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DSP6001
User Manual
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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.
COPYRIGHT
Copyright ©2001-2010 Magtrol, Inc. All rights reserved. Copying or reproduction of all or any part of the contents of this manual without the express permission of Magtrol is strictly prohibited.
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.
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.
i
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
ii
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
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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
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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
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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
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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
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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.
ix
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.
x
1. Introduction
MODEL DSP6001
DYNAMOMETER CONTROLLER
POWER
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
1
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.
2
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
3
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
or
RS-232
PC
– 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
or
RS-232
PC
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
4
DES Power Supply
PC
M-TEST
GPIB
or
RS-232
Magtrol Model DSP6001 Dynamometer Controller
Eddy-Current (WB)
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
or
PC
M-TEST
DSP6001 Connected to 2 Eddy-Current or Powder Brake Dynamometers (Independent Setup)
Eddy-Current (WB) Dynamometer
Eddy-Current (WB)
Dynamometer
OR
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
or
RS-232
PC
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
PC
M-TEST
GPIB
or
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
5
Torque Transducer
Hysteresis
System Configurations
Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – Introduction
INFORMATION
DSP6001
GENERAL
Brake
OR
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
or
(TM)
PC
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
6
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.
7
2. Controls
MODEL DSP6001
DYNAMOMETER CONTROLLER
POWER
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
8
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).
when adjusting a numerical value (speed, torque or max. speed).
Increases or decreases the parameter selected.
9
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
10
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.
11
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
2
8
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
12
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
13
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
1.
6.
9. N/C
3. RX
8.
2. TX
4.
7.
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
14
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
15
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
16
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.
17
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.
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