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MODEL 6200
Open Loop
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 ©2002- 2014 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.
1st Edition rev. A – March 2014
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 6200.
3. Make sure that dynamometers and motors under test are equipped with appropriate safety guards.
iii
Revisions To This Manual
The contents of this manual are subject to change without prior notice. Should revisions be necessary, updates to all
Magtrol User’s Manuals can be found at Magtrol’s web site at www.magtrol.com/support/manuals.htm.
Please compare the date of this manual with the revision date on the web site, then refer to the manual’s Table of
Revisions for any changes/updates that have been made since this edition.
Revision Date
1st Edition rev. A – March 2014
Table of Revisions
Date
Edition
Change
Section(s)
03/03/14
1st Edition - rev. A
Torque Offset and Gain procedure updated.
6.3.2
03/03/14
1st Edition - rev. A
Basic Calibration Process updated.
6.3
03/03/14
1st Edition - rev. A
Accessory Torque/Speed Output diagram updated.
2.2.1
iv
Table of Contents
Safety Precautions........................................................................................................................ iii
Revisions To This Manual............................................................................................................... iv
Revision Date.................................................................................................................................................................iv
Table of Revisions......................................................................................................................................................iv
Preface................................................................................................................................................ vii
Purpose of This Manual.........................................................................................................................................vii
Who Should Use This Manual..............................................................................................................................vii
Manual Organization.............................................................................................................................................vii
Conventions Used in This Manual.................................................................................................................. viii
1. Introduction................................................................................................................................. 9
1.1 Unpacking Your 6200............................................................................................................................................. 9
1.2 Features of the 6200.............................................................................................................................................. 9
1.3 Data Sheet................................................................................................................................................................ 10
2. Controls........................................................................................................................................ 12
2.1 Front Panel............................................................................................................................................................. 12
2.1.1 Front Panel Controls and Buttons................................................................................................................... 12
2.1.2How to Use Front Panel Controls and Buttons............................................................................................... 13
2.2rear panel............................................................................................................................................................... 14
2.2.1 Rear Panel Functions....................................................................................................................................... 14
2.3 Vacuum Fluorescent Display (VFD)............................................................................................................ 16
2.3.1 Contrast Settings............................................................................................................................................. 16
2.3.2 Displaying Desired Information...................................................................................................................... 16
3. Installation.................................................................................................................................... 9
3.1 Powering up the 6200............................................................................................................................................ 9
3.1.1 Setting Unit for Line Voltage............................................................................................................................ 9
3.1.2Hardware Connection...................................................................................................................................... 10
3.1.3Self-Test.......................................................................................................................................................... 10
3.2 Basic Test Setup.................................................................................................................................................... 10
4. Manually Controlled Operation........................................................................................ 11
4.1setting desired operating parameters.................................................................................................. 11
4.1.1 Set Power Display to Desired Units (Watts, Hp or Aux.)............................................................................... 11
4.1.2 Set Display to Desired Torque Units............................................................................................................... 11
4.1.3 Set up System Parameters............................................................................................................................... 11
4.1.4 Set Up Pass/Fail Parameters............................................................................................................................ 11
4.1.5 Set Up I/O Parameters..................................................................................................................................... 12
4.2setting dynamometer load.......................................................................................................................... 12
4.3using internal memory................................................................................................................................... 13
4.3.1 Storing Data Points......................................................................................................................................... 13
4.3.2 Recalling Data Points...................................................................................................................................... 13
4.3.3 Exiting the Memory Mode.............................................................................................................................. 13
4.3.4 Clearing the Memory...................................................................................................................................... 13
5. Computer Controlled Operation....................................................................................... 14
5.1about the gpib interface................................................................................................................................ 14
v
Table of Contents
Magtrol Model 6200 Open Loop Dynamometer Controller
5.1.1 Installing the GPIB (IEEE-488) Connector Cable.......................................................................................... 14
5.1.2 Changing the GPIB Primary Address............................................................................................................. 15
5.2checking the 6200-to-pc connection......................................................................................................... 15
5.3programming......................................................................................................................................................... 16
5.4 6200 command set................................................................................................................................................. 16
5.4.1 Command Set for 6200................................................................................................................................... 16
5.5 ACQUIRING SPEED-TORQUE DATA....................................................................................................................... 18
5.6selecting the baud rate for the rs-232 interface............................................................................ 19
6. Calibration................................................................................................................................... 21
6.1 Closed-Box Calibration.................................................................................................................................. 21
6.2 Calibration Schedule....................................................................................................................................... 21
6.3Basic Calibration Process.............................................................................................................................. 21
6.3.1 Initial Calibration Procedure........................................................................................................................... 21
6.3.2 Torque Offset and Gain................................................................................................................................... 22
6.3.3 Accessory Torque Offset and Gain................................................................................................................. 23
6.3.4 Auxiliary Input Offset and Gain..................................................................................................................... 23
6.4 Alternate Calibration Procedure............................................................................................................ 23
7. Troubleshooting........................................................................................................................ 26
Appendix A: LabVIEW Programming Examples...................................................................... 27
A.1Simple Read............................................................................................................................................................. 27
A.2Current Stabilized............................................................................................................................................. 28
Appendix B: Front Panel/Display Menu Flow Charts........................................................ 29
B.1sETUP Menu.............................................................................................................................................................. 29
B.2 Power Units Menu................................................................................................................................................ 30
B.3 Aux Setup Menu..................................................................................................................................................... 30
B.4 Torque Units Menu............................................................................................................................................. 31
Appendix C: Schematics................................................................................................................. 32
C.1encoder/Switch Board..................................................................................................................................... 32
C.2 Power Supply.......................................................................................................................................................... 32
C.3 DSP & Memory......................................................................................................................................................... 33
C.4 Analog I/O................................................................................................................................................................ 34
Service Information....................................................................................................................... 35
Returning Magtrol equipment for Repair and/or Calibration....................................................... 35
Returning Equipment to Magtrol, Inc. (United States)................................................................................................. 35
Returning Equipment to Magtrol SA (Switzerland)...................................................................................................... 35
vi
Magtrol Model 6200 Open Loop Dynamometer Controller
Table of Contents
Table of Figures
2. Controls........................................................................................................................................ 12
Figure 2–1
Figure 2–2
Figure 2–3
Figure 2–4
Figure 2–5
Figure 2–6
Figure 2–7
Figure 2–8
Front Panel ................................................................................................................................................ 12
Secondary Function Menu......................................................................................................................... 12
Rear Panel.................................................................................................................................................. 14
Dynamometer Brake Output...................................................................................................................... 14
Accessory Torque-Speed Output................................................................................................................ 14
Dynamometer/TSC1 Connector................................................................................................................. 15
RS-232C Interface...................................................................................................................................... 15
GPIB/IEEE-488 Interface.......................................................................................................................... 15
3. Installation.................................................................................................................................... 9
Figure 3–1 Cover for Voltage Selector, Fuses................................................................................................................ 9
5. Computer Controlled Operation....................................................................................... 14
Figure 5–1 GPIB (IEEE-488) Interface........................................................................................................................ 15
Figure 5–2 Connector Pin-Out..................................................................................................................................... 19
6. Calibration................................................................................................................................... 21
Figure 6–1 Alternative Calibration............................................................................................................................... 24
vii
Preface
Purpose of This Manual
This manual contains all the information required for the installation and general use of the Model
6200 Open Loop 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 6200 Dynamometer
Controller in conjunction with any Magtrol Hysteresis Dynamometer 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.
The structure of the manual is as follows:
Chapter 1:
Introduction - Contains the technical data sheet for the 6200 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 - Provides setup options available with the 6200 Dynamometer
Controller. Illustrates and outlines the hardware connection setup and software
configurations for each option.
Chapter 4:
MANUALLY CONTROLLED OPERATION - How to run a test when the 6200 is
used as a stand-alone unit. Includes information on setting power and torque units,
torque and speed control and open loop control.
