for analog ﬁlter setup (AF1# and AF2#) 8.6.4 12/20/01 1st Edition - rev. C Added ﬁlter cutoff frequency 4.1 08/27/01 1st Edition - rev. B Changed name of chapter titles Chap. 7 & 8 08/27/01 1st Edition - rev. B Changed name and location of Additional Scale Factor Table Appendix F 08/27/01 1st Edition - rev. B Updated Power Analyzers in System Options table 1.3 07/23/01 1st Edition - rev. A Updated Motor Testing Software section and System Options 1.3 07/23/01 1st Edition - rev. A Increased range of PID numbers when using the multiplier 5.4 07/23/01 1st Edition - rev. A Changed Contact Conﬁguration and Manufacturer P/N under

07/23/01 1st Edition - rev. A Air Flow Alarm for Eddy-Current/Powder Brake Dynamometers

07/23/01 1st Edition - rev. A Changed IDN? command to *IDN? command 8.6 07/23/01 1st Edition - rev. A Added alarm condition to explanation of OD command 8.6 07/23/01 1st Edition - rev. A Entered exact ﬁgures for reference voltage 9.3.2, 9.3.3 07/23/01 1st Edition - rev. A Deﬁned accepted voltage range in steps 3, 6, 9 & 14 9.3.4 03/27/01 1st Edition Complete re-write of Preliminary Manual entire manual

Changed M-TEST 4.0 references to “M-TEST” or “M-TEST 5.0” throughout

manual

1.3

Temperature Coefﬁcient and Accessory Torque/Speed Output

9.3.5 & 9.3.6

procedure

6.1.1

Relay Speciﬁcations

6.1.3

is not available

Table of Contents

SAFETY PRECAUTIONS ......................................................................................................................... I

REVISIONS TO THIS MANUAL ............................................................................................................... II

REVISION DATE ................................................................................................................................................................. II

TABLE OF REVISIONS ...................................................................................................................................................... II

TABLE OF CONTENTS .......................................................................................................................... III

TABLE OF FIGURES ........................................................................................................................................................VII

PREFACE ................................................................................................................................................IX

PURPOSE OF THIS MANUAL .........................................................................................................................................IX

WHO SHOULD USE THIS MANUAL ..............................................................................................................................IX

MANUAL ORGANIZATION ............................................................................................................................................. IX

CONVENTIONS USED IN THIS MANUAL ..................................................................................................................... X

1. INTRODUCTION ................................................................................................................................ 1

1.1 UNPACKING YOUR DSP6001 ..................................................................................................................................... 1

1.2 NEW FEATURES OF THE DSP6001 ........................................................................................................................... 1

1.3 DATA SHEET ................................................................................................................................................................. 2

2. CONTROLS ......................................................................................................................................... 8

2.1 FRONT PANEL .............................................................................................................................................................. 8

2.2 FRONT PANEL CONTROLS AND BUTTONS ........................................................................................................... 8

2.2.1 Enabling Secondary Functions ......................................................................................................................... 8

2.2.2 Enabling Saving Function ................................................................................................................................ 9

2.2.3 How to Use Front Panel Controls and Buttons ................................................................................................ 9

2.3 VACUUM FLUORESCENT DISPLAY (VFD) ........................................................................................................... 10

2.3.1 Contrast Settings ............................................................................................................................................ 11

2.3.2 Screen Saver ................................................................................................................................................... 11

2.3.3 Status Display Messages ................................................................................................................................ 11

2.4 REAR PANEL .............................................................................................................................................................. 12

2.5 REAR PANEL INPUTS AND OUTPUTS................................................................................................................... 12

3. INSTALLATION/CONFIGURATION .................................................................................................. 15

3.1 POWERING UP THE DSP6001 .................................................................................................................................. 15

3.1.1 Setting Unit for Line Voltage ......................................................................................................................... 15

3.1.2 Self-Test ......................................................................................................................................................... 16

3.1.3 Main Menu ..................................................................................................................................................... 16

3.2 TESTING INSTRUMENTATION SETUP .................................................................................................................. 17

3.2.1 Dynamometer Conﬁguration Menu ............................................................................................................... 18

3.2.2 Hysteresis Dynamometer Setup ..................................................................................................................... 19

3.2.3 Hysteresis Dynamometer with Torque Transducer Setup .............................................................................. 20

3.2.4 Hysteresis Dynamometer with Auxiliary Instrumentation Setup................................................................... 22

3.2.5 Hysteresis Dynamometer with Eddy-Current or Powder Brake Setup .......................................................... 24

3.2.6 Eddy-Current or Powder Brake Dynamometer Setup .................................................................................... 26

3.2.7 Eddy-Current or Powder Brake Dynamometer with Torque Transducer Setup ............................................. 27

3.2.8 Eddy-Current or Powder Brake Dynamometer with Auxiliary Instrumentation Setup ................................. 28

3.2.9 Two Eddy-Current/Powder Brake Dynamometers (Independent Setup) ....................................................... 29

3.2.10 Two Eddy-Current/Powder Brake Dynamometers (Tandem Setup) .............................................................. 31

3.2.11 Eddy-Current Dynamometer with Powder Brake Dynamometer (Tandem Setup) ........................................ 33

3.2.12 In-Line Torque Transducer Cross Loop Function .......................................................................................... 35

iii

Magtrol Model DSP6001 Dynamometer ControllerTable of Contents

3.3 SPEED ENCODER SETUP ......................................................................................................................................... 36

3.3.1 Bit Conﬁgurations .......................................................................................................................................... 36

3.4 TORQUE/SPEED ANALOG OUTPUTS .................................................................................................................... 37

3.4.1 Torque DAC Scale Factor ............................................................................................................................... 37

3.4.2 Speed DAC Scale Factor ................................................................................................................................ 37

3.4.3 Torque/Speed DAC Setup .............................................................................................................................. 37

4. DIGITAL FILTERS ............................................................................................................................. 38

4.1 FILTER PARAMETERS ............................................................................................................................................. 38

4.2 FILTER SETUP ............................................................................................................................................................ 39

5. PID SETTINGS .................................................................................................................................. 40

5.1 ABOUT THE PID LOOP ............................................................................................................................................. 40

5.1.1 P (Proportional Gain) ..................................................................................................................................... 40

5.1.2 I (Integral) ...................................................................................................................................................... 40

5.1.3 D (Derivative) ................................................................................................................................................. 40

5.2 SETTING PID VALUES .............................................................................................................................................. 40

5.2.1 How To Set P (Proportional Gain) Value ....................................................................................................... 40

5.2.2 How to Set I (Integral) Value .......................................................................................................................... 40

5.2.3 How to Set D (Derivative) Value .................................................................................................................... 40

5.3 HOW THE PID LOOP WORKS .................................................................................................................................. 41

5.3.1 Scale Factors for Hysteresis, Eddy-Current and Powder Brake Dynamometers ........................................... 41

5.3.2 Speed Correction for WB (Eddy-Current Brake) Dynamometer ................................................................... 41

5.3.3 Equations ........................................................................................................................................................ 42

5.4 ADDITIONAL SCALE FACTOR ...............................................................................................................................42

5.4.1 How To Set Additional Scale Factor .............................................................................................................. 42

5.5 SETTING THE CORRECT PID’S FOR YOUR MOTOR .......................................................................................... 43

5.5.1 Setting the PID with an Unknown Motor or System ..................................................................................... 43

5.5.2 Setting the PID for Torque Control ................................................................................................................ 43

5.5.3 Setting the PID for Speed Control ................................................................................................................. 46

5.5.4 Setting the PID for Ramp Down .................................................................................................................... 48

6. ALARM SYSTEM .............................................................................................................................. 50

6.1 GENERAL INFORMATION ....................................................................................................................................... 50

6.1.1 Alarm Relay ................................................................................................................................................... 50

6.1.2 Alarm Operation.............................................................................................................................................51

6.1.3 Alarm Priority ................................................................................................................................................ 52

6.2 POWER ALARM ......................................................................................................................................................... 52

6.2.1 Instructions for Power Alarm Setup ............................................................................................................... 52

6.2.2 Power Alarm Action ....................................................................................................................................... 53

6.2.3 To Reset Power Alarm .................................................................................................................................... 53

6.3 MAXIMUM SPEED ALARM .................................................................................................................................... 53

6.3.1 Instructions for Maximum Speed Alarm Setup .............................................................................................. 53

6.3.2 Maximum Speed Alarm Action ...................................................................................................................... 54

6.3.3 To Reset Maximum Speed Alarm .................................................................................................................. 54

6.4 MAXIMUM TORQUE ALARM ................................................................................................................................ 54

6.4.1 Instructions for Maximum Torque Alarm Setup ............................................................................................ 54

6.4.2 Maximum Torque Alarm Action ....................................................................................................................55

6.4.3 To Reset Maximum Torque Alarm ................................................................................................................. 55

6.5 AIR FLOW ALARM .................................................................................................................................................... 56

6.5.1 Instructions for Air Flow Alarm Setup ........................................................................................................... 56

6.5.2 Air Flow Alarm Action ................................................................................................................................... 56

6.5.3 To Reset Air Flow Alarm ............................................................................................................................... 56

Magtrol Model DSP6001 Dynamometer Controller

Table of Contents

6.6 WATER FLOW ALARM ............................................................................................................................................. 57

6.6.1 Instructions for Water Flow Alarm Setup ....................................................................................................... 57

6.6.2 Water Flow Alarm Action .............................................................................................................................. 57

6.6.3 To Reset Water Flow Alarm ........................................................................................................................... 57

6.7 EXTERNAL ALARM .................................................................................................................................................. 58

6.7.1 Instructions for External Alarm Setup............................................................................................................ 58

6.7.2 External Alarm Action.................................................................................................................................... 58

6.7.3 To Reset External Alarm ................................................................................................................................ 58

6.8 TEMPERATURE ALARM .......................................................................................................................................... 59

6.8.1 Instructions for Temperature Alarm Setup ..................................................................................................... 59

6.8.2 Temperature Alarm Action ............................................................................................................................. 59

6.8.3 To Reset Temperature Alarm .......................................................................................................................... 59

6.9 ELECTRICAL ALARM .............................................................................................................................................. 60

6.9.1 Instructions for Electrical Alarm Setup .......................................................................................................... 60

6.9.2 Electrical Alarm Action .................................................................................................................................. 60

6.9.3 To Reset Electrical Alarm ..............................................................................................................................60

7. MANUALLY CONTROLLED OPERATION ....................................................................................... 61

7.1 HOW TO CHOOSE DESIRED CHANNEL WHEN USING TWO DYNAMOMETERS ......................................... 61

7.2 HOW TO SET DESIRED POWER UNITS ................................................................................................................ 62

7.3 HOW TO SET DESIRED TORQUE UNITS .............................................................................................................. 62

7.4 HOW TO SET TORQUE CONTROL .......................................................................................................................... 62

7.5 HOW TO SET SPEED CONTROL ............................................................................................................................. 63

7.6 HOW TO SET OPEN LOOP CONTROL .................................................................................................................... 64

8. COMPUTER CONTROLLED OPERATION ...................................................................................... 65

8.1 ABOUT THE GPIB INTERFACE ............................................................................................................................... 65

8.1.1 Installing the GPIB (IEEE-488) Connector Cable ......................................................................................... 65

8.1.2 Changing the GPIB Primary Address ............................................................................................................66

8.2 ABOUT THE RS-232 INTERFACE ............................................................................................................................ 66

8.2.1 Connection ..................................................................................................................................................... 66

8.2.2 Communication Parameters ........................................................................................................................... 67

8.2.3 Baud Rate ....................................................................................................................................................... 67

8.3 CHECKING THE DSP6001-TO-PC CONNECTION ................................................................................................. 67

8.4 DATA FORMAT ........................................................................................................................................................... 68

8.5 PROGRAMMING ....................................................................................................................................................... 68

8.5.1 Data Termination Characters .......................................................................................................................... 68

8.5.2 Timeout ..........................................................................................................................................................69

8.6 DSP6001 COMMAND SET ........................................................................................................................................ 69

8.6.1 Alarm Commands .......................................................................................................................................... 69

8.6.2 Communication Commands ........................................................................................................................... 70

8.6.3 Ramp Commands ........................................................................................................................................... 71

8.6.4 Setup Commands ........................................................................................................................................... 72

8.6.5 Speed Commands ........................................................................................................................................... 74

8.6.6 Torque Commands ......................................................................................................................................... 74

8.6.7 Miscellaneous Command ............................................................................................................................... 75

9. CALIBRATION .................................................................................................................................. 76

9.1 CLOSED-BOX CALIBRATION ................................................................................................................................. 76

9.2 CALIBRATION SCHEDULE ...................................................................................................................................... 76

9.3 BASIC CALIBRATION PROCESS ............................................................................................................................. 76

9.3.1 Initial Calibration Procedure .......................................................................................................................... 76

Magtrol Model DSP6001 Dynamometer ControllerTable of Contents

9.3.2 TSC1 Offset and Gain .................................................................................................................................... 77

9.3.3 TSC2 Offset and Gain .................................................................................................................................... 78

9.3.4 DAC Output Offset and Gain ......................................................................................................................... 78

9.3.5 Speed Check ................................................................................................................................................... 80

9.3.6 Decimal Point Check......................................................................................................................................81

10. TROUBLESHOOTING ..................................................................................................................... 82

APPENDIX A: LABVIEW PROGRAMMING EXAMPLES

A.1 SIMPLE READ ............................................................................................................................................................ 83

A.2 TORQUE STABILIZED .............................................................................................................................................. 84

A.3 SPEED STABILIZED .................................................................................................................................................. 85

..................................................................... 83

APPENDIX B: INERTIA CORRECTION ............................................................................................... 86

B.1 INERTIAL EFFECT ON MOTOR TEST DATA ......................................................................................................... 86

B.2 PROCEDURE FOR INERTIA CORRECTION ..........................................................................................................86

B.2.1 Key Conditions ............................................................................................................................................... 87

APPENDIX C: FRONT PANEL/DISPLAY MENU FLOW CHARTS ....................................................... 88

C.1 PRIMARY KEY FUNCTIONS.................................................................................................................................... 88

C.2 SECONDARY KEY FUNCTIONS .............................................................................................................................89

C.2.1 Power Units Menu .......................................................................................................................................... 89

C.2.2 Torque Units Menu......................................................................................................................................... 89

C.2.3 Max Speed Menu ...........................................................................................................................................90

C.2.4 Aux Setup Menu ............................................................................................................................................ 90

C.2.5 Com Setup Menu............................................................................................................................................ 91

C.2.6 Dyno Setup Menu .......................................................................................................................................... 92

APPENDIX D: REMOTE CONFIGURATION FLOW CHARTS ............................................................ 101

D.1 ADVANCED CONFIGURATION ............................................................................................................................. 101

D.2 PRE-TEST .................................................................................................................................................................. 102

D.3 RAMP ......................................................................................................................................................................... 103

D.4 SPEED ........................................................................................................................................................................ 104

D.5 TORQUE .................................................................................................................................................................... 105

D.6 MISCELLANEOUS ................................................................................................................................................... 106

D.7 DATA .......................................................................................................................................................................... 106

APPENDIX E: SCHEMATICS .............................................................................................................. 107

E.1 DYNAMOMETER POWER SUPPLY ....................................................................................................................... 107

E.2 DYNAMOMETER DSP & MEMORY ...................................................................................................................... 108

E.3 DSP DYNAMOMETER ANALOG I/O ..................................................................................................................... 109

APPENDIX F: ADDITIONAL SCALE FACTOR TABLE ....................................................................... 110

INDEX

................................................................................................................................................... 111

Magtrol Model DSP6001 Dynamometer Controller

TABLE OF FIGURES

2. CONTROLS

Figure 2–1 Front Panel ..............................................................................................................................................8

Figure 2–2 Secondary Function Menu ........................................................................................................................8

Figure 2–3 Saving Function Menu ..............................................................................................................................9

Figure 2–4 Rear Panel ..............................................................................................................................................12

Figure 2–5 Dynamometer Brake Input .....................................................................................................................12

Figure 2–6 Accessory Torque-Speed Output .............................................................................................................12

Figure 2–7 Dynamometer/TSC1 Connector .............................................................................................................13

Figure 2–8 AUX/TSC2 Connector .............................................................................................................................13

Figure 2–9 Supply 1 Connector ................................................................................................................................13

Figure 2–10 Supply 2 Connector ..............................................................................................................................14

Figure 2–11 RS-232C Interface ................................................................................................................................14

3. INSTALLATION/CONFIGURATION

Figure 3–1 Cover for Voltage Selector, Fuses ...........................................................................................................15

Figure 3–2 Program Download Display ...................................................................................................................16

Figure 3–3 Revision Display .....................................................................................................................................16

Figure 3–4 Alarm Warning Display ..........................................................................................................................16

Figure 3–5 Main Menu .............................................................................................................................................16

Figure 3–6 Dyno Setup Menu ...................................................................................................................................18

Figure 3–7 Dynamometer Conﬁguration Menu ........................................................................................................18

Figure 3–8 Hysteresis Dynamometer Setup ..............................................................................................................19

Figure 3–9 Hysteresis Setup Menu ...........................................................................................................................19

Figure 3–10 Hysteresis Dynamometer with Torque Transducer Setup .....................................................................20

Figure 3–11 Torque Transducer Setup Menu ............................................................................................................21

Figure 3–12 Aux Setup Menu - Display On ..............................................................................................................21

Figure 3–13 TSC1 with TM2XX Output Menu ..........................................................................................................21

Figure 3–14 Hysteresis Dynamometer with Auxiliary Instrumentation Setup ..........................................................22

Figure 3–15 TSC2 Aux Setup Menu ..........................................................................................................................23

Figure 3–16 TSC1 with AUX Output Menu ...............................................................................................................23

Figure 3–17 Hysteresis Dynamometer with Eddy-Current or Powder Brake Setup .................................................24

