Model DSP6000 High Speed P rogrammable Programmable Dynamometer Controller User ’s Manual
MAGTROL, INC. Sales and TTechnical echnical Assistance 70 Gardenville Parkway Buffalo, New York 14224 USA Tel: (716) 668-5555 or 1-800-828-7844 Fax: (716) 668-8705 ww w. magtr ol.c om w.m agtro l.co Manufacturers of: Motor Test Equipment ! Hysteresis Brakes and Clutches While every precaution has been exercised in the compilation of this document, Magtrol, Inc. assumes no responsibility for errors or omissions.
Safety Notes 1. Make sure that all Magtrol dynamometers and electronic products are earthgrounded, to ensure personal safety and proper operation. 2. Check line voltage before operating the DSP6000. 3. Make sure that dynamometers and motors under test are equipped with appropriate safety guards.
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Table of Contents SALES AND TECHNICAL ASSISTANCE .............................................................................................. ii SAFETY NOTES ..................................................................................................................................... iii 1 - INTRODUCTION ................................................................................................................................ 1 About This Manual ................................................
EXITING THE MEMORY MODE .......................................................................................................................................... 14 CLEARING THE MEMORY .................................................................................................................................................. 14 5 - THE DSP6000 WITH A PC (REMOTE CONTROL) ......................................................................... 15 About the GPIB Interface ..............................
1 - Introduction ABOUT THIS MANUAL This manual contains information about the DSP6000 Dynamometer Controller and procedures for optimal use. To obtain the best results from your unit, please follow the procedures for operation. SHIPPING Your DSP6000 was packaged carefully for shipping. Please notify your carrier and Magtrol Customer Service if you believe your unit was damaged in shipping. UNPACKING YOUR DSP6000 1. Save all shipping cartons and packaging material until you inspect the DSP6000. 2.
Chapter 1 - Introduction Magtrol Model DSP6000 Dynamometer Controller SPECIFICATIONS Dimensions 19" W x 13.8" D x 3.5" H Weight 16.5 lb Operating Temperature 18°C to 25°C Relative Humidity < 80% Speed: 0.01% of reading from 10 RPM to 100,000 RPM Torque: 0.2% of range (± 2 V) Aux: 0.1% of range (± 5 V) Accuracy Temperature Coefficient 0.001% of range/°C Aux.
Magtrol Model DSP6000 Dynamometer Controller Chapter 1 - Introduction FRONT PANEL Figure 1. Front Panel MODEL DSP6000 DYNAMOMETER CONTROLLER The front panel provides a power switch, eight control buttons, a Decrease/Increase Dial, and Vacuum Fluorescent Display (VFD).
Chapter 1 - Introduction Magtrol Model DSP6000 Dynamometer Controller FRONT PANEL CONTROLS Controls/Single Function Buttons AND BUTTONS DoubleFunction Buttons POWER POWER UNITS BRAKE ON/OFF TORQUE UNITS TORQUE SET To Use Press I to turn power ON Press O to turn power OFF. Press SHIFT and release; then press this button. Function Turns power ON or OFF. Sets power display to Watts. Press this button. Toggles brake OFF or ON. Press SHIFT and release; then press this button.
Magtrol Model DSP6000 Dynamometer Controller Chapter 1 - Introduction VACUUM FLUORESCENT DISPLAY (VFD) DISPLAYING DESIRED INFORMATION The VFD provides information about the control functions, the motor under test, and an auxiliary input device (if connected). The displays, from left to right, are: Local control: 1. Press SHIFT and release; then press POWER UNITS to see UNITS displayed. 2. Press UP ! or DOWN " to scroll through available choices.
Chapter 1 - Introduction Magtrol Model DSP6000 Dynamometer Controller REAR PANEL The rear panel provides connectors and receptacles for connecting to appropriate equipment. Figure 2. Rear Panel Figure 3. Brake Connector Figure 5. Dynamometer Connector N/C N/C ISOLATED 22 VDC Figure 4. Accessory Torque/Speed Output 6 3 2 D.P. 5 N/C TORQUE OUTPUT For use with Magtrol Readouts only. Connecting another device to this output may cause equipment failure.