Chapter 5:
COMPUTER CONTROLLED OPERATION - How to run a test when the 6200 is
used with a PC. Includes information on GPIB Interface, RS-232 Interface, data
format, programming and command set.
Chapter 6:
Calibration - Provides recommended calibration schedules along with stepby-step instructions for the calibration procedure.
Chapter 7:
Troubleshooting - Solutions to common problems encountered during setup
and testing.
Appendix A:
LabVIEW™ Programming Examples - Magtrol’s comprehensive motortest software programs, made specifically to compliment the 6200 Dynamometer
Controller.
Appendix B:
Front Panel/Display Menu Flow Charts - A visual display of various
setup procedures.
vii
Preface
Magtrol Model 6200 Open Loop Dynamometer Controller
Appendix C:
Schematics - For Encoder/Switch Board, Power Supply, DSP & Memory and
Analog I/O.
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 party may be put at
risk. The reader must absolutely take note
of the accompanying text, and act upon it,
before proceeding further.
viii
Introduction
1.1Unpacking Your 6200
Your 6200 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 6200.
2. Inspect the 6200 for any evidence of damage in shipping.
3. Make sure the carton contains the following:
MODEL 6200
POWER/AUX
CONTROLLER/DISPLAY
TORQUE
SPEED
DECREASE
POWER
POWER UNITS
TORQUE UNITS
AUX SETUP
CLR MENU
SETUP
BRAKE ON/OFF
TORQUE SET
DISPLAY
STORE
RECALL
INCREASE
SHIFT
UP
DOWN
6200 Dynamometer Controller/Readout
Line cord
Calibration Certificate
Magtrol User Manual CD-Rom
1.2Features of the 6200
•
•
•
•
•
•
•
•
•
•
High quality, easy to read display - Vacuum fluorescent readout with 0.36” (9.1 mm) high digits.
High-speed data acquisition - 120 torque and speed readings per second via IEEE (GPIB) bus.
Pass/Fail testing - Upper and lower limits are programmable for torque, speed, and auxiliary
input.
Current regulated supply - Provides up to 1 amp output.
Internal data storage - Nonvolatile memory of up to 100 data points.
Dynamometer overload protection - Maximum power limit can be programmed to shut down if
exceeded.
Two standard computer interfaces - RS-232 and IEEE-488.
Additional analog input - Accepts any ± 5 VDC transducer.
Many torque measurement options - Includes English, metric, and SI torque readings as standard.
Closed box calibration of torque and auxiliary input - Eliminates need to open box for adjustments.
The 6200 is designed to work with any personal computer using an IEEE-488 or an RS-232 interface,
or as a stand-alone unit. In a computer-controlled environment, the 6200 provides the following
motor testing capabilities:
• Current regulated control of dynamometer brake for open-loop testing
• Torque (Q) and Speed (N) data acquisition at a rate of up to 120 readings per second.
• Saving - Allows user to save programmed values within their configurations.
9
GENERAL
INFORMATION
1.
Chapter 1 – Introduction
M
AGTROL
Data Sheet
6200
Data Sheet
GENERAL
INFORMATION
1.3
Magtrol Model 6200 Open Loop Dynamometer Controller
Model 6200 Open-Loop
Dynamometer Controller
Features
•
•
•
•
•
•
•
•
•
•
•
•
Open-LoopDynamometerControl
Built-inPass/FailMotorTestingCapability
Interfaces:RS-232andIEEE-488
HighSpeedDataAcquisition:120torqueandspeed
pointspersecondviaIEEEbus(approx.60/sec.via
RS-232)
HighQuality,Easy-to-ReadVacuumFluorescent
Readout:Displaystorque,speed,powerandauxiliary
values
Current-RegulatedSupply:Providesupto1amp
output
AdjustableTorqueUnits:English,MetricandSIare
standard
DynamometerOverloadProtection
InternalDataStorage:Upto100datapoints
Auxiliary±5VDCAnalogInput:Foradditional
transducer
ClosedBoxCalibration
RackMounting:19"(482.6mm)withhandles
andmechanicalpowervaluesofthemotorundertest.Inplace
ofmechanicalpower,itcanalsodisplayauxiliarytransducer
readings via the ±5VDC analog input. These displayed
valuescanbestoredinternallyoroutputviatheRS-232or
IEEE-488interface.
pass/Fail motor testing
The Model 6200 comes with an easy-to-use motor testing
Pass/Fail feature. This feature is ideal for quick pass/fail
(go/no go) testing in production and incoming inspection
applications.
Whenthe6200isoperatedinthePass/Failmode,oneofthree
readingsisusedasthetestedparameter:torque,speedorthe
auxiliarytransducer.Thetwoparametersnotusedaresetwith
user-definedupperandloweracceptablelimits.Asthemotor
isloadedtothetestedparametervalue(forexample,speed),
theothertwoparameters(inthiscase,torqueandtransducer)
aremeasured.Testresults(fortheother2parameters)are
indicated with a “PASS” or “FAIL”, or the display can be
toggledtoshowtheactualvalues.
Description
Magtrol'sModel6200isanOpen-LoopControllerdesigned
forusewithanyMagtrolHysteresisDynamometer.Theunit
providesopen-loopcontrolofthedynamometerviaaninternal
current-regulatedpowersupply.Withahigh-qualityvacuum
fluorescentreadout,theModel6200displaystorque,speed
system conFiguration
Hysteresis Dynamometer
MODEL 6200 CONTROLLER
Motor
Under
Test
CAUTION: DOUBLE POLE FUSING
75VA 50/60 Hz
BRAKE
ACCESSORY
TORQUE-SPEED
OUTPUT
CTRL OUT
DYNAMOMETER
AUX.
INPUT
RS–232C
GPIB/IEEE–488
EARTH
GROUND
BRAKE FUSE
(5×20mm): UL/CSA 1.25A 250V SB
IEC 1A 250V T
MAGTROL, INC. BUFFALO, NY
FUSE (5×20mm):
120V UL/CSA 800mA 250V SB
240V IEC 315mA 250V T
orDering inFormation
6200OpenLoopDynamometerController120VAC
6200AOpenLoopDynamometerController240VAC
10
www.magtrol.com
Chapter 1 – Introduction
Magtrol Model 6200 Open Loop Dynamometer Controller
GENERAL
INFORMATION
Specifications
6200
MEASUREMENT CHARACTERISTICS
MaximumTorque
2000units
MaximumSpeed
99,999rpm
Speed:0.01%ofreadingfrom10rpmto100,000rpm
Accuracy
Torque:0.2%ofrange(±2V)
Aux:0.1%ofrange(±5V)
ELECTRICAL CHARACTERISTICS
Brake:
UL/CSA 1.25A
250VSB
IEC
1.00A
250VT
Fuses(5×20mm)
Power(120V): UL/CSA 800mA 250VSB
Power(240V): IEC
315mA 250VT
PowerRequirements
75VA
VoltageRequirements
120/240V60/50Hz
Max.ComplianceVoltage 45VDC
INPUTS AND OUTPUTS
AuxiliaryInput
±5VDC
Accessory
Torque:±2VDC
Torque/SpeedOutput
Speed:60TTLpulses/rev,50%dutycycle
CtrlOut
0–3VDC
ENVIRONMENT
OperatingTemperature
18ºCto25ºC
RelativeHumidity
<80%
TemperatureCoefficient 0.001%ofrange/°C
DIMENSIONS
Width
19.0in 483mm
Height
3.5in 89mm
Depth
12.4in 315mm
withhandles 13.8in 351mm
Weight
16.37lb 7.42kg
Front panel
Ready for Rack Mounting
Displays Torque, Speed and Mechanical Power Values
Internal
Memory
Set Desired Power Units
(W, Hp or AUX)
Enables Pass/Fail Testing
of Torque, Speed or
Auxiliary Input
Set Desired Torque Units
(oz.in., oz.ft., lb.in., lb.ft., g.cm, kg.cm, Nmm, Ncm, Nm)
rear panel
Auxiliary Input Accepts
±5 VDC Transducer
Connector for Optional
Magtrol Readout
Connector for Model 5241 Power Supply
(for HD-825 Dynamometer only)
RS-232 and GPIB/IEEE-488
Interfaces for Connection to PC
For Use With Any Magtrol
Hysteresis Dynamometer
Due to the continual development of our products, we reserve the right to modify specifications without forewarning.