Figure 3–18 TSC2 Eddy-Current/Powder Brake Setup Menu ..................................................................................25

Figure 3–19 Nominal Speed Setup Menu ..................................................................................................................25

Figure 3–20 Eddy-Current or Powder Brake Dynamometer Setup ..........................................................................26

Figure 3–21 TSC1 Eddy-Current/Powder Brake Setup Menu ..................................................................................26

Figure 3–22 Eddy-Current or Powder Brake Dynamometer with Torque Transducer Setup ...................................27

Figure 3–23 Eddy-Current or Powder Brake Dynamometer with Auxiliary Instrumentation Setup ........................28

Figure 3–24 Two Eddy-Current/Powder Brake Dynamometers (Independent Setup) ..............................................29

Figure 3–25 Tandem Conﬁguration Menu ................................................................................................................30

Figure 3–26 Two Eddy-Current/Powder Brake Dynamometers (Tandem Setup) .....................................................31

Figure 3–27 Eddy-Current Dynamometer with Powder Brake Dynamometer (Tandem Setup) ...............................33

Figure 3–28 TSC1 Eddy-Current Setup Menu ...........................................................................................................33

Figure 3–29 TSC2 Powder Brake Setup Menu ..........................................................................................................34

Figure 3–30 Maximum Speed Excited Menu ............................................................................................................34

Figure 3–31 In-Line Torque Transducer Cross Loop Function ................................................................................35

Figure 3–32 Brake Type Menu ..................................................................................................................................35

Figure 3–33 Brake Type Menu (for WB) ...................................................................................................................36

Figure 3–34 Encoder Menu ......................................................................................................................................36

Figure 3–35 Torque/Speed DAC Setup Menu ............................................................................................................37

Table of Contents

4. DIGITAL FILTERS

Figure 4–1 Transposed Direct Form II Architecture .................................................................................................38

5. PID SETTINGS

Figure 5–1 System Block Diagram............................................................................................................................41

Figure 5–2 Open Loop Control Menu .......................................................................................................................43

Figure 5–3 Initial P Setting for Torque Control at 25% ...........................................................................................44

vii

Magtrol Model DSP6001 Dynamometer ControllerTable of Contents

Figure 5–4 High Initial P Setting for Torque Control .............................................................................................44

Figure 5–5 Initial I Setting for Torque Control .........................................................................................................45

Figure 5–6 Initial D Setting for Torque Control .......................................................................................................45

Figure 5–7 Initial P Setting for Speed Control at 25% ..............................................................................................46

Figure 5–8 Initial I Setting for Speed Control ..........................................................................................................47

Figure 5–9 Initial D Setting for Speed Control .........................................................................................................47

Figure 5–10 Ramp Down Low I ................................................................................................................................48

Figure 5–11 Ramp Down High I ...............................................................................................................................49

Figure 5–12 Ramp Down Dynamic I ........................................................................................................................49

6. ALARM SYSTEM

Figure 6–1 Normal Condition “Energized Relay” ...................................................................................................50

Figure 6–2 Alarm Condition “De-Energized Relay” ...............................................................................................50

Figure 6–3 Typical Application .................................................................................................................................51

Figure 6–4 Alarm Enable/Disable Menu ..................................................................................................................51

Figure 6–5 Max Power Menu ....................................................................................................................................52

Figure 6–6 Power Alarm Display .............................................................................................................................53

Figure 6–7 Speed Alarm Setup Menu........................................................................................................................53

Figure 6–8 -OL- Speed Alarm Display .....................................................................................................................54

Figure 6–9 Over Speed Alarm Message Display ......................................................................................................54

Figure 6–10 Torque Alarm Setup Menu ....................................................................................................................55

Figure 6–11 -OL- Torque Alarm Display ..................................................................................................................55

Figure 6–12 Over Torque Alarm Message Display ...................................................................................................55

Figure 6–13 Air Flow Alarm Setup Display .............................................................................................................56

Figure 6–14 Air Flow Alarm Message Display ........................................................................................................56

Figure 6–15 Water Flow Alarm Setup Display .........................................................................................................57

Figure 6–16 Water Flow Alarm Message Display ....................................................................................................57

Figure 6–17 External Alarm Setup Display ..............................................................................................................58

Figure 6–18 External Alarm Message Display .........................................................................................................58

Figure 6–19 Temperature Alarm Message Display ...................................................................................................59

Figure 6–20 Electrical Alarm Message Display .......................................................................................................60

7. MANUALLY CONTROLLED OPERATION

Figure 7–1 Dynamometer Channel Menu .................................................................................................................61

Figure 7–2 Power Units Menu ..................................................................................................................................62

Figure 7–3 Torque Units Menu .................................................................................................................................62

Figure 7–4 Torque Control Menu ..............................................................................................................................62

Figure 7–5 Max Speed Menu ....................................................................................................................................63

8. COMPUTER CONTROLLED OPERATION

Figure 8–1 GPIB Installation ..................................................................................................................................65

Figure 8–2 Com Setup Menu Display .......................................................................................................................66

Figure 8–3 RS-232 Interface .....................................................................................................................................66

Figure 8–4 Straight Through Pin-to-Pin Cable Connection .....................................................................................67

9. CALIBRATION

Figure 9–1 Calibration Display Analog Inputs ........................................................................................................77

Figure 9–2 TSC1 Input Connector ............................................................................................................................77

Figure 9–3 TSC2 Input Connector ............................................................................................................................78

Figure 9–4 Calibration Output DAC Display Menu .................................................................................................78

Figure 9–5 Supply 1 Connector ................................................................................................................................79

Figure 9–6 Supply 2 Connector ................................................................................................................................79

Figure 9–7 Calibration Accessory Torque DAC Display Menu ................................................................................79

Figure 9–8 Accessory Torque-Speed Output .............................................................................................................80

Figure 9–9 Calibration Accessory Speed DAC Display Menu .................................................................................80

viii

PURPOSE OF THIS MANUAL

This manual contains all the information required for the installation and general use of the Model DSP6001 Dynamometer Controller. To ensure proper use of the instrument, please read this manual thoroughly before operating it. Keep the manual in a safe place for quick reference whenever a question arises.

WHO SHOULD USE THIS MANUAL

This manual is intended for bench test operators who are going to use the Model DSP6001 Dynamometer Controller in conjunction with any Magtrol Hysteresis, Eddy-Current or Powder Brake Dynamometer, Magtrol In-Line Torque Transducer or auxiliary instrumentation.

MANUAL ORGANIZATION

This section gives an overview of the structure of the manual and the information contained within it. Some information has been deliberately repeated in different sections of the document to minimize cross-referencing and to facilitate understanding through reiteration.

Preface

The structure of the manual is as follows:

Chapter 1: INTRODUCTION - Contains the technical data sheet for the DSP6001 Dynamometer

Controller, which describes the unit and provides its technical characteristics.

Chapter 2: CONTROLS - Description of the elements located on the front and rear panels of

the unit.

Chapter 3: INSTALLATION/CONFIGURATION - Provides setup options available with the

DSP6001 Dynamometer Controller. Illustrates and outlines the hardware connection setup and software conﬁgurations for each option.

Chapter 4: DIGITAL FILTERS - Contains theory and setup information pertaining to Digital

Filters.

Chapter 5: PID SETTINGS - Describes the Proportional Integral Derivative (PID) Loop and

provides information on theory, setup and use.

Chapter 6: ALARM SYSTEM - Describes the new built-in alarm feature providing the user

with information on how each different alarm operates along with instructions for setup and use.

Chapter 7: MANUALLY CONTROLLED OPERATION - How to run a test when the DSP6001

is used as a stand-alone unit. Includes information on setting power and torque units, torque and speed control and open loop control.

Chapter 8: COMPUTER CONTROLLED OPERATION - How to run a test when the DSP6001

is used with a PC. Includes information on GPIB Interface, RS-232 Interface, data format, programming and command set.

Chapter 9: CALIBRATION - Provides recommended calibration schedules along with step-

by-step instructions for the calibration procedure.

Magtrol Model DSP6001 Dynamometer ControllerPreface

Chapter 10: TROUBLESHOOTING - Solutions to common problems encountered during setup

and testing.

Appendix A: LABVIEW™ PROGRAMMING EXAMPLES - Magtrol’s comprehensive motor-test

software programs, made speciﬁcally to compliment the DSP6001 Dynamometer Controller.

Appendix B: INERTIA CORRECTION - Describes the inertial effect on motor test data providing

solutions for correction.

Appendix C: FRONT PANEL/DISPLAY MENU FLOW CHARTS - A visual display of various

setup procedures.

Appendix D: REMOTE CONFIGURATION FLOW CHARTS - A visual display of the command

set used when programming the DSP6001.

Appendix E: SCHEMATICS - For Encoder/Switch Board, Power Supply, DSP & Memory and

Analog I/O.

Appendix F: ADDITIONAL SCALE FACTOR TABLE - Provides additional scale factor values

based on test instrument selection.

CONVENTIONS USED IN THIS MANUAL

The following symbols and type styles may be used in this manual to highlight certain parts of the text:

Note: This is intended to draw the operator’s attention to complementary

information or advice relating to the subject being treated. It introduces information enabling the correct and optimal functioning of the product to be obtained.

Caution : this is used to draw the operator's attention to information,

direCtives, proCedures, etC. whiCh, if ignored, may result in damage being Caused to the material being used. the assoCiated text desCribes the neCessary preCautions to take and the ConsequenCes that may arise if the preCautions are ignored.

WARNING! THIS INTRODUCES DIRECTIVES, PROCEDURES,

PRECAUTIONARY MEASURES, ETC. WHICH MUST BE EXECUTED OR FOLLOWED WITH THE UTMOST CARE AND ATTENTION, OTHERWISE THE PERSONAL SAFETY OF THE OPERATOR OR THIRD PARTIES MAY BE PUT AT RISK. THE READER MUST ABSOLUTELY TAKE NOTE OF THE ACCOMPANYING TEXT, AND ACT UPON IT, BEFORE PROCEEDING FURTHER.

1. Introduction

MODEL DSP6001

DYNAMOMETER CONTROLLER

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

DECREASE INCREASE

UPDIP

DYNO SETUP

SHIFT

COM SETUPAUX SETUP

SPEED SET

MAX SPEED

TORQUE SET

TORQUE UNITS

BRAKE ON/OFF

POWER UNITS

DOWN

1.1 UNPACKING YOUR DSP6001

Your DSP6001 was packaged carefully for shipping. Please notify your carrier and Magtrol Customer Service if you believe your unit was damaged in shipping.

1. Save all shipping cartons and packaging material until you inspect the DSP6001.

2. Inspect the DSP6001 for any evidence of damage in shipping.

3. Make sure the carton contains the following:

DSP6001 Dynamometer Controller

INFORMATION

GENERAL

Line cord

Calibration Certiﬁcate

1.2 NEW FEATURES OF THE DSP6001

Magtrol’s new Model DSP6001 Dynamometer Controller is an upgraded version of the DSP6000, providing superior motor testing capabilities by using state-of-the-art digital signal processing technology. Designed for use with any Magtrol Hysteresis, Eddy-Current or Powder Brake Dynamometer, Magtrol In-Line Torque Transducer or auxiliary instrumentation, the DSP6001 both controls the dynamometer and provides digital readouts on the front panel. The features that make the DSP6001 unique include:

• TwoChannels-Enablesunittosupportacombinationofuptotwotestinginstrumentswith

independent or tandem conﬁgurations.

• Built-InAlarm System - Tocaution the user whenproblems occur,there are automatic

electrical and temperature alarms programmed into the unit. Also inherent to the unit are optional power, speed, torque, air ﬂow, water ﬂow and external input alarms that become active when enabled by the user.

• Torque/SpeedAnalogOutputs -Ableto interface with adataacquisitionsystem or strip

chart recorder.

• DigitalFilter-Removesundesirednoisefromtorquesignals.

• CrossLoopFunction-Allowsclosedloopcontrolofabrakeviathetorquetransducer.

• Saving-Allowsusertosaveprogrammedvalueswithintheircongurations.

Magtrol User Manual CD-Rom

Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – Introduction

DSP6001

Data Sheet

MAGTROL

SignalProcessingTechnologytoprovidesuperiormotortesting

1.3 DATA SHEET

DSP6001 High-Speed Programmable Dynamometer Controller

FEATURES

• Two Channels:Enabletheunittosupportupto

twotestinginstrumentswithindependentortandem configurations.

• Built-in Alarm System:Forpower,speed,torque,

temperature,airflow,waterflow,electricaloverload andexternalinputs

• Torque/Speed Analog Outputs:Forinterfacewitha

dataacquisitionsystemorstripchartrecorder

• Interfaces:RS-232andIEEE-488

• High Speed Data Acquisition:120torqueandspeed

pointspersecondviaIEEEbus(approx.60/sec.via RS-232)

• High Quality, Easy-to-Read Vacuum Fluorescent Readout:Displaystorque,speed,power,auxiliaryand PID(proportionalgain,integralandderivative)values

• Fast Full-Curve Data Acquisition: Free-runto lockedrotorinseconds

• Speed & Torque Operating Modes:Provide independentPIDsettingsforimprovedDynamometer control

• Built-in Current-Regulated Supply:Forusewith HysteresisDynamometeronly

• Adjustable Torque Units:English,MetricandSIare standard

• Dynamometer Overload Protection

• Digital Filter: Removesundesirednoisefromtorque signals

• Cross Loop Function: Allowsclosedloopcontrolof brakeviatorquetransducer

• Programmable Digital PID Values:Controlledand storedviaM-TestSoftwareorcontrolledmanually

• Saving:Savesprogrammedvalueswithin configuration

• Auxiliary ± 10 V DC Analog Input:Foradditional transducer

• Single or Multi-point Torque and Speed Stabilized Testing: ViaM-TEST5.0Software

• Closed Box Calibration

• Rack Mounting: 19"(482.6mm)withhandles

capabilities. Designedfor use withanyMagtrolHysteresis, Eddy-Current or Powder Dynamometer, Magtrol In-Line TorqueTransducerorauxiliaryinstrumentation,theDSP6001 canprovidecompletePCcontrolviatheIEEE-488orRS-232 interface.With120readingspersecond,theDSP6001isideally suitedforboththetestlabandtheproductionline.

APPLICATIONS

Inthe laboratory,the DSP6001’shigh samplerateprovides superior resolution for data acquisition and curve plotting. Thisallowsforcapturingmoreusablemotortestdataduring switching, breakdown and other transitional areas of the motor test curve. For production and incoming inspection, theDSP6001displaystorque,speedandpoweratalltimes, allowingthe Controller to be used as a manualstand alone unitoraspartofacompletePCsystem.

MOTOR TESTING SOFTWARE

Magtrol’sM-TEST5.0Software(sold separately)isastate- of-the-artmotortestingprogramforWindows®-baseddata acquisition.  Used with the Magtrol DSP6001 Controller, MagtrolM-TEST5.0Software providesthe control of any MagtrolDynamometerandrunstestsequencesinamanner bestsuitedtotheoverallaccuracyandefficiencyoftheMagtrol MotorTestSystem.ThedatathatisgeneratedbyMagtrol’s MotorTestingSoftwarecanbestored,displayedandprinted intabularorgraphicformats,and aspreadsheet.

Writtenin LabVIEW™, M-TEST 5.0has the flexibilityto testamajorityofmotortypesinavarietyofways.Because ofLabVIEW’sversatility,obtainingdatafromothersources (e.g.thermocouples),controllingmotorpowerandproviding audio/visualindicatorsisrelativelyeasy.

INFORMATION

GENERAL

canbeeasilyimportedinto

DESCRIPTION

Magtrol’s Model DSP6001 High Speed Programmable Dynamometer Controller employs state-of-the-art Digital

Magtrol’sM-TEST5.0Softwareisidealforsimulatingloads, cyclingtheunitundertestandmotorramping.Becauseitis easytogatherdataandduplicatetests,thesoftwareis ideal foruseinengineeringlabs,productiontestingandincoming/ outgoinginspection.