Magtrol Model DSP6000 Dynamometer Controller Chapter 1 - Introduction REAR PANEL FUNCTIONS The rear panel, from left to right, provides the following functions: Label Function BRAKE Connect dynamometer brake cable here BRAKE FUSE Contains brake fuse (5 x 20mm) UL/CSA 1.25A 250V SB IEC 1A 250V T CTRL OUT Connect to Model 5241 Power Amplifier when using HD-825 Dynamometer Connect accessory output cable here (optional). ACCESSORY TORQUE-SPEED OUTPUT For use with Magtrol Readouts only.
2 - About the PID L oop Loop The DSP6000 has PID adjustment capability for both the speed and torque modes to provide you with the best system response. The PID Loop comprises the following three variables: P = Proportional Gain I = Integral D = Magtrol offers a comprehensive motor-test program which would satisfy most of your needs. Call Magtrol Sales at 1-800-828-7844 or 1-716-668-5555 to request your custom software. NOTE: To set PID values, see Chapter 3 - Installation.
Magtrol Model DSP6000 Dynamometer Controller 3. Turn the brake to the ON position and observe how the actual speed moves toward the target speed. 4. If the speed moves slowly or not at all, increase the P until the target speed is achieved. 5. Turn the brake OFF. 6. Turn the brake ON and note how fast the free-run speed changes to the target speed. 7. If the speed conversion does not happen quickly, increase the I value. 8.
3 - Installation Before installing your DSP6000, you should become familiar with the front and rear panels, as outlined in Chapter 1-Introduction. Make sure the DSP6000 is earth grounded before starting! CHECKING YOUR DSP6000 Do not overload or stall the motor. Prolonged overload can cause the motor to overheat. NOTE: SETTING UNIT FOR LINE VOLTAGE The DSP6000 will operate with either of the following power sources: • 120V 50/60 Hz • 240V 50/60 Hz 1. Find the line cord receptacle on rear panel.
Magtrol Model DSP6000 Dynamometer Controller Chapter 3 - Installation 7. Start the test motor. 8. Allow the motor speed to stabilize at its no-load speed for a few seconds. 9. Press the BRAKE ON/OFF button to ON. 10. Press the TORQUE SET button. 11. Turn the Decrease/Increase Dial clockwise. Desired results: • The torque reading will increase. As brake power is applied, load is applied to the motor. The applied torque increases as the Decrease/Increase Dial is turned clockwise.
4 - The DSP6000 as a StandAlone Unit (L ocal Control) Stand-Alone (Local NOTE: Although the DSP6000 can be used without a computer, it will only perform at a fraction of its capability. SETTING DESIRED OPERATING PARAMETERS NOTE: See Appendix C: Front Panel/ Display Menu Flow Charts. 4. Select baud rate. Press RS-232 BAUD until appropriate baud rate appears. 5. Press SHIFT to exit. SET UP AUXILIARY INPUT (If necessary) See “Displaying Desired Information” in Chapter 1 Introduction.
Magtrol Model DSP6000 Dynamometer Controller 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. Chapter 4 - The DSP6000 as a Stand-Alone Unit (Local Control) 12. Use the BRAKE ON/OFF button to turn the brake ON. 13. Start your motor under test. 14. Press the SPEED SET button and adjust the setpoint to the desired speed.
Chapter 4 - The DSP6000 as a Stand-Alone Unit (Local Control) 6. Press SHIFT. 7. Press UP ! or DOWN " until you see the desired GPIB address. 8. Press SHIFT. 9. Press UP ! or DOWN " until you see the desired RS-232 baud rate. 10. Press SHIFT to exit. SETTING DYNAMOMETER LOAD 1. Press the UNITS DISPLAY button. 2. Use the Decrease/Increase Dial to adjust the current output to 0%. 3. Use the BRAKE ON/OFF button to turn the brake ON. 4. Start the motor under test. 5.
5 - The DSP6000 with a PC (R emote Control) (Remote The DSP6000 can be used with a computer to control a dynamometer and to transmit data from motor testing directly to the computer. Using the DSP6000 with a computer enables the unit to perform at its full capacity. Figure 8.