magtrol inc
70GardenvilleParkway
Buffalo,NewYork14224USA
Phone:+17166685555
Fax:+17166688705
magtrol sa
11
CentretechnologiqueMontena
1728Rossens/Fribourg,Switzerland
Phone:+41(0)264073000
Fax:+41(0)264073001
Subsidiaries in:
GreatBritain
Germany•France
China•India
WorldwideNetwork
00-US 03/06
www.magtrol.com
2.1
Front Panel
The front panel provides a power switch, nine control buttons, a Decrease/Increase Dial, and Vacuum
Fluorescent Display (VFD)
model 6200
POWER/AUX
CONTROLLER/DISPLAY
TORQUE
SPEED
DECREASE
POWER
POWER UNITS
TORQUE UNITS
AUX SETUP
CLR MENU
SETUP
BRAKE ON/OFF
TORQUE SET
DISPLAY
STORE
RECALL
INCREASE
SHIFT
UP
DOWN
Figure 2–1 Front Panel
2.1.1
Front Panel Controls and Buttons
The front panel controls and buttons, from left to right, are:
• Power switch
• Five double-function control button:
•
•
2.1.1.1
Primary Function
Secondary Function
BRAKE ON/OFF
POWER UNITS
UNITS DISPLAY
TORQUE UNITS
DISPLAY
AUX SETUP
STORE
CLR MEM
RECALL
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)
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 dispay:
POWER/AUX
TORQUE
SPEED
Figure 2–2 Secondary Function Menu
2. Press any control button to enable the function shown in blue letters above the button:
12
GENERAL
INFORMATION
2. Controls
Magtrol Model 6200 Open Loop Dynamometer Controller
Chapter 2 – Controls
2.1.2
How to Use Front Panel Controls and Buttons
2.1.2.1
Controls/Single-Function Buttons
Button
2.1.2.2
To Use
Function
POWER
Press I to turn power ON.
Press O to turn power off.
Turns power ON or OFF.
SHIFT
Press this button and release;
then press desired control
button.
Enables the function written in blue
above control button.
UP/LEFT
Press.
Increases magnitude of change when
adjusting a numerical value (speed,
torque or max. speed).
DOWN/RIGHT
Press.
Decreases magnitude of change when
adjusting a numerical value (speed,
torque or max. speed).
DECREASE/
INCREASE DIAL
Turn clockwise or
counterclockwise.
Increases or decreases the parameter
selected.
Double-Function Buttons
Button
To Use
Function
POWER UNITS
Press SHIFT and release; then
press this button
Sets power display to WATTS, HP or
AUX input.
BRAKE ON/OFF
Press.
Toggles brake ON or OFF.
TORQUE UNITS
Press SHIFT and release; then
press this button
Enables you to set desired unit of
measure. Press UP or DOWN button
to see options. Press SHIFT to enable
option.
UNITS DISPLAY
Press.
Shows power units, torque units and
percent of full scale current output.
AUX SETUP
Press SHIFT and release; then
press this button
Enables you to set the scaling of the
auxilary input.
DISPLAY
Press.
When in the PASS/FAIL mode, shows
actual value of parameter.
CLR MEM
Press SHIFT and release; then
press this button
Clears the data memory. Resets next
memory location to 0.
STORE
Press.
Stores data into next available memory
location.
SETUP
Press SHIFT and release; then
press this button
Enables user to select SYSTEM,
PASS/FAIL and I/O menus.
RECALL
Press.
Displays memory contents beginning at
last stored value.
13
GENERAL
INFORMATION
POWER UNITS, TORQUE UNITS, AUX SETUP, CLR MEM OR SETUP
3. Press the SHIFT button again to exit the secondary function and return to main menu.
Chapter 2 – Controls
rear panel
The rear panel provides connectors and receptacles for connecting to appropriate equipment. Refer
to figures 3, 4 and 5 in this chapter for detailed drawings of the brake




CAUTION: DOUBLE POLE FUSING
75VA 50/60 Hz
BRAKE
ACCESSORY
TORQUE-SPEED
OUTPUT
CTRL OUT
AUX.
INPUT
DYNAMOMETER
RS–232C
GPIB/IEEE–488
EARTH
GROUND
BRAKE FUSE
(5×20mm): UL/CSA 1.25A 250V SB
IEC 1A 250V T
2.2.1



FUSE (5×20mm): 120V UL/CSA 800mA 250V SB
240V IEC 315mA 250V T
MAGTROL, INC. BUFFALO, NY

Figure 2–3 Rear Panel
 
Rear Panel Functions
The rear panel, from left to right, provides the following functions:
 BRAKE
Connect dynamometer brake cable here.
Current
Regulation
+35V
Fused
Figure 2–4 Dynamometer Brake Output
 BRAKE
Contains brake fuse (5 x 20 mm)
(UL/CSA
1.25A250V SB)
(IEC1A250V
T)
 CTRL OUT
Connect to Model 5241 Power Amplifier when using HD-825
Dynamometer.
 ACCESSORY
Connect accessory output cable here (optional).
FUSE
TORQUE/
SPEED
OUTPUT
7
6
3
5
1
2
4
1. TACH. SIGNAL
2. TORQUE OUTPUT
3. D.P.
4. TORQUE COMMON
5. N/C
6. TACH. COMMON
7. D.P.
Figure 2–5 Accessory Torque-Speed Output
C
aution:
For
use with
Magtrol Readouts
only.
Connecting
another device to this output may
cause equipment failure.
14
GENERAL
INFORMATION
2.2
Magtrol Model 6200 Open Loop Dynamometer Controller
Chapter 2 – Controls
Magtrol Model 6200 Open Loop Dynamometer Controller
Connect dynamometer signal cable here.
7
6
5
4
3
2
1
14
13
12
11
10
9
8
8. COMMON
9. D.P.
10. TACH. SIGNAL
11. N/C
12. D.P.
13. TORQUE COMMON
14. TORQUE SIGNAL
1. N/C
2. N/C
3. ISOLATED +22 VDC
4. ISOLATED -22 VDC
5. ISOLATED +22 VDC
6. ISOLATED -22 VDC
7. TACH. +5.0 VDC
Figure 2–6 Dynamometer/TSC1 Connector
 AUX INPUT
Connect auxiliary instrument signal cable here.
 RS-232C
Use this socket for RS-232 connector cable
5
4
9
3
8
2
7
1
6
1.
2. TX
3. RX
4.
5. GND
6.
7.
8.
9. N/C
Figure 2–7 RS-232C Interface
 GPIB/IEEE-488
Use this socket for GPIB cable (meets IEEE-488 specifications).
12
11
10
9
8
7
6
5
4
3
2
1
24
23
22
21
20 19
18
17
16
15
14
13
1. D1
2. D2
3. D3
4. D4
5. E01
6. DAV
7. NRFD
8. NDAC
9. IFC
10. SRQ
11. ATN
12. SHIELD
13. D5
14. D6
15. D7
16. D8
17. REN
18. DAV-COM
19. NRFD-COM
20. NDAC-COM
21. IFC-COM
22. SRQ-COM
23. ATN-COM
24. SIGNAL GROUND
Figure 2–8 GPIB/IEEE-488 Interface
 POWER
Attach power cord here.
 EARTH GROUND
Attach earth ground here.
15
GENERAL
INFORMATION
 DYNAMOMETER
Chapter 2 – Controls
Vacuum Fluorescent Display (VFD)
The VFD provides information about the control functions, the motor under test, and an auxiliary
input device (if connected). The displays, from left to right, are:
• POWER (expressed in horsepower or watts)/AUX INPUT
• TORQUE
• SPEED
• Memory Indicator
2.3.1
Contrast Settings
The 6200 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 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.