Magtrol Model DSP6001 Dynamometer Controller

Specifications

Chapter 1 – Introduction

DSP6001

INFORMATION

GENERAL

MEASUREMENT CHARACTERISTICS

Maximum Torque 10,000 units, ±5 V TSC1, ±10 V TSC2 Maximum Speed 99,999 rpm

Speed: 0.01% of reading from 10 rpm to 100,000 rpm

Accuracy

TSC1: 0.02% of range (±1 mV) TSC2: 0.02% of range (±2 mV)

ELECTRICAL CHARACTERISTICS

Brake: UL/CSA 1.25 A 250 V SB

Fuses (5 × 20 mm)

IEC 1.00 A 250 V T Power (120 V): UL/CSA 800 mA 250 V SB

Power (240 V): IEC 315 mA 250 V T Power Requirements 75 VA Voltage Requirements 120/240 V 60/50 Hz Max. Compliance Voltage 45 V DC, Brake Output

INPUTS AND OUTPUTS

Maximum Torque Input

Accessory Torque/Speed Output

TSC1: ±5 V DC

TSC2: ±10 V DC

Torque: ±10 V DC

Speed: ±10 V DC Ctrl Out 0–3 V DC

ENVIRONMENT

Operating Temperature 5 ºC to 40 ºC Relative Humidity < 80% Temperature Coefficient 0.004% of range/°C of 5 V DC for both channels

DIMENSIONS

Width 19.0 in 483 mm Height 3.5 in 89 mm Depth

with handles

12.4 in

13.8 in

315 mm 351 mm

Weight 16.73 lb 7.58 kg

FRONT PANEL

Set Desired Power Units

REAR PANEL

Connector for Model 5241 Power Supply

Displays Torque, Speed, Power,

Auxiliary and PID Values

(W, kW or Hp)

Set Desired Torque Units

(oz.in., oz.ft., lb.in., lb.ft., g.cm, kg.cm, Nmm, Ncm, Nm)

For use with any Magtrol Dynamometer

(Hysteresis, Eddy-Current, Powder Brake),

Magtrol Torque Transducer or auxiliary instrumentation

(for HD-825 Dynamometer only)

Speed Control

(up to 99,000 rpm)

Ready for Rack Mounting

Adjustable PID (Proportional Gain, Integral and Derivative) settings provide the best system response

RS-232 and GPIB/IEEE-488 Interfaces for Connection to PC

Torque/Speed Analog Output for Interfacing with Data Acquisiton System or Strip Chart Recorder

Connectors for Models DES310/DES311 Power Supplies

System Configurations

OPTIONAL:

Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – Introduction

INFORMATION

DSP6001

GENERAL

Hysteresis Dynamometer (HD)

AC Mains

DSP6001 DYNAMOMETER CONTROLLER

BRAKE

TORQUE–SPEED

CTRL OUT

BRAKE FUSE

UL/CSA 1.25A 250V SB

(5×20mm):

IEC 1A 250V T

ACCESSORY

OUTPUT

AUX / TSC2

DYNAMOMETER / TSC1

No Connection

SUPPLY 2

SUPPLY 1

RS-232C

MAGTROL, INC. BUFFALO, NY

GPIB/IEEE–488

Motor Under

Test

FUSE (5×20mm):

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

GROUND

EARTH

TM Torque Transducer

GPIB

RS-232

– OR –

Auxiliary Input

±10 volts

TSC2 only

14-pin connector

pin 13 = com

pin 14 = signal

M-TEST

Hysteresis on TSC1 only

DSP6001 Connected to Hysteresis Dynamometer with Optional Auxiliary Input or In-Line Torque Transducer

Hysteresis Dynamometer (HD)

AC Mains

DSP6001 DYNAMOMETER CONTROLLER

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

BRAKE FUSE

UL/CSA 1.25A 250V SB

(5×20mm):

IEC 1A 250V T

AUX / TSC2

DYNAMOMETER / TSC1

SUPPLY 2

SUPPLY 1

RS-232C

MAGTROL, INC. BUFFALO, NY

No Connection

Hysteresis on TSC1 only

GPIB/IEEE–488

Motor

Under

Test

FUSE (5×20mm):

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

EARTH

GROUND

Eddy-Current (WB)

OR Powder Brake (PB)

Dynamometer

TSC 401

Torque-Speed

Conditioner

DES 31x Power Supply

GPIB

RS-232

M-TEST

Speed

Torque

Excitation

DSP6001 Connected to Hysteresis Dynamometer and Eddy-Current or Powder Brake Dynamometer

OPTIONAL:

TM Torque

Transducer

– OR –

Auxiliary Input

±10 volts

TSC2 only

14-pin connector

pin 13 = com

pin 14 = signal

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

DYNAMOMETER / TSC1

CTRL OUT

BRAKE FUSE

UL/CSA 1.25A 250V SB

(5×20mm):

IEC 1A 250V T

DSP6001 Connected to Eddy-Current or Powder Brake Dynamometer (WB/PB)

AUX / TSC2

SUPPLY 2

SUPPLY 1

MAGTROL, INC. BUFFALO, NY

Eddy-Current (WB) OR Powder Brake (PB) Dynamometer

TSC 401

Torque-Speed

Conditioner

Speed

Torque

Excitation

DSP6001 Dynamometer Controller

GPIB/IEEE–488

RS-232C

FUSE (5×20mm):

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

GROUND

EARTH

DES Power Supply

M-TEST

GPIB

RS-232

Magtrol Model DSP6001 Dynamometer Controller

Eddy-Current (WB)

System Configurations

Chapter 1 – Introduction

DSP6001

INFORMATION

GENERAL

OR Powder Brake (PB) Dynamometer

TSC 401 Torque-Speed

Speed

Torque

Excitation

Conditioner

DES 31x Power Supply

AUX / TSC2

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

DYNAMOMETER / TSC1

CTRL OUT

BRAKE FUSE

UL/CSA 1.25A 250V SB

(5×20mm):

IEC 1A 250V T

DYNAMOMETER CONTROLLER

DSP6001

SUPPLY 2

SUPPLY 1

RS-232C

MAGTROL, INC. BUFFALO, NY

OR Powder Brake (PB)

TSC 401 Torque-Speed

Conditioner

DES 31x Power Supply

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

GPIB/IEEE–488

120V UL/CSA 800mA 250V SB

FUSE (5×20mm):

240V IEC 315mA 250V T

Dynamometer

GPIB

RS-232

EARTH

GROUND

Speed

Torque

Excitation

M-TEST

DSP6001 Connected to 2 Eddy-Current or Powder Brake Dynamometers (Independent Setup)

Eddy-Current (WB) Dynamometer

Eddy-Current (WB)

Dynamometer

Powder Brake (PB)

Dynamometer

Torque-Speed Conditioner

DES 31x Power Supply

TSC 401

Speed

Torque

Excitation

Torque-Speed Conditioner

Speed

Torque

Excitation

DES 31x Power Supply

TSC 401

Powder Brake (PB) Dynamometer

GPIB

GROUND

RS-232

EARTH

M-TEST

AUX / TSC2

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

DYNAMOMETER / TSC1

CTRL OUT

BRAKE FUSE

UL/CSA 1.25A 250V SB

(5×20mm):

IEC 1A 250V T

DYNAMOMETER CONTROLLER

SUPPLY 2

SUPPLY 1

RS-232C

MAGTROL, INC. BUFFALO, NY

DSP6001

GPIB/IEEE–488

FUSE (5×20mm):

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

DSP6001 Connected to 2 Eddy-Current or 2 Powder Brake Dynamometers (Tandem Setup)

Speed

Torque

Excitation

GPIB/IEEE–488

FUSE (5×20mm):

Eddy-Current Brake Dynamometer (WB)

TSC 401

Torque-Speed

Conditioner

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

EARTH

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

GROUND

DES Power Supply

M-TEST

GPIB

RS-232

Dynamometer (PB)

TSC 401

Torque/Speed

Conditioner

DES Power Supply

Dynamometer

Powder Brake

Torque

DSP6001

Controller

Excitation

BRAKE FUSE

(5×20mm):

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

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

Clutch

Transformer

AUX / TSC2

DYNAMOMETER / TSC1

(EK)

SUPPLY 2

SUPPLY 1

RS-232C

MAGTROL, INC. BUFFALO, NY

Torque Transducer

Hysteresis

System Configurations

Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – Introduction

INFORMATION

DSP6001

GENERAL

Brake

Eddy-Current/ Powder Brake

DSP6001

DYNAMOMETER

CONTROLLER

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

BRAKE FUSE

UL/CSA 1.25A 250V SB

(5×20mm):

IEC 1A 250V T

AUX / TSC2

DYNAMOMETER / TSC1

No Connection

SUPPLY 2

SUPPLY 1

RS-232C

MAGTROL, INC. BUFFALO, NY

GPIB/IEEE–488

FUSE (5×20mm):

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

EARTH GROUND

GPIB

RS-232

(TM)

M-TEST

DES 31x

In-Line Torque Transducer Cross Loop Function

CUSTOM MOTOR TEST SYSTEM

TheDSP6001canbeincorporatedintoaCustomizedMotorTestSystem.ThesePCbased,turn-keysystemsarecustomdesigned andbuilttomeetspecificuserrequirements.

heavy-duty equipment rack

emergency stop button

WB Eddy-Current Dynamometer

TSC Torque Signal Conditioner

DES Power Supply

M-TEST Motor Testing Software

LCD monitor

6530 Power Analyzer

DSP6001 Dynamometer Controller

space for rackmounted third-party power supply and computer

side panel connectors allow for easy hook-up

HD Hysteresis

Dynamometer AMF Adjustable Motor Fixture

keyboard drawer

Dynamometer

Table

Magtrol Model DSP6001 Dynamometer Controller

Ordering Information

Chapter 1 – Introduction

DSP6001

ORDERING INFORMATION

DSP6001 High-Speed Programmable Dynamometer Controller 120 VAC DSP6001A High-Speed Programmable Dynamometer Controller 240 VAC

SYSTEM OPTIONS AND ACCESSORIES

CATEGORY DESCRIPTION MODEL / PART #

Hysteresis Dynamometers HD series

TESTING DEVICES

POWER

ANALYZERS

SOFTWARE

POWER

SUPPLIES

MISC.

CARDS &

CABLES

Eddy-Current Dynamometers WB series

Powder Brake Dynamometers PB series

In-Line Torque Transducers TM/TMHS/TMB series

High-Speed Single-Phase Power Analyzer

High-Speed Three-Phase Power Analyzer 6530

M-TEST 5.0 Motor Testing Software SW-M-TEST5.0-WE

Temperature Testing Hardware HW-TTEST

Closed-Loop Speed Control/Power Supply 6100

Power Supply 5200

Current-Regulated Power Supply 5210

Power Amplifier (required for HD-825 Dynamometer only) 5241

Power Supply for WB & PB Dynamometers series 2.7 and 43 DES 310

Power Supply for WB & PB Dynamometer series 65, 115 and 15 DES 311

Torque/Speed Conditioner

(required for connecting WB/PB Series Dynamometers to DSP6001)

GPIB Interface Card (PCI) 73-M023

GPIB Cable, 1 meter 88M047

GPIB Cable, 2 meters 88M048

Torque Transducer Connector Cable ER 113/01

6510e

TSC 401

INFORMATION

GENERAL

Due to the continual development of our products, we reserve the right to modify speciﬁcations without forewarning.

2. Controls

MODEL DSP6001

DYNAMOMETER CONTROLLER

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

DECREASE INCREASE

UPDIP

DYNO SETUP

SHIFT

COM SETUPAUX SETUP

SPEED SET

MAX SPEED

TORQUE SET

TORQUE UNITS

BRAKE ON/OFF

POWER UNITS

DOWN

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

2.1 FRONT PANEL

The front panel provides a power switch, nine control buttons, a Decrease/Increase Dial, and Vacuum Fluorescent Display (VFD).

Figure 2–1 Front Panel

2.2 FRONT PANEL CONTROLS AND BUTTONS

The front panel controls and buttons, from left to right, are:

• Powerswitch

• Sixdouble-functioncontrolbutton:

INFORMATION

GENERAL

Primary Function Secondary Function BRAKE ON/OFF POWER UNITS TORQUE SET TORQUE UNITS SPEED SET MAX SPEED P AUX SETUP I COM SETUP D DYNO SETUP

• Threesingle-functioncontrolbuttons:

• SHIFT(enablessavingfunctionandsecondaryfunctionsprintedinblueabovecontrol

buttons)

• UP-Leftarrow (moves cursor to the left)

• DOWN-Rightarrow (moves cursor to the right)

• Decrease/IncreaseDial(decreasesorincreasestheselectedparameter)

2.2.1 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:

Figure 2–2 Secondary Function Menu

Magtrol Model DSP6001 Dynamometer Controller

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

Chapter 2 – Controls

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

3. Press the SHIFT button again to exit the secondary function and return to main menu.

Note: If the brake status is ON, the SHIFT button will be ignored.

2.2.2 Enabling Saving Function

To save all current programmed settings:

1. Press the SHIFT button two times. The word “SAVING” will appear in the display, as shown in Figure 2–3 Saving Function Menu.

2. After a few seconds, the menu will automatically return to the main menu display and all conﬁgurations of the unit will be saved into a non-volatile memory.

INFORMATION

GENERAL

Figure 2–3 Saving Function Menu

2.2.3 How to uSE Front PanEl controlS and buttonS

2.2.3.1 Controls/Single-Function Buttons

Button To Use Function

POWER Press I to turn power ON Press O

to turn power OFF.

SHIFT Press this button and release; then

press desired control button. Press this button two times and

release.

UP/LEFT  Press. Increases magnitude of change

DOWN/RIGHT  Press. Decreases magnitude of change

DECREASE / INCREASE DIAL

Turn clockwise or counterclockwise.

Turns power ON or OFF.

Enables the function written in blue above control button.

Saves current conﬁguration of unit to non-volatile memory.

when adjusting a numerical value (speed, torque or max. speed).

Increases or decreases the parameter selected.

Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – Controls

2.2.3.2 Double-Function Buttons

Button To Use Function

POWER UNITS Press SHIFT and release; then

press this button.

BRAKE ON/OFF Press this button. Turns brake ON or OFF. TORQUE UNITS Press SHIFT and release; then

press this button.

TORQUE SET Press this button. Enables adjustment of set point for

Press and hold this button until second beep.

MAX SPEED Press SHIFT and release; then

press this button.

SPEED SET Press this button. Enables adjustment of set point for

AUX SETUP Press SHIFT and release; then

press this button.

P Press this button. Enables adjustment of proportional

COM SETUP Press SHIFT and release; then

press this button.

I Press this button. Enables adjustment of integral

DYNO SETUP Press SHIFT and release; then

press this button.

D Press this button. Enables adjustment of derivative

INFORMATION

GENERAL

Sets desired unit of power. Press UP  or DOWN  button to see options. Press SHIFT to enable option.

Sets desired unit of measure. Press UP  or DOWN  button to see options. Press SHIFT to enable option.

torque loading. Enables Open Loop mode (if brake

is off). Sets the speed range of the

Controller.

speed loading. Turns auxiliary/torque transducer

display ON or OFF. Enables adjustment of scale factors for torque and speed DAC’S.

term. Adjusts GPIB primary address and

RS-232 baud rate. Also adjusts display contrast.

term. Provides options to set maximum

power, dynamometer settings (input units, maximum torque and scale factor), speed encoders and alarms.

term.

2.3 VACUUM FLUORESCENT DISPLAY (VFD)

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

Top Row Bottom Row

POWER BRAKE STATUS (ON or OFF) TORQUE SET POINT (TORQUE) SPEED SET POINT (SPEED)

AUX INPUT, TM2XX or STATUS DISPLAY

P I D

Magtrol Model DSP6001 Dynamometer Controller

Chapter 2 – Controls

2.3.1 contraSt SEttingS

The DSP6001 is shipped with the Contrast Setting at zero (lowest) in order to prolong display life. If it is necessary to increase the Contrast for improved readability, execute the following steps:

1. Press SHIFT.

2. Press COM SETUP button.

3. Select CONTRAST until desired brightness is reached.

4. Press SHIFT to return to main menu.

Note: Make sure the lowest possible setting is used to achieve desired

2.3.2 ScrEEn SavEr

In order to help eliminate the possibility of display damage, a Screen Saver has been programmed into the DSP6001. If the display has been turned on for more than 5 minutes without any activity, a Screen Saver with moving arrows will appear.

The display can be reactivated by any one of the following actions:

1. Touch any button on the Front Display Panel.

2. Send a command through the GPIB interface.

3. RPM activity in the motor under test.

INFORMATION

GENERAL

result. Using a setting higher than necessary may cause display segments to burn-in over a period of time, resulting in uneven illumination from segment to segment.

Note: This function was removed after code revision 7.2.

2.3.3 StatuS diSPlay MESSagES

Message Meaning

SHIFT Shift button was pressed. AUX Auxiliary unit is attached and enabled. Nm Torque Transducer attached and enabled. MAX SPEED Maximum motor RPM. I/O ERROR Incorrect command was sent from computer. UNITS Torque unit of measurement. REMOTE Remote control via PC enabled. RAMP DOWN Decrease motor speed by increasing load on motor. RAMP UP Increase motor speed by decreasing load on motor. SAVING Saves current conﬁguration of unit to non-volatlie memory.

Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – Controls

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2

SUPPLY 1

RS-232C

GPIB/IEEE–488

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

BRAKE FUSE

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

EARTH

GROUND

FUSE (5×20mm):

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

(5×20mm):

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

MAGTROL, INC. BUFFALO, NY

(FUSED)

+35V

REGULATION

CURRENT

7 6

3 1

5 4

8. +5.0 VDC COM

7. EXTERNAL ALARM INPUT

6. ALARM RELAY (COMMON)

5. ALARM RELAY (NORMALLY CLOSED)

4. ALARM RELAY (NORMALLY OPEN)

3. ANALOG GROUND

2. ANALOG SPEED

1. ANALOG TORQUE

2.4 REAR PANEL

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

 



Figure 2–4 Rear Panel

  

2.5 REAR PANEL INPUTS AND OUTPUTS

BRAKE Connect dynamometer brake cable here.



INFORMATION

GENERAL

 

 

Figure 2–5 Dynamometer Brake Input



BRAKE FUSE

Contains brake fuse (5 x 20 mm) (UL/CSA 1.25A 250V SB) (IEC 1A 250V T)

CTRL OUT Connect to Model 5241 Power Amplifier when using HD-825



Dynamometer.

ACCESSORY



Connect accessory output cable here (optional). TORQUE/ SPEED OUTPUT

Figure 2–6 Accessory Torque-Speed Output

Magtrol Model DSP6001 Dynamometer Controller

14. TORQUE SIGNAL

13. TORQUE COMMON

12. D.P. B

11. INDEX

10. TACH. A

9. D.P. A

8. +5.0 VDC COM

7. +5.0 VDC

6. -24 VDC

5. -24 VDC COM

4. +24 VDC COM

3. +24 VDC

2. TACH. B

1. FLOW/CLUTCH

14 3 2

891011

6 5

1213714

11. N/C

10. TACH. C

9. ROT_SENS

8. +5.0 VDC COM

14. TORQUE SIGNAL

13. TORQUE COMMON

12. BITE

6. -24 VDC

3. +24 VDC

2. N/C

5. -24 VDC COM

4. +24 VDC COM

1. SPARE

7. +5.0 VDC

14 3 2

891011

6 5

1213714

15. N/C

14. CURRENT SET POINT (ANALOG 0V)

13. +5.0 VDC COM

12. SUPPLY +24 VDC

11. STAND-BY CHANNEL 1

10. TEMPERATURE ALARM CHANNEL 1

9. SHIELD (EARTH)

8. W FLOW_1

7. CURRENT SET POINT (SIGNAL)

6. +5.0 VDC COM

5. SUPPLY +24 VDC

4. PRIMARY SUPPLY CONTR. CHANNEL 1

3. N/C

2. ELECTRICAL ALARM CHANNEL 1

1. SHIELD (EARTH)

14 3 25

912 11 10

68 7

14 1315

DYNAMOMETER/



Connect dynamometer signal cable here. TSC1

AUX/TSC2 Connect signal cables for the dynamometer, TM2XX or auxiliary



instrument here.