Chapter 5 - The DSP6000 with a PC (Remote Control) Some PC interfaces can access from one to fifteen 4-bit primary addresses. Other interfaces can access as many as thirty-one 5-bit primary addresses. The DSP6000 uses the 4-bit format. Magtrol Model DSP6000 Dynamometer Controller PROGRAMMING NOTE: 1. Press the SHIFT button and release. 2. Press the COM SETUP button to set the primary address. 3. Press the button below the GPIB address display to increase by 1 (range 0–15). 6.
Magtrol Model DSP6000 Dynamometer Controller COMMAND SET FOR Chapter 5 - The DSP6000 with a PC (Remote Control) DSP6000 Command Category Command Code Communications H Sets high data acquisition rate (120 samples per second) Communications L Communications OA Communications OD Sets low data acquisition rate (3.
Chapter 5 - The DSP6000 with a PC (Remote Control) 18 Command Category Command Code Setup R Setup UA# Setup UE# Setup UI# Setup UR# Speed A Speed B Speed C Function Magtrol Model DSP6000 Dynamometer Controller Explanation Use this command to cancel any previous commands. Note: These settings are the power-on default settings. 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.
Magtrol Model DSP6000 Dynamometer Controller Chapter 5 - The DSP6000 with a PC (Remote Control) Command Category Command Code Speed D Speed E Speed F# Sets max. speed to # RPM Speed N Speed N# • Resets speed point to maximum speed • Sets speed mode OFF • Sets brake OFF • Sets speed point to # • Sets brake ON Speed ND# Sets speed derivative to # Speed NI# Sets speed integral to # Use this command to load the motor under test to a specific speed value #.
Magtrol Model DSP6000 Dynamometer Controller Chapter 5 - The DSP6000 with a PC (Remote Control) ACQUIRING SPEED-TORQUE DATA Figure 9. Connector Pin-Out RX Speed-torque data is a fixed-length string in ASCII format with a floating point decimal. Use the following string format: SdddddTdddd.R[cr][lf] 1 2 DTR TX 3 GND 4 5 or SdddddTdddd.L[cr][lf] where . . . 6 7 8 9 S = Speed in RPM. No leading zeroes are used. The DSP6000 is equipped with an RS-232 (serial) interface.
6 - Calibration CLOSED-BOX CALIBRATION The DSP6000 features closed-box calibration. The advantage of closed-box calibration is that the user does not have to disassemble the case or make mechanical adjustments. However, the calibration of the Accessory Torque Output must be done internally with Offset and Gain trim pots. The Torque readout and Auxiliary Input can be calibrated using external reference sources. Correction factors for Offset and Gain are stored in nonvolatile memory.
Magtrol Model DSP6000 Dynamometer Controller Chapter 6 - Calibration NOTE: The magnitude of change per revolution can be increased by pressing the UP ! button or decreased by pressing the DOWN " button. 6. Apply 0.000 VDC. 7. Press the ZERO button. 8. Adjust the Decrease/Increase Dial until the display indicates 0 mVDC. 9. Repeat steps 3 through 8 to complete this procedure. 10. Record the correction factors above the ZERO and GAIN readouts for future reference. 7. Press the ZERO button. 11.
Magtrol Model DSP6000 Dynamometer Controller 8. Remove the weight for ZERO adjustment. Chapter 6 - Calibration Figure 10. Alternative Calibration 9. Press the ZERO button. Torque = Weight (W) x Distance (D) Weight (W) = Torque / Distance (D) 10. Adjust the Increase/Decrease Dial until the display indicates 0 mVDC. NOTE: D The mV output of the dynamometer will be equivalent to the Full Scale Torque Rating, disregarding any decimal point.
7 - TTroubleshooting roubleshooting PROBLEM REASON Display indicates I/O ERROR Speed command sent, but Controller does not respond. Mechanical power reads much higher or lower than expected. Command does not match the unit's programmed set of instructions. Communication occured but the Controller is not loading the motor. Torque units are incorrect. No GPIB communication Setup error and/or hardware fault. No RS-232 communication Setup error and/or hardware fault.
Appendix A abVIEW® P rogramming Examples A:: L LabVIEW Programming Magtrol offers a comprehensive motor-test software program to satisfy most of your programming needs. To order your software, call Magtrol Sales at 1-800-828-7844 or 1-716-668-5555.