2.3.2
Displaying Desired Information
2.3.2.1
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.
3. Press SHIFT to exit.
4. Press SHIFT and release; then press TORQUE UNITS to see UNITS displayed.
5. Press UP  or DOWN  to scroll through options for units.
6. Press SHIFT to exit.
7. Press RECALL to view memory contents; last in = first out.
8. Press SHIFT to exit.
2.3.2.2
Remote Control
Refer to “6200 Command Set” in Chapter 4 - The 6200 with a PC for a list of commands recognized
by the 6200.
2.3.2.3
Auxiliary Input
1. Press SHIFT and release; then press AUX SETUP.
2. Rotate Decrease/Increase Dial to select scale.
3. Press SHIFT to exit.
16
GENERAL
INFORMATION
2.3
Magtrol Model 6200 Open Loop Dynamometer Controller
3. Installation
3.1
Powering up the 6200
Warning! To reduce the risk of electric shock, Make
sure the 6200 is earth grounded before
starting!
Setting Unit for Line Voltage
The 6200 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.
Figure 3–1 Cover for Voltage Selector, Fuses
9
SETUP
3.1.1
Note:Before installing the 6200, you should become familiar with the
front and rear panels, as outlined in Chapter 2–Controls.
Chapter 3 – Installation
3.1.2
Magtrol Model 6200 Open Loop Dynamometer Controller
Hardware Connection
Do not overload or stall the motor. Prolonged overload can cause the motor to overheat.
Note:
Note:
3.1.3
Connect the 6200 to the dynamometer using the following cables:
• 14-pin signal cable
• 2-pin brake power cable
Turn on 6200 power.
Self-Test
After turning the power on to the 6200, the display panel will show all segments of the VFD
(series of rectangles), indicating that the 6200 is downloading the program.
When the program download is complete, the message “MAGTROL 6200” appears.
3.2
Basic Test Setup
1. After the Model Display wappears, press the UNITS DISPLAY button and set current
output to 0% with Decrease/Increase Dial.
2. Start the test motor.
3. Allow the motor speed to stabilize at its no-load speed for a few seconds.
4. Press the BRAKE ON/OFF button to ON.
5. Turn the Decrease/Increase Dial clockwise.
Desired results:
• The torque reading will increase.
As brake power is applied, load is applied to the motor. The applied torque increases as
the Decrease/Increase Dial is turned clockwise. For most motors, loading is indicated by
motor speed reduction.
8. Reduce the torque load to zero by turning the Decrease/Increase Dial counterclockwise.
Desired results:
• The torque reading will decrease.
9. Press the BRAKE ON/OFF Button to OFF.
10. Turn off power to the test motor.
Note:
If the desired results did not occur, please see Chapter 7 –
Troubleshooting.
10
SETUP
1. 2.
To make sure that the 6200 is operational, a Magtrol dynamometer
with a test motor installed must be connected to the 6200. It is not
required that the 6200 be connected to a computer.
4. Manually Controlled Operation
4.1
setting desired operating parameters
Note:
See Appendix B: Front Panel/Display Menu Flow Charts.
Set Power Display to Desired Units (Watts, Hp or Aux.)
1. Press and release SHIFT.
2. Press POWER UNITS.
3. Press UP  or DOWN  to scroll through choices.
4. Press SHIFT to exit.
4.1.2
Set Display to Desired Torque Units
1. Press and release SHIFT.
2. Press TORQUE UNITS.
3. Press UP  or DOWN  until you see the desired unit of measure.
4. Press SHIFT to exit.
4.1.3
Set up System Parameters
1. Press and release SHIFT.
2. Press SETUP.
3. Press SHIFT.
4. Press UP  or DOWN  until you see the desired unit of input torque.
5. Press SHIFT.
6. Press UP  or DOWN  until selection matches encoder installed on dynamometer.
(60-bit = standard)
7. Press SHIFT.
8. Use the UP  or DOWN  buttons and the Decrease/Increase Dial to adjust the
maximum power setpoint for the dynamometer in use.
9. Press SHIFT to exit.
4.1.4
Set Up Pass/Fail Parameters
1. Press and release SHIFT.
2. Press SETUP.
3. Press the DOWN  button once.
4. Press SHIFT.
5. Press UP  or DOWN  to turn ON or OFF Torque PASS/FAIL testing.
6. If ON, press SHIFT.
7. Use the  or DOWN  buttons and the Decrease/Increase Dial to adjust the high limit
for Torque.
8. Press SHIFT.
9. Use the  or DOWN  buttons and the Decrease/Increase Dial to adjust the low limit for
Torque.
11
OPERATION
4.1.1
Chapter 4 – Manually Controlled Operation
Magtrol Model 6200 Open Loop Dynamometer Controller
4.1.5
Set Up I/O Parameters
1. Press and release SHIFT.
2. Press SETUP.
3. Press the DOWN  button twice.
4. Press SHIFT.
5. Press UP  or DOWN  until you see the desired contrast level.
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.
4.2
setting dynamometer load
1.
2.
3.
4.
5.
Press the UNITS DISPLAY button.
Use the Decrease/Increase Dial to adjust the current output to 0%.
Use the BRAKE ON/OFF button to turn the brake ON.
Start the motor under test.
Use the UP  or DOWN  buttons and the Decrease/Increase Dial to adjust the loading
on the motor.
Caution:Do not exceed the capabilities of the dynamometer or the power
source in use. Motors draw very large currents when held at
locked rotor, and overheating may result. when using open loop
current control, induction motors cannot be tested beyond
breakdown, except at locked rotor.
12
OPERATION
10. Press SHIFT.
11. Press UP  or DOWN  to turn ON or OFF Speed PASS/FAIL testing.
12. If ON, press SHIFT.
13. Use the UP  or DOWN  buttons and the Decrease/Increase Dial to adjust the high
limit for Speed.
14. Press SHIFT.
15. Use the UP  or DOWN  buttons and the Decrease/Increase Dial to adjust the low
limit for Speed.
16. Press SHIFT.
17. Press UP  or DOWN  to turn ON or OFF Auxiliary Input PASS/FAIL testing.
18. If ON, press SHIFT.
19. Use the UP  or DOWN  buttons and the Decrease/Increase Dial to adjust the high
limit for Auxiliary Input.
20. Press SHIFT.
21. Use the UP  or DOWN  buttons and the Decrease/Increase Dial to adjust the low
limit for Auxiliary Input.
22. Press SHIFT to exit.
Magtrol Model 6200 Open Loop Dynamometer Controller
Chapter 4 – Manually Controlled Operation
using internal memory
4.3.1
Storing Data Points
1. Press and release STORE. The VFD will indicate STORE followed by a number. This
indicates the memory location that contains the data.
2. Continue pressing STORE at each desired point.
4.3.2
Recalling Data Points
1. Press and release RECALL. The VFD will indicate RECALL followed by a number. This
number indicates the memory location that is being displayed. The order of recalled data
is LAST IN = FIRST OUT (LIFO). A “M” also appears to the right of the SPEED display
to let the user know that the displayed data is from memory and not real time data.
2. Continue pressing RECALL until all the desired data is retrieved. Once data has been
recalled, it is lost from internal memory.
4.3.3
Exiting the Memory Mode
1. Press and release SHIFT.
4.3.4
Clearing the Memory
1. Press and release SHIFT.
2. Then press CLR MEM.
OPERATION
4.3
13
5. Computer Controlled Operation
The 6200 can be used with a personal computer to control a dynamometer and to transmit data
from motor testing directly to the computer.
5.1
about the gpib interface
Magtrol instruments use the GPIB (IEEE-488 Standard) for computer-to-instrument interfacing
because:
• The GPIB parallel interface is faster than serial interfaces.
• The GPIB enables testers to access up to 15 instruments on one port. Because typical
motor testing requires that at least five separate parameters must be synchronized, a
system of easy, fast access to more than one instrument is essential.
• The GPIB has rigid data formatting and hardware standards. These standards help to
ensure that all functions will work properly when the hardware and software are installed.
Note:
•
5.1.1
The GPIB interface is not standard on most computers. An interface
card and driver software must be installed. Magtrol recommends
National Instruments Corporation hardware and software.
An IEEE-488 cable must be installed between the computer and the 6200.
Installing the GPIB (IEEE-488) Connector Cable
caution:
make sure both the computer and the 6200 are turned off before
installing the
GPIB connector cable.
1. Connect one end of a high-quality, double-shielded cable to the 6200 GPIB connector.
2. Connect the other end to the GPIB interface in your PC.
14
OPERATION
Magtrol Model 6200 Open Loop Dynamometer Controller
Chapter 5 – Computer Controlled Operation
IEEE-488 INTERFACE
1 13
D5
D2
2 14
D6
D3
3 15
D7
D4
4 16
D8
EO1
5 17
REN
DAV
6 18
DAV-COM
NFRD
7 19
NFRD-COM
NDAC
8 20
NDAC-COM
IFC
9 21
IFC-COM
SRQ
10 22
SRQ-COM
ATN
11 23
ATN-COM
SHIELD
12 24
SIGNAL GROUND
Figure 5–1 GPIB (IEEE-488) Interface
5.1.2
Changing the GPIB Primary Address
Each instrument serviced by the GPIB has its own Primary Address code, which enables the
computer to obtain readings from the instrument. The factory default setting on the 6200 is 15.
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 6200 uses the 4-bit format.
1. Press the SHIFT button and release.
2. Press SETUP.
3. Press DOWN  twice.
4. Press SHIFT twice.
5.Press  or DOWN  until you see the desired GPIB address.
6. Press SHIFT twice to exit.
5.2
checking the 6200-to-pc connection
Note:
Make sure that the 6200 and its host computer are communicating
before acquiring data.
1. Make sure the primary address is set correctly for the 6200.
2. Set the input variable to 15 characters (13 variable characters and the two required data
termination characters CR and LF. (See “Programming” in this chapter.)
3. Issue output data command “OD” and read 15 characters according to the instructions for
your GPIB interface.
15
OPERATION
D1
Chapter 5 – Computer Controlled Operation
5.3
Magtrol Model 6200 Open Loop Dynamometer Controller
Desired results:
• Torque/speed data will be returned
Note:
If the desired results did not occur, Please see Chapter 7 Troubleshooting.
programming
Note:
Check the manual provided with your software for full instructions.
BASIC
HEX
DEC
CR =
CHR$(13)
0D
13
LF =
CHR$(10)
0A
10
2. Set the timeout for at least one second, if you are asked to set a communication fault delay
timeout.
• If the communication fault delay timeout is too short, or if the computer resets the
interface too quickly, the host instrument may stop responding.
5.4
6200 command set
When entering a command code:
1. Type all characters in uppercase ASCII format.
2. End all commands with a CR-LF (hex 0D-0A).
3. Do not string multiple commands together in one line.
The character # represents a floating point numerical value following the command. Leading
zeroes are not required.
5.4.1
Command Set for 6200
Command
Category
Command
Code
Function
Communications
H
Sets high data
acquisitionrate (120
samples per second)
The Controller/Readout outputs data
at 120 S/s (Using an RS-232 interface,
the rate is 60 S/s.)
Communications
L
Sets low data
acquisition rate (3.8
samples per second)
The Controller/Readout outputs data
at 3.8 S/s (default rate).
16
Explanation
OPERATION
1. Use the following information to answer the formatting questions asked when installing
your GPIB software.
• All GPIB data acquisition systems requires the use of data termination characters. The
6200 uses the GPIB standard termination characters “Carriage Return (CR)-Line Feed
(LF).” Provide them in that order.
Codes for CR - LF
Magtrol Model 6200 Open Loop Dynamometer Controller
Chapter 5 – Computer Controlled Operation
Command
Code
Function
Communications
OA
Prompts to return to
auxiliary input data
string
“Output Auxiliary” prompt to return
the value at the AUX INPUT x AUX
SCALING factor.
Communications
OD
Prompts to return
speedtorque-direction
data string
“Output Data” prompt to return data
string with this format:
SxxxxxTxxxxxRcrlf or
SxxxxxTxxxxxLcrlf
R or L is the shaft direction indicator,
as viewed looking at the dynamometer
shaft, where:
R = right; clockwise (CW)
L = left; counterclockwise (CCW)
The speed will equal the displayed
value and the torque will be in the
same units as displayed on the front
panel.
Setup
M1
Enables front panel
controls
Use this command to enable front
panel control of most functions.
Setup
M0
Locks out front panel
controls
Use this command to lock out the front
panel controls, so that the Controller/
Readout settings can be changed
only by using the computer with either
the GPIB (IEEE-488) or the RS-232
interface.
NOTE: The brake ON/OFF switch on
the front panel still functions.
Setup
R
Resets as follows:
• Manual control ON
• Low data acquisition
rate
• Brake OFF
Use this command to cancel any
previous commands.
NOTE: These settings are the poweron default settings.
Setup
UA#
Sets auxiliary input
scaling to #
This command sets the scaling factor
for the auxiliary input to # units/
volt. The range is 0.0 to 10000.0.
Programmed value # is not saved at
power down.
Setup
UE#
Sets encoder pulse
count to #
This command selects the pulse
count option for speed transducing.
The pulse count defaults to 60-bit if
out of range. The standard encoder
supplied with all Magtrol Load
Cell Dynamometers is 60 pulses/
revolution. Optional 600 and 6000
pulse encoders are available for lowspeed applications.
Codes for pulse count # are:
0 = 60-bit
1 = 600-bit
2 = 6000-bit
Programmed value # is not saved at
power down.
17
Explanation
OPERATION
Command
Category
Chapter 5 – Computer Controlled Operation
Command
Category
Command
Code
Function
Explanation
Setup
UI#
Sets dynamometer
torque units to #
NOTE: For Hp and watts
calculations to be correct, the correct
dynamometer torque units must be
specified. Values for # are:
0 = oz.in.
5 = kg.cm.
1 = oz.ft.
6 = N.mm.
2 = lb.in.
7 = N.cm.
3 = lb.ft.
8 = N.m.
4 = g.cm.
Torque units default to 0 (oz.in.) if out
of range. Programmed value # is not
saved at power down.
Setup
UR#
Sets readout torque
units to #
This command sets the torque unit
conversion for the torque readout.
Values for # are:
0 = oz.in.
5 = kg.cm.
1 = oz.ft.
6 = N.mm.
2 = lb.in.
7 = N.cm.
3 = lb.ft.
8 = N.m.
4 = g.cm.
Torque unit conversion defaults to 0
(oz.in.) if out of range. Programmed
value # is not saved at power down.
Misc.
X
Prompts to return %
current output
This command returns the % current
value in the format “I##.##”. The value
will be between 0 (no loading) and
99.99 (full loading).
Misc.
I#
Sets current output
to #
The power supply outputs a fixed
value of current. Use any value #
between 0 and 99.99%. (99.99% = 1
Amp.)
ACQUIRING SPEED-TORQUE DATA
Speed-torque data is a fixed-length string in ASCII format with a floating point decimal. Use the
following string format:
SdddddTdddd.R[cr][lf]
or
SdddddTdddd.L[cr][lf]
where . . .
S = speed in RPM. No leading zeroes are used.
d = decimal digit 0 through 9
T = torque in units selected during setup. The torque value always contains a decimal point.
L = counterclockwise dynamometer shaft rotation (left)
R = clockwise dynamometer shaft rotation (right)
18
OPERATION
5.5
Magtrol Model 6200 Open Loop Dynamometer Controller
Chapter 5 – Computer Controlled Operation
Magtrol Model 6200 Open Loop Dynamometer Controller
. = decimal point. The decimal point location depends on the specific dynamometer and
torque range in use.
Note:
The [cr} and [lf] characters will not display.
Example:
If a motor is running at 1725 RPM clockwise, with the dynamometer loading the motor to 22.6
oz.in., the 6200 will return:
S 1725T22.60R
By manipulating the string, the speed-torque and shaft direction (if required) can be extracted.
Then separate numerical variables can be assigned to them for data processing.
5.6
selecting the baud rate for the rs-232 interface
2-RX, 3-TX, 4-DTR, 5-GND. No other pins are connected.
RX
1
2
6
DTR
TX
3
7
4
8
GND
5
9
Figure 5–2 Connector Pin-Out
The 6200 is equipped with an RS-232 (serial) interface. To select the baud rate:
1. Press SHIFT and release.
2. Press SETUP button.
3. Press DOWN  twice.
4. Press SHIFT three times.
5. Press the UP  or DOWN  buttons to cycle through the following available baud rates:
300 2400 9600
600 4800 19200
1200
6. Press SHIFT to Exit
Other important communication parameters are:
• No Parity
• 8 Data Bits
• 1 Stop Bit
19
OPERATION
The 6200 communicates with the host computer through a DB-9 interface connector. The
connector pin-out is:
Chapter 5 – Computer Controlled Operation
Magtrol Model 6200 Open Loop Dynamometer Controller
To wire your own serial communications cable, use the following wiring diagram:
20
OPERATION
A cable may also be purchased from your local electronics store. A Radio Shack #26-152 cable
and #26-264 null modem adapter are known to work. The null modem adapter must be used on
the computer end of the cable.
6. Calibration
6.1
Closed-Box Calibration
The 6200 features closed-box calibration. The advantage of closed-box calibration is that the user
does not have to disassemble the case or make mechanical adjustments. However, the calibration
of the Accessory Torque Output must be done internally with Offset and Gain trim pots.
The Torque readout and Auxiliary Input can be calibrated using external reference sources. Correction
factors for Offset and Gain are stored in nonvolatile memory. They remain in effect until the user or
the calibration house updates them.
The front panel displays the actual values for the ZERO and GAIN correction factors. Record these
values before calibration. In the unlikely event of a Controller/Readout failure, it can re-initialized
by pressing and holding the STORE and RECALL buttons while turning the power on. All internal
memory and setups will be lost. After re-initializing, reprogram the GAIN and ZERO values into
memory.
6.2
Calibration Schedule
Calibrate the 6200:
• After any repairs are performed.
• At least once a year; more frequently to ensure required accuracy.
6.3
Basic Calibration Process
Items needed for calibrating the 6200:
• External voltage reference of 0 to 5 volts DC
• Digital multimeter (DMM)
• Function generator with square wave, TTL output
Both instruments should have a VDC accuracy of 0.05% or better.
6.3.1
Initial Calibration Procedure
Note:
Record the actual correction factors displayed before proceeding
with calibration.
21
MAINTENANCE
The basic calibration process consists of four procedures which must be performed in the following
order:
1. Initial Calibration Procedure
2. Torque Offset and Gain
3. Speed Verification
4. Accessory Torque Output Offset and Gain
5. Auxiliary Input Offset and Gain
Chapter 6 – Calibration
Magtrol Model 6200 Open Loop Dynamometer Controller
1.
2.
3.
4.
Allow the 6200 to stabilize in an environment with:
• An ambient temperature of 18°C to 25°C.
• Relative humidity less than 80%.
Turn on the 6200.
Allow the 6200 to warm up for at least 30 minutes.
Enable the calibration mode as follows:
a. Turn instrument power OFF.
b. Press in and hold the UP  and DOWN  buttons simultaneously.
c. Turn instrument power ON.
d. Continue pressing the UP  and DOWN  buttons until the display shows the software
revision date then release.
e. Press the SHIFT button once.
6.3.2
Note:
To exit CALIBRATE mode without making any changes, press
the SHIFT button 6 times.
Torque Offset and Gain
1. Connect the external voltage reference common to Pin 13 and Pin 4 of the dynamometer
input connector.
2. Connect the external voltage reference high to Pin 14 of the dynamometer input
connector.
3. Apply +2.000 VDC.
4. Press the DISPLAY button.
5. Adjust the gain by turning the Decrease/Increase Dial until the displayed voltage equals the
reference voltage.
Note:
The magnitude of change per revolution can be increased by pressing
the UP  button or decreased by pressing the DOWN  button.
22
MAINTENANCE
6. Apply 0.000 VDC.
7. Press the UNITS DISPLAY button.
8. Adjust the Decrease/Increase Dial until the display indicates 0 mVDC.
9. Repeat steps 3 through 8 to complete this procedure.
10. Press SHIFT.
11. Record the T-ZERO correction factor for future reference.
12. Press SHIFT.
13. Record the T-GAIN correction factor for future reference.
14. Speed Verification:
a. Connect the function generator output to Pin 10 of the dynamometer input connector.
b. Connect the function generator common to Pin 8 of the dynamometer input connector.
c. Apply a square wave, TTL signal of 1000 Hz.
d. Verify the 6200 Speed readout displays 1000 +/- 0.01% of applied frequency.
e. Apply several additional frequencies (10 kHz, 50 kHz) and verify the Speed readout
displays the applied frequency +/- 0.01%.
Magtrol Model 6200 Open Loop Dynamometer Controller
Chapter 6 – Calibration
6.3.3
Accessory Torque Offset and Gain
1. Connect the DMM common to Pin 4 of the Accessory Torque-Speed Output connector.
2. Connect the DMM high to Pin 2 of the Accessory Torque-Speed Output connector
3. Apply 0.000 VDC
4. Adjust R24 (OFFSET) on the circuit board for 0 mVDC on the DMM.
5. Apply +2.000 VDC.
6. Adjust R25 (GAIN) on the circuit board for +2.000 VDC on the DMM.
6.3.4
Auxiliary Input Offset and Gain
1. Press SHIFT button once. Display indicates AUX INPUT calibration as follows:
2. Connect the external voltage reference to the Auxiliary Input BNC connector.
3. Apply +5.000 VDC.
4. Press DISPLAY button.
5. Adjust the gain by turning the Decrease/Increase Dial until the displayed voltage equals the
reference voltage.
Note:
The magnitude of change per revolution can be increased by pressing
the UP  button or decreased by pressing the DOWN  button.
6. Apply 0.000 VDC.
7. Press UNITS DISPLAY button.
8. Adjust the Decrease/Increase Dial until the display indicates 0 mVDC.
9. Repeat steps 3 through 8 to complete this procedure.
10. Press SHIFT.
11. Record the A_ZERO correction factor for future reference.
12. Press SHIFT.
13. Record the A_GAIN correction factor for future reference.
14. Press the SHIFT button once to return to default display.
6.4
Alternate Calibration Procedure
Note:
Magtrol suggests you do NOT use this method. By using the
alternate calibration procedure, you are calibrating the 6200 to a
specific dynamometer, not to a reference standard. If you connect
the 6200 to a different dynamometer, the resulting torque reading
may be incorrect.
23
MAINTENANCE
The 6200 can also be calibrated by using a certified dynamometer, calibration beam, and weight
instead of an external voltage reference.
Chapter 6 – Calibration
Magtrol Model 6200 Open Loop Dynamometer Controller
1. Connect the chosen dynamometer to the 6200 using the 14-pin signal cable and the 2-pin
brake cable.
2. Attach the calibration beam to the dynamometer shaft.
3. Enter the calibration mode.
4. Press the BRAKE ON/OFF button ON to apply full loading to the dynamometer.
5. Hang the weight on the calibration beam pin and level the beam as illustrated in the following
d
CW
CCW
t
t
Torque = Weight (W) × Distance (D)
diagr
W
Weight (W) = Torque / Distance (D)
Figure 6–1 Alternative Calibration
6. Press the DISPLAY button.
7. Adjust the gain by turning the Decrease/Increase Dial until the displayed voltage equals the
reference voltage.
Note:
The magnitude of change per revolution can be increased by pressing
the UP  button or decreased by pressing the DOWN  button.
Note:
The mV output of the dynamometer will be equivalent to the Weight
times Distance on the calibration beam, disregarding any decimal
point.
Example
Magtrol’s HD-400-6 Dynamometer has a full-scale torque of 40.0 oz·in. The distance
from the center of the dynamometer shaft to the pin on the calibration beam is 5 inches.
Placing an 8 oz. weight on the pin will produce a torque of 40.0 oz·in. The mV output of the
dynamometer will be equivalent to 8 oz. multiplied by 5 inches, yielding an output signal
of 400 mV.
24
MAINTENANCE
8. Remove the weight for ZERO adjustment.
9. Press the UNITS DISPLAY button.
10. Adjust the Increase/Decrease Dial until the display indicates 0 mVDC.
Magtrol Model 6200 Open Loop Dynamometer Controller
Chapter 6 – Calibration
11. Repeat steps 5 through 10.
12. After completing calibration, press BRAKE ON/OFF button OFF to remove loading from
the dynamometer.
13. Remove the calibration beam from the dynamometer shaft.
14. Proceed with desired motor testing.
MAINTENANCE
25
7. Troubleshooting
Problem
Mechanical power reads
much higher or lower than
expected.
No GPIB communication.
No RS-232
communication.
Dynamometer shaft does
not turn smoothly when
BRAKE is OFF.
Reason
Solution
Torque units are incorrect. Set torque input units to match the
specifications on dynamometer
nameplate.
Setup error and/or
Check:
hardware fault.
• GPIB address of Controller.
• GPIB cable - should be functioning
and attached to Controller and
computer interface card.
Setup error and/or
Check:
hardware fault.
• Baud rate of Controller.
• Pinout of serial cable.
• Cable attachment to Controller and
serial interface port of computer.
Salient poles were set
Start the motor and bring up to speed.
up on the rotor by having
Press BRAKE button ON. Adjust
brake current applied with output current up to a value at least
no shaft rotation.
25% of the maximum torque rating of
the dynamometer in use (if possible).
Reduce output current to 0.
If you require additional assistance, please contact Magtrol Customer Service at 1-716-668-5555.
MAINTENANCE
26
Appendix A: LabVIEW Programming Examples
Magtrol offers a comprehensive motor testing software program to satisfy most of your programming needs. To order
your software, call Magtrol Sales at 1-716-668-5555.
A.1
Simple Read
APPENDICES
27
Appendix A: LabVIEW Programming Examples
A.2
Magtrol Model 6200 Open Loop Dynamometer Controller
Current Stabilized
APPENDICES
28
Appendix B: Front Panel/Display Menu Flow Charts
The following flow charts are a reference for navigating through the key setup functions of the 6200 Open Loop
Dynamometer Controller. For step-by-step setup instructions, refer to the corresponding chapters in this manual.
B.1
sETUP Menu
19200
9600
4800
RS-232
BAUD:
2400
1200
600
300
I/O:
GPIB
ADDRESS:
0 - 15
CONTRAST:
0-3
EXIT
ON:
AUX P/F:
PASS/FAIL:
SPEED P/F:
0 - 99999
HIGH LIMIT:
0 - 99999
LOW LIMIT:
0 - 99999
HIGH LIMIT:
0 - 99999
LOW LIMIT:
0 - 99999
HIGH LIMIT:
0 - 99999
OFF
ON:
SETUP:
LOW LIMIT:
OFF
ON:
TOR UE P/F:
OFF
MAX
POWER:
0 - 99999
6000
ENCODER:
600
60
N
S STEM:
N
N
29
APPENDICES
INPUT
UNITS:
Appendix B: Front Panel/Display Menu Flow Charts
B.2
Magtrol Model 6200 Open Loop Dynamometer Controller
Power Units Menu
AUX
POWER UNITS:
W
Hp
B.3
Aux Setup Menu
AUX SETUP:
SCALE:
0 - 10000
UNITS/VOLT
APPENDICES
30
Magtrol Model 6200 Open Loop Dynamometer Controller
Appendix B: Front Panel/Display Menu Flow Charts
B.4Torque Units Menu
N.m
N.cm
N.mm
kg.cm
TORQUE
UNITS:
g.cm
lb.ft.
lb.in.
oz.ft.
oz.in.
APPENDICES
31
Appendix C: Schematics
C.1
encoder/Switch Board
C1
R1
22K
(PB0)
(PB1)
(PB2)
(PB3)
(PB4)
(PB5)
(PB6)
(PB7)
(PB8)
(PB9)
(PB10)
(AUDIO)
(+ 5V)
(GND)
C.2
J1
1
2
3
4
5
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
3
11
4
9
U1
LM340T5
IN
OUT
COM
C23
0.1
BR1
1 TX1 12
C19
4700
PD05
C17
1000
C22
0.1
R21
5.1K
C18
1000
C21
0.1
R22
5.1K
1 TX2 7
-25V
10
PE05
6
L2
C2
1.0
+5VA
1uH
L3
d
C25
4700
R23
3.3K
12
14A-56-28
COM
32
U8
LM320T5
IN
OUT
COM
-5VA
C24
0.1
C20
1
APPENDICES
+35V
9
BR3
4
1uH
+25V
BR2
7
PD05
3
C23
0.1
+5VD
1uH
8
6
14A-30-515
L1
2.2k
r17
C12
0.01
C75
0.1
C74
0.1
C73
0.1
C9
0.01
C36
0.1
tnt4882
C15
0.01
dsp56002fC40
r15
22k
C58
0.1
125
d
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
0.1
xtal_osC
d
11
12
13
15
16
17
18
19
e 20
g 22
W 27
dQ0
dQ1
dQ2
dQ3
dQ4
dQ5
dQ6
dQ7
d1
d3
d5
d7
d6
d4
d2
d0
pb0
pb2
pb4
pb6
pb8
pb10
mCm6206baeJ25
a0
a1
a2
a3
a4
a5
a6
a7
a8
a9
a10
a11
a12
a13
a14
u12
+5vd
C38
0.1
std
srd
sCk
fsi
l/r
dpb
dpa
busy
pb11
pb10
pb9
pb8
pb7
pb6
pb5
pb4
pb3
pb2
pb1
pb0
page
22k
ds~
74hC00
C71
0.1
74hC138
C29
0.01
at28C16
C11
0.1
27C512
C30
0.01
a15
1
2
3
26
4
25
5
24
6
23
7
8
21
9
10
+5vd
r72
3 x mCm6206baeJ25
C32
0.01
C48
0.1
+5vd
C45
0.1
d
C5
0.1
118
117
115
114
112
111
109
108
107
106
104
103
101
100
96
95
94
93
91
90
88
87
85
84
83
82
80
78
77
76
74
73
72
71
68
65
64
63
61
60
59
ps
57
ds
55
x/y
d23
d22
d21
d20
d19
d18
d17
d16
d15
d14
d13
d12
d11
d10
d9
d8
d7
d6
d5
d4
d3
d2
d1
d0
haCk/pb14
hreQ/pb13
hen/pb12
hr/W/pb11
ha2/pb10
ha1/pb9
ha0/pb8
h7/pb7
h6/pb6
h5/pb5
h4/pb4
h3/pb3
h2/pb2
h1/pb1
h0/pb0
52
dso
53
dsi/os0
50
dsCk/os1
51
dr
d
+5vd
C14
0.1
tio
rd~
Wr~
C4
0.01
+5vd
r18
22k
Ckout
xtal
a15
a14
a13
a12
a11
a10
a9
a8
a7
a6
a5
a4
a3
a2
a1
a0
dsp56002fC40
extal
u4
121
moda/ irQa
22k 120 modb/ irQb
119
modC/ nmi
C6
0.01 +5vd
r19
reset~
+5vd
123
132
1
126
Ckp
128
pCap
0.012 130 ploCk
131
pinit
+5vd
C10
40mhz
2mhz
5
APPENDICES
33
C8
0.1
4 74hC00
6
5
u20b
74hC00
9
8
10
u20c
74hC00
12
14
13
u20d
d
J3
1 2
3 4
5 6
7 8
header_8
d
4 mC34064d
input
1
res
C81
0.1 gnd
2
u3
out
8
+5vd
+5vd
a0
a1
a2
a3
a4
a5
a6
a7
a8
a9
a10
a11
a12
a13
a14
u11
d
C1
0.001
r6
22k
r5
22k
r4
22k
a0
a1
a2
a3
a4
a5
a6
a7
a8
a9
a10
a11
a12
a13
a14
u10
11 d21
12 d23
13 d22
15 d19
16 d18
17 d17
18 d16
19 d20
20
e
22
g
27
W
dQ0
dQ1
dQ2
dQ3
dQ4
dQ5
dQ6
dQ7
u19
15
a y0
14
b y1
13
C y2
12
g1 y3
11
g2a y4
10
g2b y5
9
y6
7
y7
74hC138
1
2
3
6
4
5
r43
22k
+5vd
ds~
page
u20a
1 74hC00
3
2
u7
a0
9 d0
i/o0
a1
10 d1
i/o1
a2
11 d2
i/o2
a3
13 d3
i/o3
a4
14 d4
i/o4
a5
15 d5
i/o5
a6
16 d6
i/o6
a7
17 d7
i/o7
a8
a9
a10
We
+5vd
oe
Ce
r20
at28C16e-20sC
22k
8
7
6
5
4
3
2
1
23
22
19
21
20
18
330
r1
r10 r11 r12 r13
r9
22k
22k 22k 22k 22k 22k
J2
pb1
1 2
3 4
pb3
5 6
pb5
pb7
7 8
pb9
9 10
11 12
C7
13 14
0.001
keypad
+5vd
d
C79
d
header_14
Q1
r16
+
1.0 mmbt2222
pb11
r14
3.3k
a12
a13
a14
a15
mCm6206baeJ25
1
2
3
26
4
25
5
24
6
23
7
8
21
9
10
r2
22k
ds~
r3
22k
11 d15
12 d13
13 d14
15 d8
16 d9
17 d10
18 d11
19 d12
20
e
22
g
27
W
dQ0
dQ1
dQ2
dQ3
dQ4
dQ5
dQ6
dQ7
mCm6206baeJ25
1
2
3
26
4
25
5
24
6
23
7
8
21
9
10
d
d
+5vd
u6
a0 o1 11 d0
a1 o2 12 d1
a2 o3 13 d2
a3 o4 15 d3
a4 o5 16 d4
a5 o6 17 d5
a6 o7 18 d6
a7 o8 19 d7
a8
a9
a10
a11
a12
a13
a14
a15
oe/vpp
Ce
mbm27C512
10
9
8
7
6
5
4
3
25
24
21
23
2
26
27
1
22
20
0.1
C68
0.1
C77
reset~
rdy1
71
74
77
80
88
89
91
92
nC
tnt4882
paged
sWap
burst_rd
fifo_rdy
mode
CpuaCC
bbus_oe 1
abus_oe 20
rem 28
trig 23
dCas 51
tadCs 21
ladCs 66
C2-
C2+
C1-
vCC
16
v-
v+
0.1
C76
6
2
tx1out 14
tx2out 7
+5vd
d
d
15 max232Cse
0.1
J10
1
2
3
4
5
6
d 7
8
9
rs232
d
busy
C53
d
12
rx1in 13
rx1out
9
8
rx2out gnd rx2in
11
tx1in
10
tx2in
5
4
3
0.1
d
u21
1
C1+
C69
J4
d7
d6
1 2
d5
d4
3 4
d3
d2
5 6
d1
d0
7 8
9 10
11 12
+5vd
+5vd
13 14
15 16
display
d
d
header_16
52
26
29
31
30
53
22
32
drQ
33
daCk
38
intr
14
abus
62
bbus
34
dio8
dio7
dio6
dio5
dio4
dio3
dio2
dio1
data15
70
data14
ren
79
data13
ifC
81
data12
ndaC
82
data11
nrfd
84
data10
dav
85
data9
eoi
73
data8
atn
76
data7
srQ
data6
95
data5
xtal0
96
40mhz
data4
xtal1
data3
98
data2 keyClk
99
keydQ
data1
keyrst 100
data0
addr4
addr3
addr2
addr1
addr0
reset
u13
55
Cs
64
Wr
63
rd
2
3
5
6
7
9
10
11
50
49
47
46
44
43
42
39
19
18
17
16
15
67
d
J8
1 13
2 14
3 15
4 16
5 17
6 18
7 19
8 20
9 21
10 22
11 23
12 24
ieee488
d
C.3
+5vd
gnd
nC/oe vdd
d xtal_osC
4
1
u5
Magtrol Model 6200 Open Loop Dynamometer Controller
Appendix C: Schematics
DSP & Memory
Appendix C: Schematics
C.4
Magtrol Model 6200 Open Loop Dynamometer Controller
Analog I/O
APPENDICES
34
Service Information
Returning Magtrol equipment for Repair and/or Calibration
Before returning equipment to Magtrol for repair and/or calibration, please visit Magtrol’s Web site at
http://www.magtrol.com/support/rma.htm to begin the Return Material Authorization (RMA) process. Depending on
where the equipment is located and which unit(s) will be returned, you will be directed to either ship your equipment
back to Magtrol, Inc. in the United States or Magtrol SA in Switzerland.
Returning Equipment to Magtrol, Inc. (United States)
When returning equipment to Magtrol, Inc.’s factory in the United States for repair and/or calibration, a completed
Return Material Authorization (RMA) form is required.
1.
Visit Magtrol’s Web site at http://www.magtrol.com/support/rma.htm to begin the RMA process.
2.
Complete the RMA form online and submit.
3.
An RMA number will be issued to you via e-mail. Include this number on all return documentation.
4.
Ship your equipment to:
Magtrol, Inc.
70 Gardenville Parkway
Buffalo, NY 14224
Attn: Repair Department
5.
After Magtrol’s Repair Department receives and analyzes your equipment, a quotation listing all the necessary
parts and labor costs, if any, will be faxed or e-mailed to you.
6.
After receiving your repair estimate, provide Magtrol with a P.O. number as soon as possible. A purchase
order confirming the cost quoted is required before your equipment can be returned.
Returning Equipment to Magtrol SA (Switzerland)
If you are directed to ship your equipment to Switzerland, no RMA form/number is required. Just send your equipment
directly to Magtrol SA in Switzerland and follow these shipment instructions:
1.
Ship your equipment to:
Magtrol SA
After Sales Service
Route de Montena 77
1728 Rossens / Fribourg
Switzerland
VAT No: 485 572
2.
Please use our forwarder : TNT • 1-800-558-5555 • Account No 154033
Only ship ECONOMIC way (3 days max. within Europe)
3.
Include the following documents with your equipment:
• Delivery note with Magtrol SA’s address (as listed above)
• Three pro forma invoices with:
• Your VAT number
• Value - for customs purposes only • Description of returned goods • Origin of the goods (in general, Switzerland)
• Noticed failures
4.
A cost estimate for repair will be sent to you as soon as the goods have been analyzed. If the repair charges
do not exceed 25% the price of a new unit, the repair or calibration will be completed without requiring prior
customer authorization.
35
Testing, Measurement and Control of Torque-Speed-Power • Load-Force-Weight • Tension • Displacement
Magtrol Inc
70 Gardenville Parkway
Buffalo, New York 14224 USA
Phone: +1 716 668 5555
Fax: +1 716 668 8705
E-mail: [email protected]
Magtrol SA
Route de Montena 77
1728 Rossens / Fribourg, Switzerland
Phone: +41 (0)26 407 3000
Fax: +41 (0)26 407 3001
E-mail: [email protected]
www.magtrol.com
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Germany • France
China • India
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of Sales Agents