Chapter 2 – Controls

INFORMATION

GENERAL

Figure 2–7 Dynamometer/TSC1 Connector

SUPPLY 1 Connect WB/PB DES supply for TSC1.



Figure 2–8 AUX/TSC2 Connector

Figure 2–9 Supply 1 Connector

Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – Controls

3. CLUTCH

8. W FLOW_2

11. STAND-BY CHANNEL 2

1. SHIELD (EARTH)

2. ELECTRICAL ALARM CHANNEL 2

4. PRIMARY SUPPLY CONTR. CHANNEL 2

5. SUPPLY +24 VDC

6. +5.0 VDC COM

7. CURRENT SET POINT (SIGNAL)

9. SHIELD (EARTH)

10. TEMPERATURE ALARM CHANNEL 2

15. N/C

13. +5.0 VDC COM

14. CURRENT SET POINT (ANALOG 0V)

12. SUPPLY +24 VDC

14 3 25

912 11 10

68 7

14 1315

5. GND

9. N/C

3. RX

2. TX

14 3 25

69 8 7

24. SIGNAL GROUND

23. ATN-COM

22. SRQ-COM

21. IFC-COM

20. NDAC-COM

19. NRFD-COM

18. DAV-COM

17. REN

16. D8

15. D7

14. D6

13. D5

12. SHIELD

11. ATN

10. SRQ

9. IFC

8. NDAC

7. NRFD

6. DAV

5. E01

4. D4

3. D3

2. D2

1. D1

14 3 2

13141516

6 5

1718719

811 10 9

202122231224

SUPPLY 2 Connect WB/PB DES supply for TSC2.



Figure 2–10 Supply 2 Connector

RS-232C Use this socket for RS-232 connector cable



INFORMATION

GENERAL

GPIB/IEEE-488 Use this socket for GPIB cable (meets IEEE-488 speciﬁcations).



 

 

POWER Attach power cord here.

EARTH GROUND Attach earth ground here.

Figure 2–11 RS-232C Interface

Figure 2–12 GPIB/IEEE-488 Interface

3. Installation/Conﬁguration

Note: Before installing the DSP6001, you should become familiar with

the front and rear panels, as outlined in Chapter 2–Controls.

3.1 POWERING UP THE DSP6001

WARNING! TO REDUCE THE RISK OF ELECTRIC SHOCK, MAKE

SURE THE DSP6001 IS EARTH GROUNDED BEFORE STARTING!

3.1.1 Setting Unit for Line VoLtage

The DSP6001 will operate with either of the following power sources:

• 120V50/60Hz

• 240V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.

SETUP

Figure 3–1 Cover for Voltage Selector, Fuses

3.1.2 SeLf-teSt

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

After turning the power on to the DSP6001, the display panel will show all segments of the VFD (series of rectangles), indicating that the DSP6001 is downloading the program.

When the program download is complete, the message “MAGTROL MODEL DSP6001 Revision X.X” appears.

Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/Conﬁguration

SETUP

Figure 3–2 Program Download Display

If the alarms are disabled, the following display message will appear at this time.

To activate the alarms, refer to Section 6.1.2.1 – How to Enable/Disable Alarms.

3.1.3 Main MenU

When the DSP6001 is completely powered up and ready for use, the main menu will appear on the display.

Figure 3–3 Revision Display

Figure 3–4 Alarm Warning Display

Figure 3–5 Main Menu

Magtrol Model DSP6001 Dynamometer Controller

3.2 TESTING INSTRUMENTATION SETUP

The DSP6001 has the ability to support a combination of up to two testing instruments with independent or tandem conﬁgurations. Typically used combinations include:

Chapter 3 – Installation/Conﬁguration

WB or PB --- BRAKE = Hysteresis, Eddy-Current or

WB or PB TM2XX --- = no connection WB or PB AUX WB or PB WB or PB

BRAKE TM2XX

Notes:

1. Only one Hysteresis Dynamometer, In-Line Torque Transducer or Auxiliary

2. In the TSC1 (WB/PB) and TSC2 (WB/PB) combination, the instruments

3. When there is no connection on TSC1 and TM2XX is connected to TSC2,

TSC1 TSC2

HD --- WB = Eddy-Current Dynamometer HD TM2XX PB = Powder Brake Dynamometer HD AUX TM2XX = In-Line Torque Transducer HD WB or PB AUX = Auxiliary Instrumentation

HD = Hysteresis Dynamometer

Powder Brake

Instrument can be attached to the unit at any one time.

can be conﬁgured independently or as a tandem unit.

the TM2XX will control the outputs of TSC1.

SETUP

The setup of your unit will depend on which option you choose. The following sections will illustrate and outline the hardware connection and software conﬁgurations needed to begin your testing, based on your selection. For additional reference, see Appendix C: Front Panel/Display Menu Flow Charts.

3.2.1 DynaMoMeter ConfigUration MenU

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

↓ ↓ ↓ ↓

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

To reach the dynamometer conﬁguration menu:

1. Turn on DSP6001 power. See Section 3.1 – Powering Up the DSP6001.

2. Press SHIFT. The word “SHIFT” will appear in the display.

3. Press the DYNO SETUP button. The display should appear as follows:

4. Select DYNAMOMETER. The display should appear as follows:

Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/Conﬁguration

SETUP

Figure 3–6 Dyno Setup Menu

Figure 3–7 Dynamometer Conﬁguration Menu

5. Pressing the POWER UNITS button allows selection of the preferred testing device (HD, WB, PB or BRAKE) for TSC1. Pressing the MAX SPEED button allows selection of the preferred testing device (AUX, WB, PB or TM2XX) for TSC2. Refer to the remainder of this chapter for more detailed instructions on setup and conﬁguration of the different testing devices.

Note: For information on Filters, see Chapter 4 – Digital Filters.

Magtrol Model DSP6001 Dynamometer Controller

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2

SUPPLY 1

RS-232C

GPIB/IEEE–488

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

BRAKE FUSE

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

EARTH

GROUND

FUSE (5×20mm):

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

(5×20mm):

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

MAGTROL, INC. BUFFALO, NY

No Connection

Hysteresis on TSC1 only

AC Mains

Motor

Under

Test

Hysteresis Dynamometer (HD)

DSP6001 DYNAMOMETER CONTROLLER

GPIB

RS-232

M-TEST

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

3.2.2 HyStereSiS DynaMoMeter SetUp

3.2.2.1 Hardware Connection

Figure 3–8 Hysteresis Dynamometer Setup

Chapter 3 – Installation/Conﬁguration

SETUP

3.2.2.2 Software Conﬁguration

1. Turn on the DSP6001 and proceed to the dynamometer conﬁguration menu. See Section

3.2.1 – Dynamometer Conﬁguration Menu.

2. Select TSC1 until HD is reached.

3. Select TSC2 until AUX is reached.

4. Press SHIFT. The display should appear as follows:

5. Press the TORQUE UNITS button until the desired input unit for TSC1 is reached.

6. Press SHIFT 3 times to complete the initial setup and return to the main menu.

Figure 3–9 Hysteresis Setup Menu

Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/Conﬁguration

Motor Under

Test

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2

SUPPLY 1

RS-232C

GPIB/IEEE–488

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

BRAKE FUSE

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

EARTH

GROUND

FUSE (5×20mm):

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

(5×20mm):

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

MAGTROL, INC. BUFFALO, NY

TM Torque Transducer

AC Mains

Hysteresis Dynamometer (HD)

No Connection

Hysteresis on TSC1 only

DSP6001 DYNAMOMETER CONTROLLER

GPIB

RS-232

M-TEST

3.2.3 HyStereSiS DynaMoMeter witH torqUe tranSDUCer SetUp

3.2.3.1 Hardware Connection

Figure 3–10 Hysteresis Dynamometer with Torque Transducer Setup

SETUP

Magtrol Model DSP6001 Dynamometer Controller

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

3.2.3.2 Software Conﬁguration

1. Turn on the DSP6001 and proceed to the dynamometer conﬁguration menu. See Section

3.2.1 – Dynamometer Conﬁguration Menu.

2. Select TSC1 until HD is reached.

3. Select TSC2 until TM2XX is reached.

4. Press SHIFT to get to the hysteresis setup menu. See Figure 3–9 Hysteresis Setup Menu.

5. Press TORQUE UNITS button until the desired input unit for TSC1 is reached.

6. Press SHIFT. The display should appear as follows:

Figure 3–11 Torque Transducer Setup Menu

7. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC2.

8. Press SHIFT 3 times to return to the main menu.

9. To display the TSC2 torque transducer information in the main menu STATUS area, press SHIFT, AUX SETUP and the POWER UNITS button until the display says ON (as shown in Figure 3–12 Aux Setup Menu - Display On).

Chapter 3 – Installation/Conﬁguration

SETUP

Figure 3–12 Aux Setup Menu - Display On

10. Press SHIFT to complete the initial setup and return to the new main menu. The display should appear as follows:

Figure 3–13 TSC1 with TM2XX Output Menu

Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/Conﬁguration

Motor Under

Test

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2

SUPPLY 1

RS-232C

GPIB/IEEE–488

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

BRAKE FUSE

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

EARTH

GROUND

FUSE (5×20mm):

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

(5×20mm):

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

MAGTROL, INC. BUFFALO, NY

No Connection

Hysteresis on TSC1 only

±10 volts

TSC2 only

14-pin connector

pin 13 = com

pin 14 = signal

AC Mains

Hysteresis Dynamometer (HD)

DSP6001 DYNAMOMETER CONTROLLER

Auxiliary Input (optional)

GPIB

RS-232

M-TEST

3.2.4 HyStereSiS DynaMoMeter witH aUxiLiary inStrUMentation SetUp

3.2.4.1 Hardware Connection

Figure 3–14 Hysteresis Dynamometer with Auxiliary Instrumentation Setup

SETUP

Magtrol Model DSP6001 Dynamometer Controller

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

3.2.4.2 Software Conﬁguration

1. Turn on the DSP6001 and proceed to the dynamometer conﬁguration menu. See Section

3.2.1 – Dynamometer Conﬁguration Menu.

2. Select TSC1 until HD is reached.

3. Select TSC2 until AUX is reached.

4. Press SHIFT to get to the hysteresis setup menu. See Figure 3–9 Hysteresis Setup Menu.

5. Press TORQUE UNITS button until the desired input unit for TSC1 is reached.

6. Press SHIFT. The display should appear as follows:

7. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC2.

8. Press SHIFT 3 times to return to the main menu.

9. To display the TSC2 auxiliary information in the main menu STATUS area, press SHIFT, AUX SETUP and the POWER UNITS button until the display says ON. See Figure 3–12

Aux Setup Menu - Display On.

10. Press SHIFT to complete the initial setup and return to the new main menu. The display should appear as follows:

Chapter 3 – Installation/Conﬁguration

SETUP

Figure 3–15 TSC2 Aux Setup Menu

Figure 3–16 TSC1 with AUX Output Menu

Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/Conﬁguration

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2

SUPPLY 1

RS-232C

GPIB/IEEE–488

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

BRAKE FUSE

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

EARTH

GROUND

FUSE (5×20mm):

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

(5×20mm):

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

MAGTROL, INC. BUFFALO, NY

No Connection

Hysteresis on TSC1 only

Eddy-Current (WB)

OR Powder Brake (PB)

Dynamometer

AC Mains

Hysteresis Dynamometer (HD)

Excitation

Torque

Speed

TSC 401

Torque-Speed

Conditioner

DES 31x Power Supply

Motor Under

Test

GPIB

RS-232

M-TEST

DSP6001 DYNAMOMETER CONTROLLER

3.2.5 HyStereSiS DynaMoMeter witH eDDy-CUrrent or powDer Brake SetUp

3.2.5.1 Hardware Connection

Figure 3–17 Hysteresis Dynamometer with Eddy-Current or Powder Brake Setup

SETUP

Magtrol Model DSP6001 Dynamometer Controller

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

3.2.5.2 Software Conﬁguration

1. Turn on the DSP6001 and proceed to the dynamometer conﬁguration menu. See Section

3.2.1 – Dynamometer Conﬁguration Menu.

2. Select TSC1 until HD is reached.

3. Select TSC2 until WB or PB is reached.

4. Press SHIFT to get to the hysteresis setup menu. See Figure 3–9 Hysteresis Setup Menu.

5. Press TORQUE UNITS button until the desired input unit for TSC1 is reached.

6. Press SHIFT. The display should appear as follows:

Figure 3–18 TSC2 Eddy-Current/Powder Brake Setup Menu

7. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC2.

8.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as follows:

Chapter 3 – Installation/Conﬁguration

SETUP

Figure 3–19 Nominal Speed Setup Menu

Press the AUX SETUP button and use UP  and DOWN  buttons and Decrease/Increase

dial to set desired nominal speed. Press SHIFT 3 times to complete the initial setup and return to the main menu.

8.b. If using a Powder Brake Dynamometer, press SHIFT 3 times to complete the initial setup and return to the main menu.

Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/Conﬁguration

Eddy-Current (WB)

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

3.2.6 eDDy-CUrrent or powDer Brake DynaMoMeter SetUp

3.2.6.1 Hardware Connection

OR Powder Brake (PB) Dynamometer

Speed

Torque

Excitation

TSC 401

Torque-Speed

Conditioner

SETUP

DES Power Supply

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

DYNAMOMETER / TSC1

BRAKE FUSE

(5×20mm):

CTRL OUT

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

Figure 3–20 Eddy-Current or Powder Brake Dynamometer Setup

3.2.6.2 Software Conﬁguration

1. Turn on the DSP6001 and proceed to the dynamometer conﬁguration menu. See Section

3.2.1 – Dynamometer Conﬁguration Menu.

2. Select TSC1 until WB or PB is reached.

3. Select TSC2 until AUX is reached.

4. Press SHIFT. The display should appear as follows:

AUX / TSC2

SUPPLY 2

SUPPLY 1

MAGTROL, INC. BUFFALO, NY

DSP6001 Dynamometer Controller

GPIB/IEEE–488

RS-232C

FUSE (5×20mm):

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

EARTH

GROUND

GPIB

RS-232

M-TEST

Figure 3–21 TSC1 Eddy-Current/Powder Brake Setup Menu

5. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor.

6.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as shown in Figure 3–19 Nominal Speed Setup Menu. Press the AUX SETUP button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired nominal speed. Press SHIFT 4 times to complete the initial setup and return to the main menu.

6.b. If using a Powder Brake Dynamometer, press SHIFT 4 times to complete the initial setup and return to the main menu.

Magtrol Model DSP6001 Dynamometer Controller

Eddy-Current (WB)

Chapter 3 – Installation/Conﬁguration

3.2.7 eDDy-CUrrent or powDer Brake DynaMoMeter witH torqUe tranSDUCer SetUp

3.2.7.1 Hardware Connection

OR Powder Brake (PB) Dynamometer

TM Torque

Transducer

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

DYNAMOMETER / TSC1

BRAKE FUSE

(5×20mm):

CTRL OUT

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

Figure 3–22 Eddy-Current or Powder Brake Dynamometer with Torque Transducer Setup

3.2.7.2 Software Conﬁguration

1. Turn on the DSP6001 and proceed to the dynamometer conﬁguration menu. See Section

3.2.1 – Dynamometer Conﬁguration Menu.

2. Select TSC1 until WB or PB is reached.

3. Select TSC2 until TM2XX is reached.

4. Press SHIFT to get to the TSC1 eddy-current/powder brake setup menu. See Figure 3–21 TSC1 Eddy-Current/Powder Brake Setup Menu.

5. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC1.

6.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as shown in Figure 3–19 Nominal Speed Setup Menu. Press the AUX SETUP button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired nominal speed. Press SHIFT 2 times to get to the Torque Transducer Setup Menu as shown in Figure 3-

11.

6.b. If using a Powder Brake Dynamometer, press SHIFT 2 times to get to the Torque Transducer Setup Menu as shown in Figure 3–11.

7. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC2.

8. Press SHIFT 3 times to return to the main menu.

9. To display the TSC2 torque transducer information in the main menu STATUS area, press SHIFT, AUX SETUP and the POWER UNITS button until the display says ON. See Figure 3–12 Aux Setup Menu - Display On.

10. Press SHIFT to complete the initial setup and return to the new main menu. See Figure

3–13 TSCI with TM2XX Output Menu.

AUX / TSC2

SUPPLY 2

SUPPLY 1

MAGTROL, INC. BUFFALO, NY

TSC 401

Torque-Speed

75VA 50/60Hz

Conditioner

EARTH

GROUND

Speed

Torque

Excitation

DSP6001 Dynamometer Controller

GPIB/IEEE–488

RS-232C

FUSE (5×20mm):

CAUTION: DOUBLE POLE FUSING

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

DES Power Supply

M-TEST

GPIB

RS-232

SETUP

Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/Conﬁguration

Eddy-Current (WB)

3.2.8 eDDy-CUrrent or powDer Brake DynaMoMeter witH aUxiLiary inStrUMentation SetUp

3.2.8.1 Hardware Connection

OR Powder Brake (PB) Dynamometer

TSC 401

Torque-Speed

75VA 50/60Hz

Conditioner

EARTH

GROUND

DES Power Supply

M-TEST

GPIB

RS-232

OPTIONAL:

Auxiliary Input

±10 volts

TSC2 only

14-pin connector

pin 13 = com

pin 14 = signal

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

BRAKE FUSE

UL/CSA 1.25A 250V SB

(5×20mm):

IEC 1A 250V T

AUX / TSC2

DYNAMOMETER / TSC1

Speed

Torque

Excitation

DSP6001 Dynamometer Controller

SUPPLY 2

SUPPLY 1

MAGTROL, INC. BUFFALO, NY

RS-232C

GPIB/IEEE–488

FUSE (5×20mm):

CAUTION: DOUBLE POLE FUSING

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

SETUP

Figure 3–23 Eddy-Current or Powder Brake Dynamometer with Auxiliary Instrumentation Setup

3.2.8.2 Software Conﬁguration

1. Turn on the DSP6001 and proceed to the dynamometer conﬁguration menu. See Section

3.2.1 – Dynamometer Conﬁguration Menu.