Appendix A: LabVIEW Programming Examples TORQUE STABILIZED 26 Magtrol Model DSP6000 Dynamometer Controller
Magtrol Model DSP6000 Dynamometer Controller Appendix A: LabVIEW Programming Examples SPEED STABILIZED 27
Appendix B B:: Inertia Correction INERTIAL EFFECT ON MOTOR TEST DATA A major advantage of the DSP6000 is its ability to obtain full motor performance data (free run to locked rotor) by continuous load application with an absorption dynamometer. Data acquisition is fast, resulting in minimal motor I2R losses, and loading characteristics simulate actual end-use applications.
Appendix C ront P anel/Display Menu Flow Charts C:: F Front Panel/Display DYNO SETUP MENU 6000 bit ENCODER: 600 bit 60 bit N.m N.cm N.mm kg.cm DYNO SETUP: INPUT UNITS: g.cm lb.ft. lb.in. oz.ft. oz.in.
Appendix C: Front Panel/Display Menu Flow Charts Magtrol Model DSP6000 Dynamometer Controller COM SETUP MENU 19200 9600 4800 RS-232 BAUD: 2400 1200 600 300 COM SETUP: 30 GPIB ADDRESS: 0 - 15 CONTRAST: 0-3
Magtrol Model DSP6000 Dynamometer Controller Appendix C: Front Panel/Display Menu Flow Charts AUX SETUP MENU 0 - 10000 UNITS/VOLT SCALE: ON AUX SETUP: DISPLAY: OFF POWER UNITS MENU W POWER UNITS: Hp 31
Appendix C: Front Panel/Display Menu Flow Charts Magtrol Model DSP6000 Dynamometer Controller TORQUE UNITS MENU N.m N.cm N.mm kg.cm TORQUE UNITS: g.cm lb.ft. lb.in. oz.ft. oz.in.
Appendix D D:: Schematics ENCODER/SWITCH BOARD C1 R1 22K (PB0) (PB1) (PB2) (PB3) (PB4) (PB5) (PB6) (PB7) (PB8) (PB9) (PB10) (AUDIO) (+ 5V) (GND) J1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 R2 22K R3 22K R4 22K R5 22K R6 22K R7 22K R8 22K R9 22K R10 22K R11 22K SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 SW9 A B (ROTARY ENCODER) SW10 SPKR1 POWER SUPPLY J1 1 2 3 4 5 BR1 1 TX1 12 C19 4700 PD05 3 11 4 9 U1 LM340T5 IN OUT COM C23 0.1 1uH C23 0.1 1uH C2 1.0 L3 d +25V BR2 7 PD05 C17 1000 C22 0.
34 U3 2.2K R17 C12 0.01 C75 0.1 C74 0.1 C73 0.1 C9 0.01 C36 0.1 R15 22K d 125 RESET C37 0.1 TIO RD WR BN BR WT BG BS 40 nc1 49 nc2 39 47 46 41 44 42 43 54 d STD/PC8 SRD/PC7 SCK/PC6 SC2/PC5 SC1/PC4 SC0/PC3 SCLK/PC2 TXD/PC1 RXD/PC0 33 38 31 32 35 29 28 26 25 8 13 10 12 4 6 7 14 15 17 18 19 21 23 24 C35 0.1 C16 0.1 C72 0.1 RD~ WR~ C13 0.1 d +5VD C39 0.
Magtrol Model DSP6000 Dynamometer Controller Appendix D: Schematics ANALOG I/O 35
Glossar y of Abbreviations and TTerms erms BNC ............................................................................. bayonet, locking-type connector CCW ............................................................................ counterclockwise (turn to left) CF ................................................................................ correction factor (inertia correction factor) CR ................................................................................ carriage return CW .........
Magtrol Limited W arranty Warranty Magtrol, Inc. warrants its products to be free from defects in material and workmanship under normal use and service for a period of one (1) year from the date of shipment. Software is warranted to operate in accordance with its programmed instructions on appropriate Magtrol instruments.
70 Gardenville Parkway ! Buffalo, New York 14224 Phone: (716) 668-5555 ! (800) 828-7844 Fax: (716) 668-8705 Web site: www.magtrol.com ! E-mail: magtrol@magtrol.