2. Select TSC1 until WB or PB is reached.

3. Select TSC2 until AUX is reached.

4. Press SHIFT to get to the TSC1 eddy-current/powder brake setup menu. See Figure 3–21 TSC1 Eddy-Current/Powder Brake Setup Menu.

5. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC1.

6.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as shown in Figure 3–19 Nominal Speed Setup Menu. Press the AUX SETUP button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired nominal speed. Press SHIFT 2 times to get to the Auxiliary Instrumentation Setup Menu as shown in Figure 3–15.

6.b. If using a Powder Brake Dynamometer, press SHIFT 2 times to get to the Auxiliary Instrumentation Setup Menu as shown in Figure 3-15.

7. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC2.

8. Press SHIFT 3 times to return to the main menu.

9. To display the TSC2 auxiliary information in the main menu STATUS area, press SHIFT, AUX SETUP and the POWER UNITS button until the display says ON. See Figure 3–13

Aux Setup Menu - Display On.

10. Press SHIFT to complete the initial setup and return to the new main menu. See Figure 3–16 TSC1 with AUX Output Menu.

Magtrol Model DSP6001 Dynamometer Controller

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2

SUPPLY 1

RS-232C

GPIB/IEEE–488

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

BRAKE FUSE

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

EARTH

GROUND

FUSE (5×20mm):

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

(5×20mm):

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

MAGTROL, INC. BUFFALO, NY

Eddy-Current (WB)

OR Powder Brake (PB)

Dynamometer

Excitation

Torque

Speed

TSC 401 Torque-Speed

Conditioner

DES 31x Power Supply

Eddy-Current (WB) OR Powder Brake (PB) Dynamometer

Excitation

Torque

Speed

TSC 401 Torque-Speed

Conditioner

DES 31x Power Supply

DSP6001

DYNAMOMETER CONTROLLER

GPIB

RS-232

M-TEST

Chapter 3 – Installation/Conﬁguration

3.2.9 two eDDy-CUrrent/powDer Brake DynaMoMeterS (inDepenDent SetUp)

3.2.9.1 Hardware Connection

Figure 3–24 Two Eddy-Current/Powder Brake Dynamometers (Independent Setup)

SETUP

3.2.9.2 Software Conﬁguration

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

1. Turn on the DSP6001 and proceed to the dynamometer conﬁguration menu. See Section

3.2.1 – Dynamometer Conﬁguration Menu.

2. Select TSC1 until WB or PB is reached.

3. Select TSC2 until WB or PB is reached.

4. Press SHIFT to get to the TSC1 eddy-current/powder brake setup menu. See Figure 3–21 TSC1 Eddy-Current/Powder Brake Setup Menu.

5. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC1.

6.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as shown in Figure 3 –19 Nominal Speed Setup Menu. Press the AUX SETUP button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired nominal speed. Press SHIFT 2 times to get to the TSC2 Eddy-Current/Powder Brake Setup Menu as shown in Figure 3–18.

6.b. If using a Powder Brake Dynamometer, press SHIFT 2 times to get to the TSC2 EddyCurrent/Powder Brake Setup Menu as shown in Figure 3–18.

7. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC2.

8.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as shown in Figure 3–19 Nominal Speed Setup Menu. Press the AUX SETUP button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired nominal speed. Press SHIFT 2 times.

8.b. If using a Powder Brake Dynamometer, Press SHIFT 2 times.

9. The menu will appear as follows:

Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/Conﬁguration

SETUP

Figure 3–25 Tandem Conﬁguration Menu

10. Press the COM SETUP button until the menu says “NO”.

11. Press SHIFT 2 times to complete the initial setup and return to the main menu.

Magtrol Model DSP6001 Dynamometer Controller

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2

SUPPLY 1

RS-232C

GPIB/IEEE–488

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

BRAKE FUSE

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

EARTH

GROUND

FUSE (5×20mm):

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

(5×20mm):

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

MAGTROL, INC. BUFFALO, NY

Powder Brake (PB)

Dynamometer

Eddy-Current (WB)

Dynamometer

Excitation

Torque

Speed

TSC 401

Torque-Speed Conditioner

DES 31x Power Supply

Powder Brake (PB) Dynamometer

Eddy-Current (WB) Dynamometer

Excitation

Torque

Speed

TSC 401

Torque-Speed Conditioner

DES 31x Power Supply

GPIB

RS-232

M-TEST

DSP6001

DYNAMOMETER CONTROLLER

Chapter 3 – Installation/Conﬁguration

3.2.10 two eDDy-CUrrent/powDer Brake DynaMoMeterS (tanDeM SetUp)

3.2.10.1 Hardware Connection

SETUP

Figure 3–26 Two Eddy-Current/Powder Brake Dynamometers (Tandem Setup)

Note: This particular tandem conﬁguration is only applicable to a WB-

WB or PB-PB combination.

3.2.10.2 Software Conﬁguration

1. Turn on the DSP6001 and proceed to the dynamometer conﬁguration menu. See Section

3.2.1 – Dynamometer Conﬁguration Menu.

2. Select TSC1 until WB or PB is reached.

3. Select TSC2 until WB or PB is reached.

4. Press SHIFT to get to the TSC1 eddy-current/powder brake setup menu. See Figure 3–21 TSC1 Eddy-Current/Powder Brake Setup Menu.

5. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC1.

6.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as shown in Figure 3 –19 Nominal Speed Setup Menu. Press the AUX SETUP button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired nominal speed. Press SHIFT 2 times to get to the TSC2 Eddy-Current/Powder Brake Setup Menu as shown in Figure 3–18.

6.b. If using a Powder Brake Dynamometer, press SHIFT 2 times to get to the TSC2 EddyCurrent/Powder Brake Setup Menu as shown in Figure 3–18.

7. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC2.

8.b. If using a Powder Brake Dynamometer, Press SHIFT 2 times.

9. The Tandem Conﬁguration Menu will appear as shown in Figure 3–25.

10. Press the COM SETUP button until the menu says “YES”.

11. Press SHIFT 2 times to complete the initial setup and return to the main menu.

Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/Conﬁguration

SETUP

Magtrol Model DSP6001 Dynamometer Controller

Powder Brake

Eddy-Current Brake

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

Chapter 3 – Installation/Conﬁguration

3.2.11 eDDy-CUrrent DynaMoMeter witH powDer Brake DynaMoMeter (tanDeM SetUp)

3.2.11.1 Hardware Connection

Dynamometer (PB)

TSC 401

Torque/Speed

Conditioner

Torque

DES Power Supply

DSP6001

Dynamometer

Controller

Figure 3–27 Eddy-Current Dynamometer with Powder Brake Dynamometer (Tandem Setup)

3.2.11.2 Software Conﬁguration

1. Turn on the DSP6001 and proceed to the dynamometer conﬁguration menu. See Section

3.2.1 – Dynamometer Conﬁguration Menu.

2. Select TSC1 until WB is reached.

3. Select TSC2 until PB is reached.

4. Press SHIFT to get to the TSC1 Eddy-Current Setup Menu as seen below.

Excitation

BRAKE FUSE

(5×20mm):

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

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

Clutch

Transformer

AUX / TSC2

DYNAMOMETER / TSC1

(EK)

SUPPLY 2

SUPPLY 1

RS-232C

MAGTROL, INC. BUFFALO, NY

GPIB/IEEE–488

Dynamometer (WB)

Speed

Torque

Excitation

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

120V UL/CSA 800mA 250V SB

FUSE (5×20mm):

240V IEC 315mA 250V T

TSC 401

Torque-Speed

Conditioner

EARTH

GROUND

DES Power Supply

M-TEST

GPIB

RS-232

SETUP

Figure 3–28 TSC1 Eddy-Current Setup Menu

5. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC1.

6. Press SHIFT 2 times. The display should appear as shown in Figure 3–19 Nominal Speed Setup Menu.

7. Press the AUX SETUP button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired nominal speed.

Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/Conﬁguration

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

8. Press SHIFT 2 times to get to the TSC2 Powder Brake Setup Menu as shown below.

Figure 3–29 TSC2 Powder Brake Setup Menu

9. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC2.

10. Press SHIFT 2 times. The menu will appear as shown in Figure 3–25 Tandem Conﬁguration Menu.

11. Press the COM SETUP button until the menu says “YES”.

12. Press SHIFT once to reach the Maximum Speed Excited Menu as shown below.

Figure 3–30 Maximum Speed Excited Menu

13. Press the AUX SETUP button and use UP  and DOWN  buttons and Decrease/Increase dial to set maximum speed excited of PB.

14. Press SHIFT 3 times to complete initial setup and return to the main menu.

SETUP

Magtrol Model DSP6001 Dynamometer Controller

Torque Transducer

Hysteresis

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

3.2.12 in-Line torqUe tranSDUCer CroSS Loop fUnCtion

3.2.12.1 Hardware Connection

Chapter 3 – Installation/Conﬁguration

Brake

Eddy-Current/ Powder Brake

DSP6001

DYNAMOMETER

CONTROLLER

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

BRAKE FUSE

UL/CSA 1.25A 250V SB

(5×20mm):

IEC 1A 250V T

AUX / TSC2

DYNAMOMETER / TSC1

No Connection

SUPPLY 2

SUPPLY 1

RS-232C

MAGTROL, INC. BUFFALO, NY

GPIB/IEEE–488

FUSE (5×20mm):

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

EARTH

GROUND

GPIB

RS-232

(TM)

M-TEST

DES 31x

Figure 3–31 In-Line Torque Transducer Cross Loop Function

Note: In the Torque Transducer Cross Loop Function, the TM2XX is

connected to TSC2 while controlling the outputs of TSC1. The connection allows closed loop control of a brake via the Torque Transducer.

SETUP

3.2.12.2 Software Conﬁguration

1. Turn on the DSP6001 and proceed to the dynamometer conﬁguration menu. See Section

3.2.1 – Dynamometer Conﬁguration Menu.

2. Select TSC1 until BRAKE is reached.

3. Select TSC2 until TM2XX is reached.

4. Press SHIFT to get to the Torque Transducer Setup Menu as shown in Figure 3-11.

5. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired scale factor for TSC2.

6. Press SHIFT 2 times to reach the Brake Type menu as seen below.

Figure 3–32 Brake Type Menu

7. Press POWER UNITS button until desired Brake Type is reached.

Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/Conﬁguration

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

8.a. If choosing a Hysteresis or Powder Brake Type, press SHIFT 2 times to complete setup and return to main menu.

8.b. If choosing an Eddy-Current Brake Type, menu will appear as follows:

Figure 3–33 Brake Type Menu (for WB)

Press AUX SETUP button and use UP  and DOWN  buttons and Decrease/Increase

dial to set nominal speed. Then press SHIFT 3 times to complete setup and return to main menu.

3.3 SPEED ENCODER SETUP

1. Starting from main menu, press SHIFT.

2. Press DYNO SETUP.

3. Select ENCODERS. The display should appear as follows:

4. Press TORQUE UNITS button until the desired bit selection for TSC1 is reached.

5. To set bits for TSC2, press POWER UNITS button once, then press TORQUE UNITS button until the desired bit selection is reached.

6. Press SHIFT 2 times to complete SPEED ENCODER setup and return to the main menu.

SETUP

Figure 3–34 Encoder Menu

3.3.1 Bit ConfigUrationS

Standard bit conﬁgurations are as follows:

Test Instrument Encoder

Hysteresis Dynamometer 60 bit* Eddy-Current Dynamometer 20, 30 and 60 bit* Powder Brake Dynamometer 20, 30 and 60 bit* In-Line Torque Transducer 30 and 60 bit

* 600 and 6000 bit also available

Magtrol Model DSP6001 Dynamometer Controller

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

3.4 TORQUE/SPEED ANALOG OUTPUTS

Torque and Speed DAC Outputs provide an analog output proportional to the torque and speed of the system. They are available on the Accessory Torque-Speed Output Connector (as seen in Figure 2–6 Accessory Torque-Speed Output) and are updated every 2 milliseconds. Both of the outputs have a user deﬁnable Scale Factor found under the SHIFT/AUX SETUP key sequence.

3.4.1 torqUe DaC SCaLe faCtor

Torque DAC Scale Factor is scaled in displayed torque units/volt.

Example:

If the displayed torque units are set to oz.in. and the Torque DAC scale is set to 1 unit/volt,

then 1 oz.in. will result in 1 volt at the torque output.

3.4.2 SpeeD DaC SCaLe faCtor

Speed DAC Scale Factor is scaled in rpm/volt.

Example:

If the Speed DAC scale is set to 1000 rpm/volt, then 1000 rpm will result in 1 volt at the

speed output.

Chapter 3 – Installation/Conﬁguration

SETUP

3.4.3 torqUe/SpeeD DaC SetUp

1. Starting from main menu, press SHIFT.

2. Press AUX SETUP. The display should appear as follows:

3. Press TORQUE UNITS button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired Torque DAC value.

4. Press SHIFT.

5. Press AUX SETUP button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired Speed DAC value.

6. Press SHIFT two times to return to main menu.

Figure 3–35 Torque/Speed DAC Setup Menu

4. Digital Filters

-1

-a

x(n) y(n)

The Digital Filters of the DSP6001 are used to remove undesired noise from the TSC inputs. This noise could be conducted from an undesired measured signal such as mechanical vibration or other electrical sources.

4.1 FILTER PARAMETERS

The input to the A/D converter internal to the DSP6001 has a traditional analog ﬁlter that is comprised of the following characteristics:

• -3dbPoint:3.8KHz

• A/DSampleRate:7812.5KHz

• 16AcquiredandAveragedSamples:Averageappliedtolteratarateof488.28125Hz

• FilterCutoffFrequencies:3Hz,10Hz,25Hz,50Hz

• FilterOutput:EquivalenttosecondorderButterworthanaloglter

• TransposedDirectFormIIArchitecture:Thediagrambelowshowsthisarchitecture.

SETUP

Figure 4–1 Transposed Direct Form II Architecture

With a Digital Filter, the DSP6001 is able to solve the following equations:

y(n) = b0 * x(n) + w1

w1 = b1 * x(n) + a1 * y(n) + w2

w1 = b2 * x(n) + a2 * y(n)

The equations are applicable to each channel, occurring every 2.48 milliseconds.

Magtrol Model DSP6001 Dynamometer Controller

4.2 FILTER SETUP

Note: Filter setup should take place after hardware installation and software conﬁguration

of the chosen testing instruments has been completed. See Chapter 3 – Installation/Conﬁguration.

There are four different Filter settings to choose from including 10 Hz, 25 Hz, 50 Hz and OFF. The following instructions show how to select the desired Filter for each channel:

1. Starting from the main menu, press SHIFT.

2. Press DYNO SETUP button.

3. Select DYNAMOMETER.

4. Press TORQUE UNITS button until the desired TSC1 Filter setting is reached.

5. Press COM SETUP button until the desired TSC2 Filter setting is reached.

6. Press SHIFT repeatedly until the main menu is reached. The number of times will vary depending on testing instrument selection.

Chapter 4 – Digital Filters

SETUP

5. PID Settings

5.1 ABOUT THE PID LOOP

The DSP6001 has PID adjustment capability for both the speed and torque modes to provide the best system response. The PID Loop comprises the following three variables:

P = proportional gain

I = integral

D = derivative

Other important variables include:

• Setpoint-desiredloadorspeed

• Error-differencebetweenthesetpointandtheactualmeasurement

5.1.1 p (proportionaL gain)

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

SETUP

5.1.2 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 set point. If the response becomes oscillatory increase the derivative value.

5.1.3 D (DeriVatiVe)

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

5.2 SETTING PID VALUES

5.2.1 How to Set p (proportionaL gain) VaLUe

1. Starting at the main menu press the P button.

2. Use the Decrease/Increase dial until the desired percentage is reached (ranges from 0-99).

5.2.2 How to Set i (integraL) VaLUe

1. Starting at the main menu press the I button.

2. Use the Decrease/Increase dial until the desired percentage is reached (ranges from 0-99).

5.2.3 How to Set D (DeriVatiVe) VaLUe

1. Starting at the main menu press the D button.

2. Use the Decrease/Increase dial until the desired percentage is reached (ranges from 0-99).

Magtrol Model DSP6001 Dynamometer Controller

Derivative

Proportional

Integral

Set Point

Reading

e(t) Yd(t) Yp(t)

Yi(t)

Yt(t)

Ys(t)

+ +

Scale

A/D

Power

Amplifier

Brake

Coil

TSC

Load

Cell

Amplifier

TORQUE

SPEED

Speed

Correction

Yswb(t)

HD & PB

IIR Filter

Yt(t) Ys(t)Scale

Ys(t) Yswb(t)Speed Correction

5.3 HOW THE PID LOOP WORKS

The following diagram demonstrates the correlation between the variables in the PID LoOp.

Chapter 5 – PID Settings

SETUP

Figure 5–1 System Block Diagram

5.3.1 SCaLe faCtorS for HyStereSiS, eDDy-CUrrent anD powDer Brake DynaMoMeterS

TORQUE: TSC1 Ys(t) = Yt(t) / 1.725 * 2

TSC2 Ys(t) = Yt(t) / 1.725 * 2 * 1.6623

SPEED: TSC1 & TSC2 Ys(t) = Yt(t) * 5319.93 / MAX SPEED

5.3.2 SpeeD CorreCtion for wB (eDDy-CUrrent Brake) DynaMoMeter

The WB Dynamometer follows the same scaling as the HYST and PB with the addition of one calculation for both torque and speed. This calculation is due to the fact that for a given current the torque changes with speed. This is referred to as speed correction.

Yswb(t) = (Ys(t) + Ys(t) / speed correction factor) / 2

The speed correction factor is calculated on each entry into the PID loop equations.

Speed Correction Factor = - 0.0001 * x * 2 + 0.0203 * x + 0.005 limited to 0.051 to 1

where x = RPM / NOMINAL SPEED * 100

NOMINAL SPEED is set by the user and obtained from the data sheets for the dynamometer or brake.

5.3.3 eqUationS

Where Skp, Ski and Skd are system coefﬁcients…

Yd(t) = (e(t) - e(t-3) + 3 * (e(t-1) - e(t-2))) * (10/Skd) * D%

Yp(t) = (e(t) + Yd(t)) * (10/Skp) * P%

Yi(t) = Yi(t-1) + (e(t) + Yd(t)) * (10/Ski) * I%

Yt(t) = Yp(t) + Yi(t)

Ys(t) = Scale * Yt(t)

Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID Settings

5.4 ADDITIONAL SCALE FACTOR

The Additional Scale Factor is a multiplier of the P, I or D term. Due to the fact there are so many different dynamometer types and motor combinations, this multiplier is needed to extend the range of the PID. The letters represent the following:

A = 0.001 F = 0.5

B = 0.005 G = 1

C = 0.01 H = 5

D = 0.05 I = 10

E = 0.1

In using the multiplier, the user can input PID numbers from 0.001 (.001 x 1%) to 990 (10.0 x 99%) with good resolution.

5.4.1 How to Set aDDitionaL SCaLe faCtor

Before following the setup instructions, the values that must be set will need to determined. This will depend on which testing instrument has been chosen for the conﬁguration. For appropriate settings, refer to the guide provided in Appendix F: Additional Scale Factor Table. Once the proper settings have been determined, proceed with the following instructions for setup.

5.4.1.1 Setting Additional Scale Factor for P (Proportional Gain)

1. Starting from the main menu, press and hold the P button. While holding the P button, press SHIFT.

2. Use the P button to toggle through the letters in the unit (A, B, C, D, E, F, G, H and I).

3. Choose the letter that corresponds with the pre-determined setting provided in the Additional Scale Factor Table shown in Appendix F.

4. Once the letter is chosen, press SHIFT to return to the main menu.

SETUP

5.4.1.2 Setting Additional Scale Factor for I (Integral)

1. Starting from the main menu, press and hold the I button. While holding the I button, press SHIFT.

2. Use the I button to toggle through the letters in the unit (A, B, C, D, E, F, G, H and I).

3. Choose the letter that corresponds with the pre-determined setting provided in the Additional Scale Factor Table shown in Appendix F.

4. Once the letter is chosen, press SHIFT to return to the main menu.

Magtrol Model DSP6001 Dynamometer Controller

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

5.4.1.3 Setting Additional Scale Factor for D (Derivative)

1. Starting from the main menu, press and hold the D button. While holding the D button, press SHIFT.

2. Use the D button to toggle through the letters in the unit (A, B, C, D, E, F, G, H and I).

3. Choose the letter that corresponds with the pre-determined setting provided in the Additional Scale Factor Table shown in Appendix F.

4. Once the letter is chosen, press SHIFT to return to the main menu.

Chapter 5 – PID Settings

5.5 SETTING THE CORRECT PID’S FOR YOUR MOTOR

Note: Each type of motor will have it’s own optimum PID setting at

different load points.

5.5.1 Setting tHe piD witH an Unknown Motor or SySteM

If the user is unfamiliar with the characteristics of the motor under test, it is recommended to begin in Open Loop Control mode. In doing so, the user can safely get an idea of the motor’s performance.

1. To enter Open Loop Control mode, begin with the motor and brake OFF. Press and hold the TORQUE SET button until a second beep is heard. The display will appear as follows:

Figure 5–2 Open Loop Control Menu

SETUP

2. Set the percent excitation to zero.

3. Start the motor.

4. Slowly increase the excitation current to the brake.

5. Make a note of the torque and speed values of which the motor is capable.

6. To exit the Open Loop Control mode and return to the main menu, turn the motor and brake OFF and press and hold the TORQUE SET button until a second beep is heard.

5.5.2 Setting tHe piD for torqUe ControL

1. With the motor and brake OFF, set the desired Torque Set Point by pressing the TORQUE SET button and using the UP  and DOWN  buttons and Decrease/Increase dial.

2. Set the P, I and D values to zero.

3. Turn the motor ON.

4. Turn the brake ON.

5. Slowly increase the P term until the torque read is about 25% of the desired load point.

Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID Settings

SETUP

Figure 5–3 Initial P Setting for Torque Control at 25%

6. Turn the brake OFF.

7. Increase the I term to 10%.

8. Turn the brake ON and observe response, then turn the brake OFF. Desired Result is a fast response with some over shoot.

Figure 5–4 High Initial P Setting for Torque Control

Magtrol Model DSP6001 Dynamometer Controller

a. If the response was too slow, increase the I term in 1-5% increments and repeat #8.

b. If the response was too fast, decrease the I term in 1-5% increments and repeat #8.

Chapter 5 – PID Settings

SETUP

Figure 5–5 Initial I Setting for Torque Control

c. If there is too much over shoot, increase the D term in 1% increments and repeat #8. For

each incremental increase of the D term, reduce the P term by a proportional amount.

Figure 5–6 Initial D Setting for Torque Control

5.5.3 Setting tHe piD for SpeeD ControL

1. With the motor and brake OFF, set the desired Speed Set Point by pressing the SPEED SET button and using the UP  and DOWN  buttons and Decrease/Increase dial.

2. Set the P, I and D values to zero.

3. Turn the motor ON.

4. Turn the brake ON.

5. Slowly increase the P term until the speed read is about 25% of the desired load point.

Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID Settings

SETUP

Figure 5–7 Initial P Setting for Speed Control at 25%

6. Turn the brake OFF.

7. Increase the I term to 10%.

8. Turn the brake ON and observe response, then turn the brake OFF. Desired Result is a fast response with some over shoot.

a. If the response was too slow, increase the I term in 1-5% increments and repeat #8.

b. If the response was too fast, decrease the I term in 1-5% incremets and repeat #8.

Magtrol Model DSP6001 Dynamometer Controller

Chapter 5 – PID Settings

SETUP

Figure 5–8 Initial I Setting for Speed Control

c. If there is too much over shoot, increase the D term in 1% increments and repeat #8. For

each incremental increase of the D term, reduce the P term by a proportional amount.

Figure 5–9 Initial D Setting for Speed Control

5.5.4 Setting tHe piD for raMp Down

It is nearly impossible to select a PID value that optimizes the control loop over a wide range of speed. With Magtrol’s experience in motor test, their engineers have developed a dynamic PID algorithm. The PID values change with the Speed Set Point. In most cases, the PID values are high when the motor is lightly loaded and tend to decrease at higher loads.

Magtrol’s M-TEST Software provides a setup PID function in the setup for the ramp test. In the M-TEST Software, the dynamic scaling can be enabled or disabled and the span of the scaling can also be selected.

Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID Settings

SETUP

Figure 5–10 Ramp Down Low I

Ramp shows low value for I term. Note “bump” at beginning of ramp and good results toward end of ramp.

Magtrol Model DSP6001 Dynamometer Controller

Chapter 5 – PID Settings

SETUP

Figure 5–11 Ramp Down High I

Ramp shows higher value for I term. Note “bump” at beginning of ramp has been reduced but there are poor results toward end of ramp.

Ramp shows Dynamic Scale effect. Note “bump” at beginning of ramp has been reduced and there are good results toward end of ramp. DIL was set to .01. At the end of the ramp, the I term is 1/100th of the starting value.

Figure 5–12 Ramp Down Dynamic I

6. Alarm System

COMMON

N.O.

N.C.

Normal Operation

“CLOSED”

COMMON

N.O.

N.C.

Alarm Condition

“OPEN”

6.1 GENERAL INFORMATION

New to the DSP6001 is a built-in alarm system, designed to caution the user when problems occur. An automatic electrical and temperature alarm is programmed into the unit to protect against electrical overloads and overheating equipment when using a Magtrol DES 3XX Power Supply. There are also power, speed, torque, air ﬂow, water ﬂow and external input alarms internal to the unit, which only become active when enabled by the user. Instructions on how to set up and activate these alarms are included in this chapter.

6.1.1 aLarM reLay

Internal to the DSP6001 is a relay that operates in conjunction with the alarms.

Relay Speciﬁcations:

•ContactConguration:1FORMC

•ContactRating:1amp,24VDC

•ManufacturerP/N:OMRONG5V-2-H1-DC24

The relay has normally open and normally closed contacts. Under normal conditions, the relay is energized as shown in Figure 6–1.

SETUP • OPERATION

In an alarm condition (or power failure), the relay is de-energized as shown in Figure 6–2.

Figure 6–1 Normal Condition “Energized Relay”

Figure 6–2 Alarm Condition “De-Energized Relay”

Magtrol Model DSP6001 Dynamometer Controller

COMMON

N.O.

N.C.

24VDC

Contactor coil

AC Mains

Motor Under Test

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

The relay contacts are made accessible on the Accessory Torque/Speed Output rear panel connector. See Figure 2–6.

Chapter 6 – Alarm System

SETUP • OPERATION

Figure 6–3 Typical Application

6.1.2 aLarM operation

The DSP6001 gives the user the ability to enable or disable the alarms in the unit. The default is set in the OFF position. In order for the alarms to be operative the user must enable them.

6.1.2.1 How to Enable/Disable Alarms

1. Starting from main menu, press SHIFT.

2. Press DYNO SETUP button.

3. Select ALARMS.

4. Press SHIFT 3 times. The display should appear as follows:

Figure 6–4 Alarm Enable/Disable Menu

5. Press COM SETUP button until you reach desired selection (YES or NO).

6. Press SHIFT 2 times to return to the main menu.

Note: Once the alarms are activated, they are only monitored for the

channel that the control loop is closed on. For example, if the DSP6001 is controlling on TSC1, alarms for TSC2 are ignored.

6.1.3 aLarM priority

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

While in an alarm condition, a higher priority alarm will be acknowledged, while lower priority alarms are ignored. The priority order is as follows.

Priority Alarm

1 Electrical Alarm N/A X 2 Temperature Alarm N/A X 3 External Alarm X X 4 Air Flow Alarm X N/A 5 Water Flow Alarm N/A X 6 Maximum Torque X X 7 Maximum Speed X X 8 Power X X

6.2 POWER ALARM

• Usedtoindicateanoverpowercondition

• Defaultissetat1kW

Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm System

Hysteresis

Dynamometer

Availability

Eddy-Current/Powder

Brake Dynamometer

SETUP • OPERATION

6.2.1 inStrUCtionS for power aLarM SetUp

1. Starting from main menu, press SHIFT.

2. Press DYNO SETUP button.

3. Select MAXPOWER. The display should appear as follows:

Figure 6–5 Max Power Menu

4. Press MAX SPEED button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired maximum power value for TSC1.

5. Press SHIFT.

6. Press POWER UNITS button, then MAX SPEED button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired maximum power value for TSC2.

7. Press SHIFT 3 times to complete Power Alarm setup and return to the main menu.

Magtrol Model DSP6001 Dynamometer Controller

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

6.2.2 power aLarM aCtion

When the power exceeds that of the maximum power setting, the message -OL- will appear and blink in the power section of the display accompanied by an audible beeping sound (as indicated in Figure 6–6).

Chapter 6 – Alarm System

Figure 6–6 Power Alarm Display

Because torque and speed have separate setable limits, no other action will be taken. If condition persists the temperature sensors will open causing the temperature alarm to activate.

6.2.3 to reSet power aLarM

This is a non-latching alarm. When the condition goes away, the alarm will automatically stop.

6.3 MAXIMUM SPEED ALARM

• Usedtolimitspeedofsystem(motor,dynamometer,couplings,etc.)

• Defaultissetat4000rpm

6.3.1 inStrUCtionS for MaxiMUM SpeeD aLarM SetUp

1. Starting from main menu, press SHIFT.

2. Press DYNO SETUP button.

3. Select ENCODERS. The display should appear as follows:

SETUP • OPERATION

Figure 6–7 Speed Alarm Setup Menu

4. Press MAX SPEED button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired maximum speed for TSC1.

5. Press SHIFT.

6. Press POWER UNITS button, then MAX SPEED button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired maximum speed for TSC2.

7. Press SHIFT 3 times to complete Maximum Speed Alarm setup and return to the main menu.

6.3.2 MaxiMUM SpeeD aLarM aCtion

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

∗∗∗∗ ∗∗∗∗

A. If speed is greater than the maximum speed setting but less than 120%, -OL- will ﬂash on the

display where the speed reading was (as indicated in Figure 6–8) and will be accompanied by an audible beeping sound.

Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm System

Figure 6–8 -OL- Speed Alarm Display

B. If speed is greater than 120% of the maximum speed setting or in condition A for greater

than 5 seconds, the display will ﬂash “OVER SPEED ALARM TSCX” (as indicated in Figure 6–9) and will be accompanied by an audible beeping sound. The alarm relay will open, excitation current will hold at last value for 3 seconds then drop to zero.

Figure 6–9 Over Speed Alarm Message Display

6.3.3 to reSet MaxiMUM SpeeD aLarM

Press any front panel button other than SHIFT. If the alarm condition is clear, the unit will return to normal operation. Although not recommended, another option would be to disable the alarm by following the alarm setup instructions in Section 6.3.1 – Instructions for Maximum Speed Alarm Setup.

SETUP • OPERATION

6.4 MAXIMUM TORQUE ALARM

• Used to protect the system (motor, dynamometer, couplings, etc.) from over torque

condition

• Defaultissetat1inputunit

6.4.1 inStrUCtionS for MaxiMUM torqUe aLarM SetUp

1. Starting from main menu, press SHIFT.

2. Press DYNO SETUP button.

3. Select DYNAMOMETER.

4. Press SHIFT. The display should appear as follows:

Magtrol Model DSP6001 Dynamometer Controller

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

∗∗∗∗ ∗∗∗∗

Figure 6–10 Torque Alarm Setup Menu

5. Press AUX SETUP button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired maximum torque for TSC1.

6. Press SHIFT until Torque Alarm Setup Menu for TSC2 is reached.

7. Press AUX SETUP button and use UP  and DOWN  buttons and Decrease/Increase dial to set desired maximum torque for TSC2.

8. To complete Maximum Torque alarm setup, continue pressing SHIFT until main menu is reached.

6.4.2 MaxiMUM torqUe aLarM aCtion

A. If torque is greater than the maximum torque setting but less than 120%, -OL- will ﬂash on

the display where the torque reading was (as indicated in Figure 6–11), accompanied by an audible beeping sound.

Chapter 6 – Alarm System

SETUP • OPERATION

B. If torque is greater than 120% of the maximum torque setting or in condition A for greater

than 5 seconds, the display will ﬂash “OVER TORQUE ALARM TSCX” (as indicated in Figure 6–12) and will be accompanied by an audible beeping sound. The alarm relay will open, excitation current will hold at last value for 3 seconds then drop to zero.

Figure 6–12 Over Torque Alarm Message Display

6.4.3 to reSet MaxiMUM torqUe aLarM

Setup.

Figure 6–11 -OL- Torque Alarm Display

6.5 AIR FLOW ALARM

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

∗∗∗∗ ∗∗∗∗

• Usedtoindicatealackofairowfromablowerorairline

• OnlyforusewithHysteresisDynamometers

• MonitoredonlywhenthebrakeisON

• Defaultissetin“OFF”mode

6.5.1 inStrUCtionS for air fLow aLarM SetUp

1. Starting from main menu, press SHIFT.

2. Press DYNO SETUP button.

3. Select ALARMS. The display should appear as follows:

Figure 6–13 Air Flow Alarm Setup Display

Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm System

SETUP • OPERATION

4. Press COM SETUP button to select YES.

5. Press SHIFT 5 times to complete Air Flow Alarm setup and return to the main menu.

6.5.2 air fLow aLarM aCtion

When there is a lack of air ﬂow, the display will ﬂash “LOW AIR FLOW” (as indicated in Figure 6–14) and will be accompanied by an audible beeping sound. The alarm relay will open and the

excitation current will automatically drop to 10% of the last excitation current.

6.5.3 to reSet air fLow aLarM

Figure 6–14 Air Flow Alarm Message Display

Magtrol Model DSP6001 Dynamometer Controller

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

6.6 WATER FLOW ALARM

• Usedtoindicatelackofwaterow

• OnlyforusewithEddy-CurrentorPowderBrakeDynamometers

• Defaultissetin“OFF”mode

• Monitoredonlywhenthebrakeis“ON”

6.6.1 inStrUCtionS for water fLow aLarM SetUp

1. Starting from main menu, press SHIFT.

2. Press DYNO SETUP button.

3. Select ALARMS.

4. Press SHIFT 2 times. The display should appear as follows:

Chapter 6 – Alarm System

SETUP • OPERATION

Figure 6–15 Water Flow Alarm Setup Display

5. Press COM SETUP button to select YES.

6. Press SHIFT 3 times to complete Water Flow Alarm setup and return to the main menu.

6.6.2 water fLow aLarM aCtion

When there is a lack of water ﬂow, the display will ﬂash “LOW WATER FLOW” (as indicated in Figure 6–16) and will be accompanied by an audible beeping sound. The alarm relay will open and the excitation current will automatically drop to 10% of the last excitation current.

Figure 6–16 Water Flow Alarm Message Display

6.6.3 to reSet water fLow aLarM

6.7 EXTERNAL ALARM

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

∗∗∗∗ ∗∗∗∗

• Usedtoshutdownsystembasedonadditionaluserinput

• Defaultissetin“OFF”mode

6.7.1 inStrUCtionS for externaL aLarM SetUp

1. Starting from main menu, press SHIFT.

2. Press DYNO SETUP button.

3. Select ALARMS.

4. Press SHIFT. The display should read as follows:

Figure 6–17 External Alarm Setup Display

Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm System

SETUP • OPERATION

5. Press COM SETUP button to select YES.

6. Press SHIFT 4 times to complete External Alarm setup and return to the main menu.

6.7.2 externaL aLarM aCtion

If the external input is at a high level, the display will ﬂash “EXTERNAL ALARM” (as indicated in Figure 6–18) and will be accompanied by an audible beeping sound. The alarm relay will open and the excitation current will automatically drop to 10% of the last excitation current.

6.7.3 to reSet externaL aLarM

Figure 6–18 External Alarm Message Display

Magtrol Model DSP6001 Dynamometer Controller

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

∗∗∗∗ ∗∗∗∗

6.8 TEMPERATURE ALARM

• Toalertuserwhendynamometergetstoohotandthermalswitchopens

• OnlyavailableforusewithWBorPBdynamometers

• Default-alwaysactive

6.8.1 inStrUCtionS for teMperatUre aLarM SetUp

No setup needed.

6.8.2 teMperatUre aLarM aCtion

Chapter 6 – Alarm System

When the dynamometer in use becomes too hot, the display will ﬂash “TEMPERATURE ALARM TSCX” (as indicated in Figure 6–19) and will be accompanied by an audible beeping sound. The alarm relay will open and the excitation current will immediately decrease to 10%. After approximately 3 seconds, the current wll drop to 0.

Figure 6–19 Temperature Alarm Message Display

6.8.3 to reSet teMperatUre aLarM

Press any front panel button other than SHIFT. The alarm condition must be cleared before the unit will return to normal operation.

SETUP • OPERATION

6.9 ELECTRICAL ALARM

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

∗∗∗∗ ∗∗∗∗

• UsedtoprotecttheDESsupply

• Monitorselectricalinput(mains)andcircuitryoftheDES

• OnlyavailableforusewithWBorPBdynamometers

• Default-alwaysactive

6.9.1 inStrUCtionS for eLeCtriCaL aLarM SetUp

No setup needed.

Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm System

6.9.2 eLeCtriCaL aLarM aCtion

When there is an electrical overload, the display will ﬂash “ELECTRICAL ALARM TSCX” (as indicated in Figure 6–20) and will be accompanied by an audible beeping sound. The alarm relay will open and the excitation current will immediately decrease to zero.

Figure 6–20 Electrical Alarm Message Display

6.9.3 to reSet eLeCtriCaL aLarM

Press any front panel button other than SHIFT. The alarm condition must be cleared before the unit will return to normal operation.

SETUP • OPERATION

7. Manually Controlled Operation

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

Note: Using the DSP6001 without a computer will limit its testing

capabilities.

7.1 HOW TO CHOOSE DESIRED CHANNEL WHEN USING TWO DYNAMOMETERS

To select the desired channel (TSC1 or TSC2):

1. Press SHIFT.

2. Press AUX SETUP button. The display should appear as follows:

Figure 7–1 Dynamometer Channel Menu

3. Press POWER UNITS button until the desired channel is reached.

4. Press SHIFT to return to main menu.

OPERATION

Note: The desired dynamometer channel must be chosen in order to

continue with the following steps. All steps that are completed will be saved within that channel until the information is manually changed or the DSP6001 is reset. (To reset the DSP6001, refer to Section 9.4 – Resetting the DSP6001.)

Note: When using a dynamometer with a torque transducer or auxiliary

instrument, the previous instructions will turn your TSC2 channel display “ON” allowing you to view information for both channels simultaneously.

7.2 HOW TO SET DESIRED POWER UNITS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

To select the desired power units (W, kW or HP):

1. Press SHIFT.

2. Press POWER UNITS button. The display should appear as follows:

Figure 7–2 Power Units Menu

3. Use UP  and DOWN  buttons to select desired Power Units.

4. Press SHIFT to return to main menu.

Magtrol Model DSP6001 Dynamometer ControllerChapter 7 – Manually Controlled Operation

7.3 HOW TO SET DESIRED TORQUE UNITS

To select the desired torque units (N.m, N.cm, N.mm, kg.cm., g.cm., lb.ft., lb.in., oz.ft., oz.in.):

1. Press SHIFT.

2. Press TORQUE UNITS button. The display should appear as follows:

Figure 7–3 Torque Units Menu

3. Use UP  and DOWN  buttons to select desired Torque Units.

4. Press SHIFT to return to main menu.

7.4 HOW TO SET TORQUE CONTROL

1. Beginning with the brake in the OFF position, press the TORQUE SET button. The display should appear as follws:

OPERATION

Figure 7–4 Torque Control Menu

2. Use UP  and DOWN  buttons and the Decrease/Increase dial to adjust the setpoint to

zero.

Magtrol Model DSP6001 Dynamometer Controller

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

Chapter 7 – Manually Controlled Operation

Note: PID values should be set at this time. See Section 5.5 – Setting the

Correct PID’s for Your Motor.

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

4. Start the motor under test.

5. Press the TORQUE SET button and adjust the set point to the desired load.

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

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.

Note: If the response is too slow or oscillatory, adjust the values for P,

I and D. (For more detailed instruction, refer to Chapter 5– PID Settings.)

Caution: 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, induCtion motors Cannot be tested beyond breakdown, exCept at loCked rotor. refer to Section 7.5 – How to Set Speed

control.

OPERATION

7.5 HOW TO SET SPEED CONTROL

Note: When using speed control, motors between 0 and 100 rpm cannot

be tested unless the dynamometer is equipped with an optional, high resolution speed encoder.

1. Beginning with the brake in the OFF position, press SHIFT.

2. Press MAX SPEED button. The display should appear as follows:

3. Use UP  and DOWN  buttons and the Decrease/Increase dial to set a value equal to or slightly greater than the free-run speed of the motor under test.

Figure 7–5 Max Speed Menu

Magtrol Model DSP6001 Dynamometer ControllerChapter 7 – Manually Controlled Operation

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

5. Press the SPEED SET button.

6. Use UP  and DOWN  buttons and the Decrease/Increase dial to set a speed equal to the max. speed.

Note: PID values should be set at this time. See Section 5.5 – Setting the

Correct PID’s for Your Motor.

7. Use the Brake ON/OFF button to turn the brake ON.

8. Start the motor under test.

9. Press the SPEED SET button and adjust the set point 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. For more detailed instruction, refer to Chapter 5 – PID Settings.

7.6 HOW TO SET OPEN LOOP CONTROL

1. Beginning with the brake in the OFF position, press and hold the TORQUE SET button until a second beep is heard. The open loop control menu should appear. See Figure 5–2 Open Loop Contol Menu.

2. Use UP  and DOWN  buttons and the Decrease/Increase dial to set a value of current equal to the percent of full scale output.

3. If needed, POWER UNITS and DISPLAYED UNITS can be changed while in OPEN LOOP mode. (For further instruction, refer to Section 7.2 – How to Set Desired Power Units.)

4. Use the BRAKE ON/OFF button to turn the brake ON. (Note: When the brake is on, the only thing that can be adjusted is the set point. There are no other active settings at this time.)

5. To exit the Open Loop Control mode and return to the main menu, turn the brake OFF and press and hold the TORQUE SET button until a second beep is heard.

OPERATION

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.

8. Computer Controlled Operation

The DSP6001 can be used with a computer to control a dynamometer and to transmit data from the motor testing device directly to the computer. Using the DSP6001 with a computer enables the unit to perform at its full capacity.

8.1 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.

OPERATION

Note: The GPIB interface is not standard on most computers. An interface

card and driver software must be installed. An IEEE-488 cable must also be installed between the computer and the DSP6001. Magtrol recommends National Instruments Corporation hardware and software.

8.1.1 inStaLLing tHe gpiB (ieee-488) ConneCtor CaBLe

Caution: make sure both the Computer and dsp6001 are turned off

before installing the gpib ConneCtor Cable.

1. Connect one end of a high-quality, double-shielded cable to the DSP6001 GPIB connector.

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

BRAKE FUSE

(5×20mm):

BRAKE

ACCESSORY

TORQUE–SPEED

OUTPUT

CTRL OUT

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

AUX / TSC2

DYNAMOMETER / TSC1

SUPPLY 2

SUPPLY 1

RS-232C

MAGTROL, INC. BUFFALO, NY

GPIB/IEEE–488

FUSE (5×20mm):

CAUTION: DOUBLE POLE FUSING

75VA 50/60Hz

120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

EARTH

GROUND

M-TEST

Figure 8–1 GPIB Installation

8.1.2 CHanging tHe gpiB priMary aDDreSS

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

5. GND

9. N/C

3. RX

2. TX

14 3 25

69 8 7

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 of the setting on the DSP6001 is 09.

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 DSP6001 uses the 4-bit format. For setup, follow the steps below.

1. Press the SHIFT button and release.

2. Press the COM SETUP button. The display should appear as follows:

Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled Operation

Figure 8–2 Com Setup Menu Display

3. Press the button below the GPIB display until the desired primary address is reached (range 0-15).

4. Press SHIFT to exit and return to main menu.

8.2 ABOUT THE RS-232 INTERFACE

The DSP6001 is equipped with an RS-232 (serial) interface that communicates with the host computer through a DB-9 interface connector. The connector pin-out consists of 2-TX, 3-RX and 5-GND.

Figure 8–3 RS-232 Interface

OPERATION

8.2.1 ConneCtion

The RS-232 connection includes null modem wiring internal to the unit. To install, use a straight through pin-to-pin connector cable, which can be purchased from your local electronics store.

Magtrol Model DSP6001 Dynamometer Controller

DSP6001 PC

Chapter 8 – Computer Controlled Operation

DIGITAL GROUND

Figure 8–4 Straight Through Pin-to-Pin Cable Connection

8.2.2 CoMMUniCation paraMeterS

• Noparity

• 8databits

• 1stopbit

8.2.3 BaUD rate

There are several different baud rates to choose from including 300, 600, 1200, 2400, 4800, 9600 and 19200. To set up the desired baud rate, follow the instructions below.

1. Press SHIFT and release.

2. Press the COM SETUP button. The display will appear as shown in Figure 8–2 Com Setup

Menu Display.

3. Press the button under the RS-232 BAUD display until the desired baud rate is reached.

4. Press SHIFT to return to main menu.

TX RX

GND

N/C

1. DCD (DATA CARRIER DETECT)

2. RX (RECEIVE DATA)

3. TX (TRANSMIT DATA)

4. DTR (DATA TERMINAL READY)

5. GND (SIGNAL GROUND)

6. DSR (DATA SET READY)

7. RTS (REQUEST TO SEND)

8. CTS (CLEAR TO SEND)

9. RI (RING INDICATOR)

OPERATION

8.3 CHECKING THE DSP6001-TO-PC CONNECTION

Note: Make sure that the DSP6001 and its host computer are communicating

before acquiring data.

1. Make sure the primary GPIB address is set correctly for the DSP6001.

2. Set the input variable to 15 characters (13 variable characters and the two required data termination characters CR and LF. See Section 8.5 – Programming.)

3. Issue output data command “OD” and read 15 characters according to the instructions for your GPIB interface or serial.

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 10

– Troubleshooting.

8.4 DATA FORMAT

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

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.)

Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled Operation

SdddddTdddd.R(cr)(lf)

SdddddTdddd.L(cr)(lf)

OPERATION

Note: When an “A” is in the R/L position (e.g. SdddddTdddd.A(cr)(lf)),

Note: The (cr) and (lf) characters will not display.

If a motor is running at 1725 rpm clockwise, with the dynamometer loading the motor to

22.6 oz.in., the DSP6001 will return:

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.

8.5 PROGRAMMING

Note: Check t h e ma n u a l pr ovided with your so f t ware for full

it is an indication that the unit is in an alarm condition.

EXAMPLE

S 1725T22.60R

instructions.

8.5.1 Data terMination CHaraCterS

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 DSP6001 uses the GPIB standard termination characters Carriage Return (CR) and Line Feed (LF). Provide them in that order.

Magtrol Model DSP6001 Dynamometer Controller

8.5.1.2 Codes for CR - LF

CR = LF =

8.5.2 tiMeoUt

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

Chapter 8 – Computer Controlled Operation

BASIC HEX DEC

CHR$(13) 0D 13 CHR$(10) 0A 10

Note: If the communication fault delay timeout is too short, or if the

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

8.6 DSP6001 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.

8.6.1 aLarM CoMManDS

ALA# Enables or disables air ﬂow

ALE# Enables or disables external

ALL# Enables or disables all alarms. Values for # are:

ALP# Sets power alarm. Sets maximum power in kilowatts. Range is 0

ALS# Sets speed alarm point. Sets maximum speed in rpm. Range is 0 to

ALT# Sets torque alarm point. Sets maximum torque in input units. Range is 0

ALW# Enables or disables water ﬂow

Note: If a command is not recognized, the I/O ERROR message will

appear in the Status Display accompanied by a beep.

Command

Code

alarm.

Function Explanation

OPERATION

Values for # are: 0 = disable 1 = enable

0 = disable 1 = enable

to 99,999. Setting is applied to current channel.

99,999. Setting is applied to current channel.

to 10,000. Setting is applied to current channel. Values for # are:

0 = disable 1 = enable

8.6.2 CoMMUniCation CoMManDS

Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled Operation

Command

Code

Function Explanation

*IDN? Returns Magtrol Identiﬁcation

and software revision.

OA Prompts to return to auxiliary

input data string.

OD Prompts to return speed-

torque-direction data string.

OR Prompts to return direction bit

of TM2XX.

Output Auxiliary prompt to return the value at the AUX INPUT x AUX SCALING factor with this format:

Axxxxxxcrlf

Output Data prompt to return data string with this format:

SxxxxxTxxxxxRcrlf

SxxxxxTxxxxxLcrlf

SxxxxxTxxxxxAcrlf R or L is the shaft direction indicator, as viewed looking at the dynamometer shaft where: R = right; clockwise (CW) L = left; counterclockwise (CCW) A = alarm condition The speed will equal the displayed value and the torque will be in the same units as displayed on the front panel.

“Output Rotation” prompt to return the value at the direction input with this format: 0crlf = clockwise 1crlf = counterclockwise

OPERATION

Magtrol Model DSP6001 Dynamometer Controller

8.6.3 raMp CoMManDS

Chapter 8 – Computer Controlled Operation

Command

Function Explanation

Code

DILXX.XX Sets dynamic scale coefﬁcient. When using dynamic scaling, XX.XX is

multiplied by the I term to give the end I value.

DPLXX.XX Sets dynamic scale coefﬁcient. When using dynamic scaling, XX.XX is

multiplied by the P term to give the end P value.

DS# Enable or disables dynamic

scaling.

Values for # are: 0 = disable 1 = enable

PD# Sets ramp down rate to #RPM

per second.

Specify speed range (F#) AND a stop speed (S#) before using this command. This command programs a decreasing shaft speed at a rate of #rpm per second. Once initiated, the Controller will load to locked rotor unless instructed to do otherwise.

PR • Resets ramp up or down.

• Sets speed to maximum

speed.

This command resets the ramp function, halting the ramp’s progress, and returns the motor to free run.

• Turns brake off.

PU# Sets ramp up rate to #RPM per

second.

Specify speed range (F#) AND a start speed (S#) before using this command. This command increases the shaft speed at a rate of #rpm per second.

S# Sets start or stop speed for

ramp to #RPM.

When this command is used with the PD (Program Down) command, the Controller will ramp down to this speed and halt. When this command is used with the PU (Program Up) command, the Controller will load immediately to this speed and ramp up to free-run.

OPERATION

8.6.4 SetUp CoMManDS

Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled Operation

Command

Code

Function Explanation

AF1# Sets the analog ﬁlter for TSC1. Values for # are:

0 = OFF 1 = 10 Hz 2 = 25 Hz 3 = 50 Hz 4 = 3 Hz

AF2# Sets the analog ﬁlter for TSC2. Values for # are:

0 = OFF 1 = 10 Hz 2 = 25 Hz 3 = 50 Hz 4 = 3 Hz

BT# Sets the brake type for TSC1. Values for # are:

0 = HD 1 = WB 2 = PB

DIN1# Selects instrument type

connected to TSC1.

Values for # are: 0 = HD 1 = WB 2 = PB 3 = BRAKE

DIN2# Selects instrument type

connected to TSC2.

Values for # are: 0 = AUX 1 = WB 2 = PB 3 = TM2XX

M# Enables or disables front panel

controls.

Values for # are: 0 = disable 1 = enable NOTE: The brake ON/OFF switch on the front panel still functions.

NS# Sets nominal speed for WB

Dynamometer.

R Resets as follows:

• Manual control ON.

• Brake OFF.

Range is 0 to 99,999. Setting is applied to current channel.

Use this command to cancel any previous commands. Note: These settings are the power-on default settings.

SFC# Enables or disables cross loop

function.

Values for # are: 0 = disable 1 = enable

SFT# Enables or disables tandem

function.

Values for # are: 0 = disable 1 = enable

TSC1 Selects TSC1 to be the

channel that the control loop closes on.

TSC2 Selects TSC2 to be the

channel that the control loop

The TSC1 or TSC2 command should be the ﬁrst command sent during testing. All commands thereafter will be applied to that channel.

closes on. TSF1# Sets scale factor for TSC1. Range is 0 to 99,999. TSF2# Sets scale factor for TSC2. Range is 0 to 99,999.

OPERATION

Magtrol Model DSP6001 Dynamometer Controller

Chapter 8 – Computer Controlled Operation

Command

Code

Function Explanation

UA# Sets auxiliary input scaling to #.This command sets the scaling factor for the

auxiliary input to # units/volt. The range is 0.0 to 10000.0. Programmed value # is not saved at power down.

UE# Sets encoder pulse count to #. This command selects the pulse count option

for speed transducing. Values for # are: 0 = 60-bit 1 = 600-bit 2 = 6000-bit 3 = 20-bit 4 = 30-bit 5 = 1-bit 6 = 2-bit 7 = 6-bit Programmed value # is not saved at power

down.

UI# Sets dynamometer torque

units to #.

NOTE: For Hp and watts calculations to be correct, the correct dynamometer torque units must be speciﬁed. Values for # are: 0 = oz.in. 1 = oz.ft. 2 = lb.in. 3 = lb.ft. 4 = g.cm. 5 = kg.cm. 6 = N.mm. 7 = N.cm. 8 = N.m. Torque units default to 0 (oz.in.) if out of range. Programmed value # is not saved at power down.

UR# Sets readout torque units to #. This command sets the torque unit conversion

for the torque readout. Values for # are 0 = oz.in. 1 = oz.ft. 2 = lb.in. 3 = lb.ft. 4 = g.cm. 5 = kg.cm. 6 = N.mm. 7 = N.cm. 8 = N.m. Torque units default to 0 (oz.in.) if out of range. Programmed value # is not saved at power down.

OPERATION

8.6.5 SpeeD CoMManDS

Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled Operation

Command

Code

Function Explanation

F# Sets maximum speed to # rpm. Sets a speed range for the Controller. Must

be speciﬁed before using the speed or ramp mode.

G# Sets maximum speed excited

Range is 0 to 10,000.

of PB. N • Resets speed point to

maximum speed.

• Sets speed mode OFF.

Use this command, sent alone, to reset any previous speed-stabilized setting to the maximum speed range.

• Sets brake OFF.

N# • Sets speed point to #.

• Sets brake ON.

Use this command to load the motor under test to a speciﬁc speed value #. Issue a speed range command (F#) ﬁrst for best dynamic response. The Controller is functioning with the dynamometer as a closed loop system. Adjust the speed PID values to tune the response.

ND# Sets speed derivative to #. Derivative value # can be any number from 0

to 99.

NDS# Used as a multiplier for the D

coefﬁcient in the PID equation.

Values for # are A, B, C, D, E, F, G, H or I. (See Appendix F: Additional Scale Factor Table.)

NI# Sets speed integral to #. Integral value # can be any number from 0 to

99.

NIS# Used as a multiplier for the I

coefﬁcient in the PID equation. NP# Sets speed proportional to #

gain. NPS# Used as a multiplier for the P

coefﬁcient in the PID equation.

Values for # are A, B, C, D, E, F, G, H or I. (See Appendix F: Additional Scale Factor Table.)

Proportional gain value # can be any number from 0 to 99.

Values for # are A, B, C, D, E, F, G, H or I. (See Appendix F: Additional Scale Factor Table.)

OPERATION

8.6.6 torqUe CoMManDS

Command

Code

Q • Resets torque to 0.0.

• Turns torque mode OFF.

• Turns brake OFF.

Q# • Sets torque point to #.

• Turns brake ON.

QD# Sets torque derivative to #. Derivative value # can be any number from 0

QDS# Used as a multiplier for the D

coefﬁcient in the PID equation. QI# Sets torque integral to #. Integral value # can be any number from 0 to

QIS# Used as a multiplier for the I

coefﬁcient in the PID equation. QP# Sets torque proportional to #

gain. QPS# Used as a multiplier for the P

coefﬁcient in the PID equation.

Function Explanation

This command resets any previous torquestabilized command, and returns the motor to free run.

This is a closed loop command with its own set of PID parameters. The units deﬁned will be the same as those displayed by the Controller.

to 99. Values for # are A, B, C, D, E, F, G, H or I. (See

Appendix F: Additional Scale Factor Table.)

99. Values for # are A, B, C, D, E, F, G, H or I. (See

Appendix F: Additional Scale Factor Table.) Proportional gain value # can be any number

from 0 to 99. Values for # are A, B, C, D, E, F, G, H or I. (See

Appendix F: Additional Scale Factor Table.)

Magtrol Model DSP6001 Dynamometer Controller

8.6.7 MiSCeLLaneoUS CoMManD

Chapter 8 – Computer Controlled Operation

Command

Code

DIR# Selects/Deselects the quadrature

input circuitry. User has access to up/down counter via OH1

Function Explanation

Values for # are: 0 = for single frequency

1 = for quadrature input command. The displayed rpm is sent to the GPIB/RS-232 and applied to the PID Loop. NOTE: Only applies to DSP6001 Revision 7.5 and later versions.

I# Sets current output to #. The power supply outputs a ﬁxed value of

current. Use any value # between 0 and

99.99%. (99.99% = 1 Amp).

IOXX.XX Applies an offset to the output DAC

Values for # range from 0 to 99.99. on channel 1 only. Used to clamp motor speed prior to testing. NOTE: Only applies to DSP6001 Revision 7.6 and later versions.

OH1 Returns quadrature counter

information.

Two 24-bit hex values are returned. The

ﬁrst value is the up/down count. The

second value is an unused value.

SAVE Saves present conﬁguration of unit

to non-volatile memory.

X Prompts to return % current output. This command returns the % current value

in the format “I##.##”. The value will be

between 0 (no loading) and 99.99 (full

loading).

OPERATION

Note: For further reference, see Appendix F – Remote Conﬁguration Flow

Charts.

9. Calibration

9.1 CLOSED-BOX CALIBRATION

The DSP6001 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.

9.2 CALIBRATION SCHEDULE

Calibrate the DSP6001:

• Afteranyrepairsareperformed.

• Atleastonceayear;morefrequentlytoensurerequiredaccuracy.

9.3 BASIC CALIBRATION PROCESS

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

1. Initial Calibration Procedure

2. TSC1 Offset and Gain

3. TSC2 Offset and Gain

4. DAC Output Offset and Gain

5. Speed Check

6. Decimal Point Check

Items needed for calibrating the DSP6001:

• Externalvoltagereferenceof0to5voltsDC

• Digitalmultimeter(DMM)

Both instruments should have a VDC accuracy of 0.05% or better.

9.3.1 initiaL CaLiBration proCeDUre

1. Allow the DSP6001 to stabilize in an environment with:

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

 • Relativehumiditylessthan80%.

2. Turn on the DSP6001.

3. Allow the DSP6001 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 and DOWN  buttons simultaneously.

 • TurninstrumentpowerON.

• ContinuepressingtheUP and DOWN  buttons until the display shows the software

revision date then release.

The front panel displays the actual correction factors above the ZERO and GAIN readouts (see Figure 9–1 Calibration Display Analog Inputs).

MAINTENANCE

Magtrol Model DSP6001 Dynamometer Controller

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

14. TORQUE SIGNAL

13. TORQUE COMMON

12. D.P. B

11. INDEX

10. TACH. A

9. D.P. A

8. +5.0 VDC COM

7. +5.0 VDC

6. -24 VDC

5. -24 VDC COM

4. +24 VDC COM

3. +24 VDC

2. TACH. B

1. FLOW/CLUTCH

14 3 2

891011

6 5

1213714

Figure 9–1 Calibration Display Analog Inputs

Chapter 9 – Calibration

Note: To exit CALIBRATE mode without making any changes, press the

9.3.2 tSC1 offSet anD gain

1. Connect the external voltage reference common to Pin 13 of the TSC1 input connector.

2. Connect the external voltage reference high to Pin 14 of the TSC1 input connector.

3. Apply +0.000 VDC.

4. Press the ZERO button.

5. Adjust the ZERO by turning the Decrease/Increase Dial until the displayed voltage equals the reference voltage (within 00.10 mV).

SHIFT button 8 times.

Figure 9–2 TSC1 Input Connector

Note: The magnitude of change per revolution can be increased by pressing

the UP  button or decreased by pressing the DOWN  button.

6. Apply 5.0 VDC.

7. Press the GAIN button.

8. Adjust the Decrease/Increase Dial until the displayed voltage equals the reference voltage within 00.10 mV.

9. Press SHIFT to proceed to Section 9.3.3 – TSC2 Offset and Gain.

MAINTENANCE

9.3.3 tSC2 offSet anD gain

11. N/C

10. TACH. C

9. ROT_SENS

8. +5.0 VDC COM

14. TORQUE SIGNAL

13. TORQUE COMMON

12. BITE

6. -24 VDC

3. +24 VDC

2. N/C

5. -24 VDC COM

4. +24 VDC COM

1. SPARE

7. +5.0 VDC

14 3 2

891011

6 5

1213714

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

1. Connect the external voltage reference common to Pin 13 of the TSC2 input connector.

2. Connect the external voltage reference high to Pin 14 of the TSC2 input connector.

3. Apply +0.000 VDC.

4. Press the ZERO button.

5. Adjust the ZERO by turning the Decrease/Increase dial until the displayed voltage equals the reference voltage (within 00.10 mV).

Magtrol Model DSP6001 Dynamometer ControllerChapter 9 – Calibration

Figure 9–3 TSC2 Input Connector

Note: The magnitude of change per revolution can be increased by pressing

the UP  button or decreased by pressing the DOWN  button.

6. Apply 5.0 VDC.

7. Press the GAIN button.

8. Adjust the Decrease/Increase dial until the displayed voltage equals the reference voltage within 00.10 mV.

9.3.4 DaC oUtpUt offSet anD gain

1. Beginning in the TSC2 Offset and Gain screen, press SHIFT to proceed to the Calibration Output DAC Display Menu. The display should appear as follows:

Figure 9–4 Calibration Output DAC Display Menu

2. Connect meter to Pin 14 (negative) and Pin 7 (positive) of SUPPLY 1 connector.

MAINTENANCE

Magtrol Model DSP6001 Dynamometer Controller

15. N/C

14. CURRENT SET POINT (ANALOG 0V)

13. +5.0 VDC COM

12. SUPPLY +24 VDC

11. STAND-BY CHANNEL 1

10. TEMPERATURE ALARM CHANNEL 1

9. SHIELD (EARTH)

8. W FLOW_1

7. CURRENT SET POINT (SIGNAL)

6. +5.0 VDC COM

5. SUPPLY +24 VDC

4. PRIMARY SUPPLY CONTR. CHANNEL 1

3. N/C

2. ELECTRICAL ALARM CHANNEL 1

1. SHIELD (EARTH)

14 3 25

912 11 10

68 7

14 1315

3. CLUTCH

8. W FLOW_2

11. STAND-BY CHANNEL 2

1. SHIELD (EARTH)

2. ELECTRICAL ALARM CHANNEL 2

4. PRIMARY SUPPLY CONTR. CHANNEL 2

5. SUPPLY +24 VDC

6. +5.0 VDC COM

7. CURRENT SET POINT (SIGNAL)

9. SHIELD (EARTH)

10. TEMPERATURE ALARM CHANNEL 2

15. N/C

13. +5.0 VDC COM

14. CURRENT SET POINT (ANALOG 0V)

12. SUPPLY +24 VDC

14 3 25

912 11 10

68 7

14 1315

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

3. Using the Decrease/Increase dial, adjust the value so that the meter reading is 0.000 volts or within 00.20 mV.

4. Press SHIFT once.

5. Connect meter to Pin 14 (negative) and Pin 7 (positive) of SUPPLY 2 connector.

Chapter 9 – Calibration

Figure 9–5 Supply 1 Connector

6. Using the Decrease/Increase dial, adjust the value so that the meter reading is 0.000 volts or within 00.20 mV.

7. Press SHIFT once. The display should appear as follows:

Figure 9–7 Calibration Accessory Torque DAC Display Menu

Figure 9–6 Supply 2 Connector

MAINTENANCE

Magtrol Model DSP6001 Dynamometer ControllerChapter 9 – Calibration

7 6

3 1

5 4

8. +5.0 VDC COM

7. EXTERNAL ALARM INPUT

6. ALARM RELAY (COMMON)

5. ALARM RELAY (NORMALLY CLOSED)

4. ALARM RELAY (NORMALLY OPEN)

3. ANALOG GROUND

2. ANALOG SPEED

1. ANALOG TORQUE

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

8. Connect volt meter to Pin 3 (negative) and Pin 1 (positive) of ACCESSORY TORQUESPEED OUTPUT.

Figure 9–8 Accessory Torque-Speed Output

9. Using the Decrease/Increase dial, adjust the value so that the meter reading is 0.000 volts or within 00.20 mV.

10. Press SHIFT once.

11. Using the Decrease/Increase dial, adjust the value so that the meter reading is 9.000 volts or as close as possible.

12. Press SHIFT once. The display should appear as follows:

Figure 9–9 Calibration Accessory Speed DAC Display Menu

13. Connect volt meter to Pin 3 (negative) and Pin 2 (positive) of the ACCESSORY TORQUESPEED OUTPUT.

14. Using the Decrease/Increase dial, adjust the value so that the meter reading is 0.000 volts or within 00.20 mV.

15. Press SHIFT once.

16. Using the Decrease/Increase dial, adjust the value so that the meter reading is 9.000 volts or as close as possible.

17. Press SHIFT once to end calibration and return to main menu.

9.3.5 SpeeD CHeCk

1. Connect a function generator with square wave TTL output to pins 10 (TACH. A) and 8 (+5.0 VDC COM) of the 14-pin TSC1 connector. For reference, see Figure 9–2 TSC1 Input

Connector.

2. Verify that the speed display reads the same value as the function generator frequency.

3. If the speed display does not read the same value as the function generator, call Magtrol

customer service.

Note: There are no adjustments for speed calibration.

MAINTENANCE

Magtrol Model DSP6001 Dynamometer Controller

9.3.6 DeCiMaL point CHeCk

1. Connect a 0.5 VDC source to pins 14 (TORQUE SIGNAL) and 13 (TORQUE COMMON) of the 14-pin TSC1 connector. For reference, see Figure 9–2 TSC1 Input Connector.

2. Verify that the torque display reads 500.0.

3. Connect pin 9 (D.P. A) to pin 8 (+5.0 VDC COM).

4. Verify that the torque display reads 50.0.

5. Disconnect pin 9 from pin 8.

6. Connect pin 12 (D.P. B) to pin 8 (+5.0 VDC COM).

7. Verify that the torque display reads 5.000.

8. If the torque display does not show correct readings, call Magtrol Customer Service.

Chapter 9 – Calibration

Note: There are no adjustments for decimal point location.

MAINTENANCE

10. Troubleshooting

Problem Reason Solution

Display indicates I/O ERROR.

Speed command sent, but Controller does not respond.

Mechanical power reads much higher or lower than expected

No GPIB communication. Setup error and/or

No RS-232 communication.

Dynamometer shaft does not turn smoothly when BRAKE is OFF.

Dynamometer loads too quickly causing motor to stall.

Speed not reading correctly.

Command does not match the unit’s programmed set of instructions.

Communication occurred but the Controller is not loading the motor.

Torque units are incorrect. Set torque input units to match the

hardware fault.

Setup error and/or hardware fault.

Salient poles were set up on the rotor by having brake current applied with no shaft rotation.

Input units are improperly set up.

Speed encoder is improperly set up.

Use correct command and format.

Adjust PID values.

speciﬁcations on dynamometer nameplate.

Check:

• GPIB address of Controller.

• GPIB cable - should be functioning

and 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 bring up to speed.

Press BRAKE button ON. Adjust output current up to a value at least 25% of the maximum torque rating of the dynamometer in use (if possible). Reduce output current to 0.

Set torque input units to match speciﬁcations on dynamometer nameplate.

Set speed encoder bits to match speciﬁcations on dynamometer nameplate.

If you require additional assistance, please contact Magtrol Customer Service at 1-716-668-5555.

MAINTENANCE

Appendix A: LabVIEW Programming Examples

0 [0..1]

1 [0..1]

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

A.1 SIMPLE READ

APPENDICES

0 [0..2]

1 [0..2]

2 [0..2]

A.2 TORQUE STABILIZED

Magtrol Model DSP6001 Dynamometer ControllerAppendix A: LabVIEW Programming Examples

APPENDICES

Magtrol Model DSP6001 Dynamometer Controller

0 [0..2]

1 [0..2]

2 [0..2]

A.3 SPEED STABILIZED

Appendix A: LabVIEW Programming Examples

APPENDICES

Appendix B: Inertia Correction

TORQUE

DYNAMIC

TORQUE VALUE

SPEED VS TORQUE CURVE WITH CONSTANT DECELERATION

78% OF FR

STATIC TORQUE

VALUE

CF = DIFFERENCE IN TORQUE

S P E E D

DIFFERENCE IN TORQUE

B.1 INERTIAL EFFECT ON MOTOR TEST DATA

A major advantage of the DSP6001 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.

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 DSP6001, properly adjusted PID values yield constant change in rpm so that the inertial torque can be expressed as a constant.

B.2 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.

4. Immediately program your DSP6001 (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:

APPENDICES

Magtrol Model DSP6001 Dynamometer Controller

B.2.1 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:

new

= (CF

/ramp rate) × new ramp rate

old

Appendix B: Inertia Correction

APPENDICES

Appendix C: Front Panel/Display Menu Flow Charts

MODEL DSP6001

DYNAMOMETER CONTROLLER

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

DECREASE INCREASE

UPDIP

DYNO SETUP

SHIFT

COM SETUPAUX SETUP

SPEED SET

MAX SPEED

TORQUE SET

TORQUE UNITS

BRAKE ON/OFF

POWER UNITS

DOWN

The following ﬂow charts are a reference for navigating through the key functions of the DSP6001 Dynamometer Controller. For step-by-step setup instructions, refer to the corresponding chapters in this manual.

C.1 PRIMARY KEY FUNCTIONS

BRAKE

ON/OFF

TORQUE

SET

SPEED

SET

P 0–99%

I 0–99%

OFF

0.000– 99,999

D 0–99%

APPENDICES

Magtrol DSP6001 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual