Download Magtrol DSP6000 Specifications

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. Additionally, no
liability is assumed for any damages that
may result from the use of the information
contained within this publication.
LabVIEW® is a registered trademark of
National Instruments Corporation.
RadioShack® is a registered trademark of
the RadioShack Corporation.
74M041 062200
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.
iii
This page intentionally left blank.
iv
Table of Contents
SALES AND TECHNICAL ASSISTANCE .............................................................................................. ii
SAFETY NOTES ..................................................................................................................................... iii
1 - INTRODUCTION ................................................................................................................................ 1
About This Manual ............................................................................................................................................. 1
Shipping .............................................................................................................................................................. 1
UNPACKING YOUR DSP6000 ............................................................................................................................................ 1
About the Model DSP6000 Dynamometer Controller ....................................................................................... 1
FEATURES ......................................................................................................................................................................... 1
SPECIFICATIONS ................................................................................................................................................................. 2
Front Panel .......................................................................................................................................................... 3
Figure 1. Front Panel .................................................................................................................................... 3
ENABLING SECONDARY FUNCTIONS ..................................................................................................................................... 3
FRONT PANEL CONTROLS AND BUTTONS ............................................................................................................................. 4
Vacuum Fluorescent Display (VFD) .................................................................................................................. 5
STATUS DISPLAY MESSAGES .............................................................................................................................................. 5
DISPLAYING DESIRED INFORMATION .................................................................................................................................... 5
Rear Panel ........................................................................................................................................................... 6
Figure 2. Rear Panel ..................................................................................................................................... 6
Figure 3. Brake Connector ............................................................................................................................ 6
Figure 4. Accessory Torque/Speed Output .................................................................................................... 6
Figure 5. Dynamometer Connector ............................................................................................................... 6
REAR PANEL FUNCTIONS .................................................................................................................................................... 7
2 - ABOUT THE PID LOOP ..................................................................................................................... 8
P (Proportional Gain) ......................................................................................................................................... 8
I (Integral) .......................................................................................................................................................... 8
D (Derivative) .................................................................................................................................................... 8
Figure 6. PID Loop ....................................................................................................................................... 8
Setting The Correct PID'S For Your Motor ........................................................................................................ 8
3 - INSTALLATION................................................................................................................................ 10
Setting Unit for Line Voltage ........................................................................................................................... 10
Figure 7. Cover for Voltage Selector, Fuses ............................................................................................... 10
Checking Your DSP6000 .................................................................................................................................. 10
4 - THE DSP6000 AS A STAND-ALONE UNIT (LOCAL CONTROL) ................................................. 12
Setting Desired Operating Parameters .............................................................................................................. 12
SET DISPLAY TO DESIRED POWER UNITS (WATTS OR HP) .................................................................................................. 12
SET DISPLAY TO DESIRED TORQUE UNITS ......................................................................................................................... 12
SET UP DISPLAY FOR DYNAMOMETER ............................................................................................................................... 12
SET UP COMMUNICATIONS WITH PC ................................................................................................................................. 12
SET UP AUXILIARY INPUT ................................................................................................................................................ 12
SET TORQUE CONTROL .................................................................................................................................................... 12
SET SPEED CONTROL ....................................................................................................................................................... 13
SET OPEN LOOP CONTROL ............................................................................................................................................... 13
SET UP I/O PARAMETERS ................................................................................................................................................ 13
Setting Dynamometer Load .............................................................................................................................. 14
Using Internal Memory ..................................................................................................................................... 14
STORING DATA POINTS .................................................................................................................................................... 14
RECALLING DATA POINTS ................................................................................................................................................ 14
v
EXITING THE MEMORY MODE .......................................................................................................................................... 14
CLEARING THE MEMORY .................................................................................................................................................. 14
5 - THE DSP6000 WITH A PC (REMOTE CONTROL) ......................................................................... 15
About the GPIB Interface ................................................................................................................................. 15
Figure 8. GPIB (IEEE-488) Interface ......................................................................................................... 15
INSTALLING THE GPIB (IEEE-488) CONNECTOR CABLE ................................................................................................... 15
CHANGING THE GPIB PRIMARY ADDRESS ......................................................................................................................... 15
Checking the DSP6000-To-PC Connection ...................................................................................................... 16
Programming .................................................................................................................................................... 16
CODES FOR CR - LF ....................................................................................................................................................... 16
DSP6000 Command Set ................................................................................................................................... 16
COMMAND SET FOR DSP6000 ......................................................................................................................................... 17
Acquiring Speed-Torque Data .......................................................................................................................... 20
Selecting the Baud Rate for the RS-232 Interface ............................................................................................ 20
Figure 9. Connector Pin-Out ...................................................................................................................... 20
6 - CALIBRATION ................................................................................................................................. 21
Closed-Box Calibration .................................................................................................................................... 21
Calibration Schedule ......................................................................................................................................... 21
Basic Calibration Process ................................................................................................................................. 21
INITIAL CALIBRATION PROCEDURE .................................................................................................................................... 21
TORQUE OFFSET AND GAIN .............................................................................................................................................. 21
ACCESSORY TORQUE OFFSET AND GAIN ............................................................................................................................ 22
AUXILIARY INPUT OFFSET AND GAIN ................................................................................................................................ 22
ALTERNATE CALIBRATION PROCEDURE .............................................................................................................................. 22
Figure 10. Alternative Calibration ................................................................................................................ 23
7 - TROUBLESHOOTING ..................................................................................................................... 24
APPENDIX A: LABVIEW® PROGRAMMING EXAMPLES................................................................. 25
Simple Read ...................................................................................................................................................... 25
Torque Stabilized .............................................................................................................................................. 26
Speed Stabilized ................................................................................................................................................ 27
APPENDIX B: INERTIA CORRECTION .............................................................................................. 28
Inertial Effect on Motor Test Data .................................................................................................................... 28
Procedure for Inertia Correction ....................................................................................................................... 28
KEY CONDITIONS ............................................................................................................................................................ 28
APPENDIX C: FRONT PANEL/DISPLAY MENU FLOW CHARTS..................................................... 29
Dyno Setup Menu ............................................................................................................................................. 29
Com Setup Menu .............................................................................................................................................. 30
Aux Setup Menu ............................................................................................................................................... 31
Power Units Menu ............................................................................................................................................ 31
Torque Units Menu ........................................................................................................................................... 32
APPENDIX D: SCHEMATICS .............................................................................................................. 33
Encoder/Switch Board ...................................................................................................................................... 33
Power Supply .................................................................................................................................................... 33
DSP & Memory ................................................................................................................................................ 34
Analog I/O ........................................................................................................................................................ 35
GLOSSARY OF ABBREVIATIONS AND TERMS ................................................................................ 36
MAGTROL LIMITED WARRANTY ....................................................................................................... 37
vi
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. Inspect the DSP6000 for any evidence of damage
in shipping.
3. Make sure the carton contains the following:
• DSP6000 Dynamometer Controller
• Line cord
• User's Manual for the DSP6000
• Calibration certificate
ABOUT THE MODEL DSP6000
DYNAMOMETER CONTROLLER
Magtrol's Model DSP6000 Dynamometer Controller
provides superior motor testing capabilities by using
state-of-the-art digital signal processing technology.
The DSP6000 both controls the dynamometer and
provides digital readouts on the front panel. The
DSP6000 is designed to work with all Magtrol load cell
dynamometers, including the following dynamometer
models:
HD-100
HD-510
HD-800
ED-715
HD-106
HD-700
HD-805
ED-815
HD-400
HD-705
HD-810
HTD-100
HD-500
HD-710
HD-815
HTD-200
HD-505
HD-715
HD-825
HTD-300
FEATURES
Fast, full curve data acquisition
Free-run to locked rotor in seconds.
High-speed data acquisition
120 torque and speed points per second via IEEE
(GPIB) bus.
Speed and torque operating modes
Each mode provides independent PID settings for
improved dynamometer control.
Programmable digital PID values
Controlled and stored either with Magtrol M-Test
software or manually.
Single point or programmed load control
Single or multi-point torque and speed stabilized testing
using Magtrol M-Test software.
Two standard computer interfaces
RS-232 and IEEE-488.
Additional analog input
Accepts any ± 5 VDC transducer.
Vacuum fluorescent display
Displays torque, speed, power, auxiliary input and PID
values.
Many torque measurement options
Includes English, metric, and SI torque readings as
standard.
Closed box calibration of torque and auxiliary input
Eliminates need to open box for adjustments.
The DSP6000 is designed to work with any personal
computer using an IEEE-488 or an RS-232 interface,
or as a stand-alone unit. In a computer-controlled
environment, the DSP6000 provides the following
motor testing capabilities:
• Proportional (P), plus Integral (I), plus
Derivative (D) closed loop control (PID loop).
• Torque (Q) and Speed (N) data acquisition at a
rate of up to 120 readings per second.
• Automatic progressive loading in either
decreasing or increasing speed mode.
• Ability to remove the Effects of Inertia from
dynamically obtained data. (See Appendix B)
• Complete curve capability for most motor
types, including single/poly phase induction,
AC/DC series, PMDC, brushless DC, air and
internal combustion (if suitably coupled).
1
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. Input
± 5 VD C
Ctrl Out
0-3 VDC
Accessory Torque/Speed Output
Fuses (5 x 20mm)
Torque: ± 2 VDC
Speed: 60 TTL pulses/rev, 50% duty cycle
250V
1.25A
UL/CSA
Brake:
IEC
250V
1A
250V
UL/CSA
Power (120V):
800mA
250V
315mA
IEC
Power (240V):
Pow er Requirements
75 VA
Voltage Requirements
120/240V 60/50 Hz
Maximum Speed
99,999 RPM
Maximum Torque
2000 units
Maximum Compliance Voltage
45 V D C
2
SB
T
SB
T
Magtrol Model DSP6000 Dynamometer Controller
Chapter 1 - Introduction
FRONT PANEL
Figure 1.
Front Panel
MODEL DSP6000
DYNAMOMETER CONTROLLER
The front panel provides a power switch, eight control
buttons, a Decrease/Increase Dial, and Vacuum
Fluorescent Display (VFD). The front panel controls
and buttons, from left to right, are:
• Power switch
• Six double-function control buttons:
Primary Function
Secondary Function
BRAKE ON/OFF
TORQUE SET
POWER UNITS
TORQUE UNITS
SPEED SET
MAX SPEED
P
AUX SETUP
I
COM SETUP
D
DYNO SETUP
•
•
ENABLING SECONDARY FUNCTIONS
To enable the secondary function of the double-function
control buttons:
1. Press the blue SHIFT button and release it. (The
word SHIFT appears in the display.)
2. Press a control button to enable the function shown
in blue letters above the control button:
POWER UNITS, TORQUE UNITS, AUX SETUP,
COM SETUP or DYNO SETUP.
3. Press the SHIFT button again to exit the secondary
function.
Three single-function control buttons:
• SHIFT (to enable secondary functions printed
in blue above control buttons)
• Up/Left arrow ! (scroll up, increase
magnitude)
• Down/Right arrow " (scroll down,
decrease magnitude)
Decrease/Increase Dial
NOTE:
Refer to the table, “Front Panel
Controls and Buttons” later in
this chapter for further
explanation of button features
and use.
3
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.
Sets desired unit of measure. Press
UP ! or DOWN " button to see
options. Press SHIFT to enable
option.
Press this button.
Shows setpoint for torque loading
Press and hold this button until second
Shows setpoint for open loop loading.
beep.
Press SHIFT and release; then press
Sets the speed range of the controller.
MAX SPEED
this button.
SPEED SET
Press this button.
Shows setpoint for speed loading.
AUX SETUP
Press SHIFT and release; then press
this button.
Turns auxiliary display ON or OFF.
Sets scaling of auxiliary input device.
P
Press this button.
Adjusts proportional gain.
COM SETUP
Press SHIFT and release; then press
this button.
Adjusts GPIB primary address and
RS-232 baud rate. Also adjusts
display contrast.
I
Press this button.
Adjusts integral.
DYNO
SETUP
Press SHIFT and release; then press
this button.
Selects input torque units and speed
encoder.
D
Press this button.
Adjusts derivative.
SHIFT
Press this button and release, then
press desired control button.
UP/LEFT !
Press.
DOWN/RIGHT "
Press.
Actuates the function written in blue
above control button.
Increases magnitude of change when
adjusting a numerical value (speed,
torque or max. speed).
Decreases magnitude of change when
adjusting a numerical value (speed,
torque or max. speed).
DECREASE
/INCREASE
DIAL
Turn clockwise or counterclockwise.
4
Decreases or increases the
parameter selected.
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.
Top Row
Bottom Row
POWER
(expressed in Hp or Watts)
TORQUE
BRAKE STATUS
(ON or OFF)
SETPOINT (TORQUE)
3. Press SHIFT to exit.
SPEED
SETPOINT (SPEED)
AUX INPUT or STATUS
DISPLAY
P
5. Press UP ! or DOWN " to scroll through
options for units.
I
6. Press SHIFT to exit.
D
7. Press RECALL to view memory contents; last in =
first out.
The DSP6000 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, use the lowest possible setting to achieve
that 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.
STATUS DISPLAY MESSAGES
Message
Meaning
SHIFT
Shift buton was pressed.
Auxiliary unit is attached and
enabled.
Maximum motor RPM.
AUX
MAX SPEED
I/O ERROR
UNITS
Acquiring data in high-speed mode.
REMOTE
Remote control via PC enabled.
RAMP UP
8. Press SHIFT to exit.
Remote control:
Refer to “DSP6000 Command Set” in Chapter 4 - The
DSP6000 with a PC for a list of commands recognized
by the DSP6000.
Auxiliary Input:
1. Press SHIFT and release; then press AUX SETUP.
2. Rotate Decrease/Increase Dial to select scale.
3. Press SHIFT to exit.
Incorrect command was sent from
computer.
Torque unit of measurement.
FAST ACQ
RAMP DOWN
4. Press SHIFT and release; then press TORQUE
UNITS to see UNITS displayed.
Decrease motor speed by
increasing load on motor.
Increase motor speed by
decreasing load on motor.
5
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.
6
+
-
8
2
9
3
10
4
11
5
12
6
13
7
14
COMMON
D.P.
TACH. SIGNAL
N/C
D.P.
TORQUE COMMON
TORQUE SIGNAL
D.P.
7
1
4
TORQUE
COMMON
-
TACH. +5.0 VDC
TACH.
COMMON
TACH.
SIGNAL
ISOLATED
22 VDC
+
1
CONNECTOR SHELL
& CABLE SHIELD
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. Connecting another device to
this output may cause equipment failure.
DYNAMOMETER
Connect dynamometer signal cable here
AUX INPUT
Connect auxiliary instrument cable here
RS-232C
Use this socket for RS-232 connector cable
GPIB/IEEE-488
Use this socket for GPIB cable (meets IEEE-488 specifications)
POWER
Attach power cord here
EARTH GROUND
Attach earth ground here
7
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.
Derivative
The setpoint is the desired load or speed. Error is the
difference between the setpoint and the actual
measurement.
Figure 6.
PID Loop
P (PROPORTIONAL GAIN)
With proportional gain, the controller output is
proportional to the error or to a change in measurement.
Deviation from the setpoint is usually present.
Increasing proportional gain will make the PID loop
unstable. Increasing integral value eliminates this
instability. For best loop control, set the proportional
gain as high as possible without causing the loop to
become unstable.
SETTING THE CORRECT PID'S FOR
YOUR MOTOR
I (INTEGRAL)
With integral, the controller output is proportional to
the amount of time the error is present. Increasing the
integral value eliminates the offset from the setpoint. If
the response becomes oscillatory, increase the derivative
value.
D (DERIVATIVE)
With derivative, the controller output is proportional to
the rate of change of the measurement or error.
Derivative can compensate for a changing measurement.
Derivative takes action to inhibit more rapid changes
of the measurement than proportional gain.
When a setpoint change occurs, the derivative causes
the controller gain to go the "wrong" way when the
measurement gets close to the setpoint. Derivative can
be used to control overshoot. If derivative is used, higher
gain and integral values are usually necessary.
NOTE:
Each type of motor may have it's
own optimum PID setting.
NOTE:
The PID settings are scaled to the
maximum speed setting;
therefore the maximum speed
setting should be adjusted to just
higher than the free-run speed of
the motor being tested.
When testing a new motor where the optimal PID's are
unknown:
1. Begin with the Proportional Gain (P) and the
Integral (I) both set to a low value and the Derivative
(D) set to zero. This will allow the best opportunity
for finding the optimum in the lowest amount of
steps.
2. Using the DSP6000 in the speed mode: Set the
speed target at approximately 90% of the free-run
speed.
8
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. Repeat steps 4-7 until the motor moves from the
free-run to the target speed as quickly as possible
without excessive overshoot.
Chapter 2 - About the PID Loop
The larger the I value the faster the DSP6000 will move
to the target number, but an I value too large will cause
instability (oscillation). Once the optimum values are
found, these steps should be repeated at different
percentages of speed to ensure that they are the best
combination for the entire speed range.
NOTE:
The PID values for a speed
stabilized test and a ramp test
will vary. Therefore, PID
adjustments may be needed when
changing from a stabilized test to
ramp testing with the same
motor.
Example:
Motor type:
Free-Run speed:
AC
1750
The D value has little or no effect on this type of testing,
therefore the D value can remain at zero.
1. Set maximum speed to 1800
2. Set P = 5
I =5
D=0
3. Set target speed to 1600
4. Turn brake ON—no response
5. Move P value to 10—still slow, not reaching 1600
Note:
Increasing the P more will not
increase the operating
characteristics without first
increasing the I value.
6. Turn brake OFF
7. Move I value to 10
8. Turn brake ON—Reaching 1600 very slowly
9. With the brake OFF, adjust the P to 15
10. Turn the brake ON—never reaching 1600
11. Turn the brake OFF. Decrease the P to 10 and
increase the I to 15
12. Turn the brake ON—reaches 1600 Faster
13. Turn the brake OFF. Increase I to 20
14. Turn the brake ON—reaches 1600 Faster
15. Turn the brake OFF. Increase I to 25
16. Turn the brake ON—reaches 1600 Faster
17. Turn the brake OFF. Repeat
9
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. 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 7.
Cover for Voltage Selector, Fuses
To ensure that the DSP6000 is
operational, a Magtrol
Dynamometer with a test motor
installed must be connected to
the DSP6000. It is not required
that the DSP6000 be connected
to a computer.
1. Connect the DSP6000 to the dynamometer using
the following cables:
• 14-pin signal cable
• 2-pin brake power cable
2. Turn on DSP6000 power.
Desired results:
• The display panel will show all segments of
the VFD (series of rectangles), indicating that
the DSP6000 is executing a self-test routine.
• Message "MAGTROL MODEL DSP6000"
appears.
• Next screen “INPUT UNITS/ENCODER”
appears.
NOTE:
•
The dynamometer torque units
and the speed encoder can be
selected now, or after the normal
display panel appears.
Normal display panel appears.
3. Press P button and set to 20% with Decrease/
Increase Dial.
4. Press I button and set to 30% with Decrease/Increase
Dial.
5. Press TORQUE SET button.
6. Adjust torque value so that it equals zero.
10
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. For
most motors, loading is indicated by motor
speed reduction.
12. Reduce the torque load to zero by turning the
Decrease/Increase Dial counterclockwise.
Desired results:
• The torque reading will decrease.
13. Press the BRAKE ON/OFF Button to OFF.
14. Use the SHIFT button to enable the MAX SPEED
function.
15. Turn the Decrease/Increase Dial clockwise until the
MAX speed reading is slightly greater than the
motor’s free-run speed.
16. Press the SPEED SET button - Turn the
DECREASE/INCREASE DIAL until speed
setpoint no longer increases (max. speed setting).
17. Press P button and set to 10%.
18. Press I button and set to 15%.
19. Press the BRAKE ON/OFF button ON.
20. Press the SPEED SET button.
21. Turn the Decrease/Increase Dial counterclockwise.
Desired results:
•
The motor speed will decrease.
NOTE:
Adjust the motor’s stability by
adjusting the PID values. See
Chapter 2 - About the PID Loop.
22. Turn off power to the test motor.
NOTE:
If the desired results did not
occur, please see Chapter 7 Troubleshooting.
11
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.
SET TORQUE CONTROL
NOTE:
SET DISPLAY TO DESIRED POWER UNITS (WATTS
OR HP)
See Chapter 2 - About the PID
Loop.
1. Press and release SHIFT.
1. Press the TORQUE SET button.
2. Press POWER UNITS.
2. Use the UP ! and DOWN " buttons and the
Decrease/Increase Dial to adjust the setpoint to zero.
SET DISPLAY TO DESIRED TORQUE UNITS
3. Press the P button.
1. Press and release SHIFT.
4. Use the Decrease/Increase Dial to preset an initial
value of 20.
2. Press TORQUE UNITS.
3. Continue pressing TORQUE UNITS until the
desired unit of measure is displayed.
4. Press SHIFT to exit.
SET UP DISPLAY FOR DYNAMOMETER
1. Press and release SHIFT.
2. Press DYNO SETUP.
3. Press TORQUE UNITS until input unit matches
dynamometer.
4. Press ENCODER until selection matches encoder
installed on dynamometer (60 bit = standard).
5. Press SHIFT to exit.
SET UP COMMUNICATIONS WITH PC
5. Press the I button.
6. Use the Decrease/Increase Dial to preset an initial
value of 30.
7. Press the D button.
8. Use the Decrease/Increase Dial to preset an initial
value of 0.
9. Use the BRAKE ON/OFF button to turn the brake
ON.
10. Start your motor under test.
11. Press the TORQUE SET button and adjust the
setpoint to the desired load.
12. Check the torque display to make sure that the
dynamometer loads the motor under test to that
torque load.
(If necessary)
1. Press and release SHIFT.
2. Then press COM SETUP.
3. Select GPIB ADDRESS. Press GPIB ADDRS until
appropriate address appears. (See “Changing the
GPIB Primary Address” in Chapter 5 - The
DSP6000 with a PC (Remote Control.)
12
NOTE:
If the response is too slow or
oscillatory, adjust the values for
P, I, and D.
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.
Desired results:
•
Do not exceed the capabilities of the
dynamometer or the power source in use.
Motors draw very large currents when
held at locked rotor, and overheating may
result.
When using torque control, you cannot
test induction motors beyond breakdown,
except at locked rotor.
SET SPEED CONTROL
When using speed control, motors between 0 and 100
RPM cannot be tested unless the dynamometer is
equipped with an optional speed encoder.
1. Use the SHIFT button to enable the MAX SPEED
function.
2. Use the UP ! and DOWN " buttons and the
Decrease/Increase Dial to set a value equal to or
slightly greater than the free-run speed of the motor
under test.
3. Press the SHIFT button to exit the MAX SPEED
function.
4. Press the SPEED SET button.
5. Use the UP ! and DOWN " buttons and the
Decrease/Increase Dial to set a speed equal to the
max. speed.
6. Press the P button.
The dynamometer should load the motor under test
to the desired speed quickly with little or no
overshoot when the BRAKE button is cycled ON
or OFF.
NOTE:
If the response is too slow or
oscillatory, adjust the values for
P, I and D.
SET OPEN LOOP CONTROL
1. Use the BRAKE ON/OFF button to turn the brake
ON.
2. Press and hold the TORQUE SET button until you
hear a second beep.
3. The TORQUE SET POINT display will now
indicate 0.00%.
4. Use the UP ! and DOWN " buttons and the
Decrease/Increase Dial to set a value of current
equal to the percent of full scale output (1 Amp).
5. To exit the Open Loop Control mode, press any of
the PID buttons or the SPEED SET button.
Desired results:
•
The dynamometer should load the motor under test.
Because the mode is open loop, the controller will
not stabilize on speed or torque, but will apply a
constant current to the dynamometer brake. The
actual loading will change as the brake heats up or
as other external factors change. The PID's have no
effect in this mode.
7. Use the Decrease/Increase Dial to preset a value of
10.
SET UP I/O PARAMETERS
8. Press the I button.
1. Press and release SHIFT.
9. Use the Decrease/Increase Dial to preset a value of
15.
2. Press SETUP.
3. Press the DOWN " button twice.
10. Press the D button.
4. Press SHIFT.
5. Press UP ! or DOWN " until you see the
desired contrast level.
11. Use the Decrease/Increase Dial to preset a value of
0.
13
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. Use the UP ! and DOWN " buttons and the
Decrease/Increase Dial to adjust the loading on the
motor.
Do not exceed the capabilities of the
dynamometer or the power source in use.
Motors draw very large currents when
held at locked rotor, and overheating may
result. When using open loop current
control, induction motors cannot be
tested beyond breakdown, except at
locked rotor.
USING INTERNAL MEMORY
STORING DATA POINTS
1. Press and release STORE. The VFD will indicate
STORE followed by a number. This indicates the
memory location that contains the data.
2. Continue pressing STORE at each desired point.
14
Magtrol Model DSP6000 Dynamometer Controller
RECALLING DATA POINTS
1. Press and release RECALL. The VFD will indicate
RECALL followed by a number. This number
indicates the memory location that is being
displayed. The order of recalled data is LAST IN =
FIRST OUT (LIFO). A "M" also appears to the
right of the SPEED display to let the user know
that the displayed data is from memory and not real
time data.
2. Continue pressing RECALL until all the desired
data is retrieved. Once data has been recalled, it is
lost from internal memory.
EXITING THE MEMORY MODE
1. Press and release SHIFT.
CLEARING
THE
MEMORY
1. Press and release SHIFT.
2. Then press CLR MEM.
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.
GPIB (IEEE-488) Interface
D1
1 13
D5
D2
2 14
D6
ABOUT THE GPIB INTERFACE
D3
3 15
D7
(General Purpose Interface Bus)
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
Magtrol instruments use the GPIB (IEEE-488 Standard)
for computer-to-instrument interfacing because:
• The GPIB parallel interface is faster than serial
interfaces.
• The GPIB enables testers to access up to 15
instruments on one port. Because typical motor
testing requires that at least five separate
parameters be synchronized, a system of easy,
fast access to more than one instrument is
essential.
• The GPIB has rigid data formatting and
hardware standards. These standards help to
ensure that all functions will work properly
when the hardware and software are installed.
NOTE:
•
The GPIB interface is not
standard on most computers. An
interface card and driver software
must be installed. Magtrol
recommends National
Instruments Corporation
hardware and software.
An IEEE-488 cable must also be installed
between the computer and the DSP6000.
INSTALLING
CABLE
THE
GPIB (IEEE-488) CONNECTOR
Make sure both the computer and the
DSP6000 are turned OFF before
installing the GPIB connector cable.
1. Connect one end of a high-quality, double-shielded
cable to the DSP6000 GPIB connector.
2. Connect the other end to the GPIB interface in your
PC.
CHANGING
THE
GPIB PRIMARY ADDRESS
Each instrument serviced by the GPIB has its own
Primary Address code, which enables the computer to
obtain readings from the instrument. The factory default
setting on the DSP6000 is 09.
15
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. Press SHIFT to input the address.
CHECKING THE DSP6000-TO-PC
CONNECTION
NOTE:
Make sure that the DSP6000 and
its host computer are
communicating before acquiring
data.
1. Make sure the primary address is set correctly for
the DSP6000 (see above).
2. Set the input variable to 15 characters (13 variable
characters and the two required data termination
characters CR and LF. (See “Programming” later
in this chapter.)
3. Issue output data command "OD" and read 15
characters according to the instructions for your
GPIB interface.
Check the manual provided with
your software for full
instructions.
1. Use the following information to answer the
formatting questions asked when installing your
GPIB software.
• All GPIB data acquisition systems require the
use of data termination characters. The
DSP6000 uses the GPIB standard termination
characters "Carriage Return (CR)-Line Feed
(LF)." Provide them in that order.
CODES FOR CR - LF
BASIC
H EX
D EC
CR =
CHR$(13) 0D
13
LF =
CHR$(10) 0A
10
2. Set the timeout for at least one second if asked to
set a communication fault delay timeout.
• If the communication fault delay timeout is too
short, or if the computer resets the interface too
quickly, the host instrument may stop
responding.
DSP6000 COMMAND SET
Desired results:
When entering a command code:
•
Torque/speed data will be returned
1. Type all characters in uppercase ASCII format.
•
The error message I/O ERROR does not appear on
the display panel.
2. End all commands with a CR-LF (hex 0D-0A).
NOTE:
If the desired results did not
occur, please see Chapter 7 Troubleshooting.
3. Do not string multiple commands together in one
line.
The character # represents a floating point numerical
value following the command. Leading zeroes are not
required.
NOTE:
16
If a command is not recognized,
the I/O ERROR message will
appear in the Status Display.
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 (3.8 samples per
second)
Prompts to return to
auxiliary input data string
Prompts to return speedtorque-direction data string
Ramp
PD#
Sets ramp down rate to
#RPM per second
Ramp
PR
Ramp
PU#
Ramp
S#
Setup
M1
Setup
M0
• Resets ramp up or down
• Sets speed to max.
speed
• Turns brake off
Sets ramp up rate to #RPM Specify a speed range (A, B, C, D, E, F#) AND
per second
a start speed (S#) before using this command.
This command increases the shaft speed at a
rate of #RPM per second.
Sets start or stop speed for When this command is used with the PD
ramp to #RPM
(Program Down) command, the Controller will
ramp down to this speed and halt.
When this command is used with the PU
(Program Up) command, the Controller will load
immediately to this speed and ramp up to freerun.
Enables front panel controls Use this command to enable front panel control
of most functions.
Locks out front panel
Use this command to lock out the front panel
controls
controls, so that the Controller 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.
Function
Explanation
The Controller outputs data at 120 S/s (Using an
RS-232 interface, the rate is 60 S/s.) Use this
command during the ramp up/down when a short
test time is required.
The Controller outputs data at 3.8 S/s (default
rate).
"Output Auxiliary" prompt to return the value at
the AUX INPUT x AUX SCALING factor.
"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.
Specify a speed range (A, B, C, D, E, F#) AND
a stop speed (S#) before using this command.
This command programs a decreasing shaft
speed at a rate of #RPM per second. Once
initiated, the Controller will load to locked rotor
unless instructed to do otherwise.
This command resets the ramp function, halting
the ramp's progress, and returns the motor to
free-run.
17
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.
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 low-speed applications.
Codes for pulse count # are:
0 = 60-bit
1 = 600-bit
2 = 6000-bit
Programmed value # is not saved at power
down.
Note: For Hp and watts calculations to be
Sets dynamometer torque
correct, the correct dynamometer torque units
units to #
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.
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.
Sets max. speed to 2000
Commands A, B, C, D, E and F# set a speed
RPM
range for the Controller. One of these commands
must be specified before using the speed or
Sets max. speed to 4000
ramp
mode.
RPM
Resets as follows:
• Manual control ON
• Low data acquisition rate
• Brake OFF
Sets auxiliary input scaling
to #
Sets max. speed to 8000
RPM
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 #. Issue a speed
range command (A, B, C, D, E, F#) first for best
dynamic response. The Controller is functioning
with the dynamometer as a closed loop system.
Adjust the speed PID values to tune the
response.
Derivative value # can be any number from 0 to
99.
Integral value # can be any number from 0 to 99.
Speed
NP
Sets speed proportional to
# gain
Proportional gain value # can be any number
from 0 to 99.
Torque
Q
Torque
Q#
•
•
•
•
•
Torque
QD#
Sets torque derivative to #
This command resets any previous torquestabilized command, and returns the motor to
free run.
This is a closed loop command with its own set
of PID parameters. The units defined will be the
same as those displayed by the Controller.
Derivative value # can be any number from 0 to
99.
Torque
QI#
Sets torque integral to #
Integral value # can be any number from 0 to 99.
Torque
QP#
Sets torque proportional to
# gain
Proportional gain value # can be any number
from 0 to 99.
Misc
X
Prompts to return % current
output
Misc
I#
Sets current output to #
This command returns the % current value in the
format "I##.##". The value will be between 0 (no
loading) and 99.99 (full loading).
The power supply outputs a fixed value of current.
Use any value # between 0 and 99.99%.
(99.99% = 1 Amp.)
Function
Sets maximum speed to
16,000 RPM
Sets maximum speed to
32,000 RPM
Resets torque to 0.0
Turns torque mode OFF
Turns brake OFF
Sets torque point to #
Turns brake ON
Explanation
Commands A, B, C, D, E and F# set a speed
range for the Controller. One of these commands
must be specified before using the speed or
ramp mode.
Use this command, sent alone, to reset any
previous speed-stabilized setting to the maximum
speed range.
19
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. To select the baud rate:
d = Decimal digit 0 through 9
1. Press SHIFT and release.
T = Torque in units selected during setup. The torque
value always contains a decimal point.
2. Press the COM SETUP button.
3. Press the button under the RS-232 display to cycle
through the following available baud rates:
300
2400
9600
600
4800
19200
1200
L = Counterclockwise dynamometer shaft rotation (left)
R = Clockwise dynamometer shaft rotation (right)
. = Decimal point. The decimal point location depends
on the specific dynamometer and torque range in
use.
NOTE:
The [cr] and [lf] characters will
not display.
Example:
If a motor is running at 1725 RPM clockwise, with the
dynamometer loading the motor to 22.6 oz.in., the
DSP6000 will return:
Other important communication parameters are:
• No Parity
• 8 Data Bits
• 1 Stop Bit
To wire your own serial communications cable, use the
following wiring diagram:
9 Pin
(DSP6000)
2
3
4
5
9 Pin
(Computer)
3
2
6
5
S 1725T22.60R
By manipulating the string, the speed-torque and shaft
direction (if required) can be extracted. Then separate
numerical variables can be assigned to them for data
processing.
SELECTING THE BAUD RATE FOR THE
RS-232 INTERFACE
The DSP6000 communicates with the host computer
through a DB-9 interface connector. The connector pinout is: 2-RX, 3-TX, 4-DTR, 5-GND. No other pins are
connected.
20
A cable may also be purchased from your local
electronics store. A RadioShack #26-152 cable and #26264 null modem adapter are known to work. The null
modem adapter must be used on the computer end of
the cable.
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. They remain in effect until the user or the
calibration house updates them.
The front panel displays the actual correction factors
above the ZERO and GAIN readouts. Record these
values before calibration. In the unlikely event of a
Controller failure, it can re-initialized by pressing and
holding the P, I nad D buttons while turning the power
on. All internal memory and setups will be lost. After
re-initializing, reprogram the GAIN and ZERO values
into memory.
CALIBRATION SCHEDULE
Calibrate your DSP6000:
• After any repairs are performed
• At least once a year; more frequently to ensure
required accuracy
INITIAL CALIBRATION PROCEDURE
NOTE:
Record the actual correction
factors displayed before
proceeding with calibration.
1. Allow the DSP6000 to stabilize in an environment
with:
• An ambient temperature of 18°C to 25°C
• Relative humidity less than 80%
2. Turn on the DSP6000.
3. Allow the DSP6000 to warm up for at least 30
minutes.
4. Enable the calibration mode as follows:
• Turn instrument power OFF
• Press in and hold the UP ! and DOWN "
arrow buttons simultaneously
• Turn instrument power ON
5. Continue pressing the UP ! and DOWN
" arrow buttons until the display shows the
software revision date.
6. Press the SHIFT button once.
NOTE:
To exit CALIBRATE mode
without making any changes,
press the SHIFT button six times.
BASIC CALIBRATION PROCESS
TORQUE OFFSET
The basic calibration process consists of four procedures
which must be performed in the following order:
1. Connect the external voltage reference common to
Pin 13 of the dynamometer input connector.
1. Initial Procedure
2. Connect the external voltage reference high to Pin
14 of the dynamometer input connector.
2. Torque Offset and Gain
3. Accessory Torque Output Offset and Gain
4. Auxiliary Input Offset and Gain
To calibrate the DSP6000, you will need:
• External voltage reference of 0 to 5 volts DC
• Digital multimeter (DMM) with VDC accuracy
of 0.05% or better
AND
GAIN
3. Apply +2.000 VDC.
4. Press the GAIN button.
5. Adjust the gain by turning the Decrease/Increase
Dial until the displayed voltage equals the reference
voltage.
21
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. Press the SHIFT button once to return to default
display.
8. Adjust the Decrease/Increase Dial until the display
indicates 0 mVDC.
ALTERNATE CALIBRATION PROCEDURE
9. Repeat steps 3 through 8 to complete this procedure.
10. Record the correction factors displayed above the
ZERO and GAIN readouts for future reference.
ACCESSORY TORQUE OFFSET
AND
GAIN
The DSP6000 can also be calibrated by using a certified
dynamometer, calibration beam, and weight instead of
an external voltage reference.
NOTE:
1. Connect the DMM common to Pin 4 of the
Accessory Torque-Speed Output connector.
2. Connect the DMM high to Pin 2 of the Accessory
Torque-Speed Output connector
3. Apply 0.000 VDC
4. Adjust R24 (OFFSET) on the circuit board for 0
mVDC on the DMM.
5. Apply +2.000 VDC.
6. Adjust R25 (GAIN) on the circuit board for +2.000
VDC on the DMM.
AUXILIARY INPUT OFFSET AND GAIN
1. Press the SHIFT button once. Display indicates
AUX INPUT calibration.
2. Connect the external voltage reference to the
Auxiliary Input BNC connector.
3. Apply +5.000 VDC.
4. Press the GAIN button.
5. Adjust the gain by turning the Decrease/Increase
Dial until the displayed voltage equals the reference
voltage.
NOTE:
The magnitude of change per
revolution can be increased by
pressing the UP ! button or
decreased by pressing the
DOWN " button.
6. Apply 0.000 VDC.
22
Magtrol suggests you do NOT
use this method. By using the
alternate calibration procedure,
you are calibrating the DSP6000
to a specific dynamometer, not to
a reference standard. If you
connect the DSP6000 to a
different dynamometer, the
resulting torque reading may be
incorrect.
1. Connect the chosen dynamometer to the DSP6000
using the 14-pin signal cable and the 2-pin brake
cable.
2. Attach the calibration beam to the dynamometer
shaft.
3. Enter the calibration mode.
4. Press the BRAKE ON/OFF button ON to apply full
loading to the dynamometer.
5. Hang the weight on the calibration beam pin and
level the beam.
6. Press the GAIN button.
7. Adjust the gain by turning the Decrease/Increase
Dial until the displayed voltage equals the reference
voltage.
NOTE:
The magnitude of change per
revolution can be increased by
pressing the UP ! button or
decreased by pressing the
DOWN " button.
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.
Example:
Magtrol’s HD-400-6 Dynamometer has a fullscale torque of 40.0 oz.in. The distance from
the center of the dynamometer shaft to the pin
on the calibration beam is 5 inches. Placing an
8 oz. weight on the pin will produce a torque of
40.0 oz.in. The mV output of the dynamometer
will be 40.0 minus decimal point or 400.
W
Be sure the shaft flat is facing down,
tighten the cal-beam screw against the
shaft flat only.
11. Repeat steps 5 through 10.
12. After completing calibration:
• Press the BRAKE ON/OFF button OFF to
remove loading from the dynamometer.
13. Remove the calibration beam from the
dynamometer shaft.
14. Proceed with your desired motor testing.
23
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.
Dynamometer shaft does not
turn smoothly when BRAKE is
OFF.
Salient poles were set up on the
rotor by having brake current
applied with no shaft rotation.
SOLUTION
Use correct command and format.
Adjust PID values.
Set torque input units to match the
specifications on dynamometer nameplate.
Check:
• GPIB address of Controller
• GPIB cable: should be functioning and
attached to Controller and computer
interface card.
Check:
• Baud rate of Controller
• Pinout of serial cable
• Cable attachment to Controller and serial
interface port of computer.
Start the motor and bring up to speed.
Press BRAKE button ON. Adjust output
current up to a value at least 25% of the
maximum torque rating of the dynamometer
in use (if possible). Reduce output current
to 0.
If you require additional assistance, please contact
Magtrol Customer Service at 1-800-828-7844 or 1-716-668-5555
24
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.
SIMPLE READ
25
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.
When a motor is accelerating or decelerating, the
measured torque is the sum of the true motor torque ±
the inertial torque, or stored energy, of the system.
Unless inertial torque is excluded, motor performance
will vary in proportion to the rate of acceleration or
deceleration.
This type of error can produce problematic test results.
For example, during rapid deceleration, system inertia
can produce apparent efficiency greater than 1.0. This
error may occur if output power is divided by input
power without extracting the stored energy in the
system.
Since "inertial effect" is only a factor when speed is
changing, and because inertial torque is proportional to
the rate of change, inertial value may be expressed as a
unit of torque per change in RPM in a given period of
time. With the DSP6000, properly adjusted PID values
yield constant change in RPM so that the inertial torque
can be expressed as a constant.
4. Immediately program your DSP6000 (Nddddd) to
a speed equal to the dynamic speed value. When
the speed stabilizes, use this as the static torque
value.
CF = Dynamic Torque - Static Torque
To correct your data, subtract the CF from each torque
point obtained during the ramp.
Example:
SPEED VS TORQUE
CURVE WITH CONSTANT
DECELERATION
FR
.78 OF FR
S
P
E
E
D
STATIC TORQUE
VALUE
2. Use the "Program Down" command (PD#) to ramp
to 75% of the free-run speed.
3. Select a data point on the performance curve where
speed will be approximately 78% of the free-run
speed. Let this represent the dynamic speed-torque
value.
28
DIFFERENCE IN TORQUE
CF = DIFFERENCE IN TORQUE
0
TORQUE
KEY CONDITIONS
•
•
PROCEDURE FOR INERTIA
CORRECTION
1. Determine the torque Correction Factor (CF) as
follows:
• Adjust the PID loop properly
• Establish a torque value equal to the inertial
torque.
DYNAMIC
TORQUE VALUE
•
•
Select appropriate value. The test point
selection of 78% is typical for an induction
motor. Use a value in the linear portion of the
motor curve where there is a substantial torque
change with speed.
Acquire data rapidly. Rapid data acquisition
is necessary so that motor heating does not
degrade performance by adding a false
difference between the static and dynamic
torque values.
Use a regulated power source. The input line
voltage must be stable for the time necessary
to perform the test. Torque varies by the square
of the change in line voltage.
Obtain new CF value for various
deceleration/ acceleration rates. The CF is
only valid for its specific ramp rate. To calculate
other CF rates, use the following equation:
CFnew = (CFold /ramp rate) X new ramp rate
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.
29
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.
32
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
0.1
R21
5.1K
C18
1000
C21
0.1
R22
5.1K
1 TX2 7
-25V
3
+5VA
L2
1uH
8
6
14A-30-515
+5VD
L1
U8
LM320T5
IN
OUT
COM
-5VA
C24
0.1
C20
1
+35V
9
BR3
4
10
PE05
6
14A-56-28
C25
4700
R23
3.3K
12
COM
33
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
0.1
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
C58
0.1
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
RD~
WR~
C4
0.01
+5VD
R18
22K
+5VD
123
132
1
126
CKP
128
PCAP
0.012 130 PLOCK
131
PINIT
+5VD
C10
40MHz
2MHz
5
8
+5VD
C6
0.01 +5VD
R19
TNT4882
C15
0.01
OUT
RESET~
DSP56002FC40
C8
0.1
4 74HC00
6
5
U20b
9 74HC00
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
+5VD
GND
NC/OE VDD
d XTAL_OSC
4
1
U5
+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
9 D0
A0
I/O0
10 D1
A1
I/O1
A2
11 D2
I/O2
13 D3
A3
I/O3
14 D4
A4
I/O4
A5
15 D5
I/O5
A6
16 D6
I/O6
17 D7
A7
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
R9
R1
R10 R11 R12 R13
22K
22K 22K 22K 22K 22K
J2
PB1
1 2
3 4
PB3
PB5
5 6
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
D6
D7
1 2
D5
D4
3 4
D2
D3
5 6
D0
D1
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
REN
DATA14
79
IFC
DATA13
81
NDAC
DATA12
82
NRFD
DATA11
84
DAV
DATA10
85
EOI
DATA9
73
ATN
DATA8
76
SRQ
DATA7
DATA6
95
XTAL0
DATA5
96
XTAL1
40MHz
DATA4
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
Appendix D: Schematics
Magtrol Model DSP6000 Dynamometer Controller
DSP & MEMORY
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 ............................................................................... clockwise (turn to right)
D .................................................................................. derivative
D/A .............................................................................. digital to analog converter
DMM ........................................................................... digital multimeter
FR ................................................................................ free-run speed
GPIB (General Purpose Interface Bus) ....................... parallel interface port; interchangeable with IEEE-488
Hp ................................................................................ horsepower; measure of mechanical power
Hz ................................................................................ hertz; frequency
I .................................................................................... integral
I/O ................................................................................ input/output
LF ................................................................................ line feed
local ............................................................................. manual control (use front panel controls)
mVDC .......................................................................... millivolts DC
N .................................................................................. speed
NEMA ......................................................................... National Electrical Manufacturers Association
P ................................................................................... proportional; proportional gain
PID ............................................................................... proportional, integral, derivative
PMDC .......................................................................... permanent magnet DC
Q .................................................................................. torque
remote .......................................................................... computer control (uses programmed controls from computer)
RPM ............................................................................. revolutions per minute
SI .................................................................................. Systeme Internationale units of measure
S/s ................................................................................ samples per second
V .................................................................................. volts; typically AC
VDC ............................................................................. volts DC
36
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. This warranty extends only to the original purchaser
and shall not apply to fuses, computer media, or any other product which, in Magtrol’s sole opinion, has been
subject to misuse, alteration, abuse or abnormal conditions of operation or shipping.
Magtrol’s obligation under this warranty is limited to repair or replacement of a product which is returned to the
factory within the warranty period and is determined, upon examination by Magtrol, to be defective. If Magtrol
determines that the defect or malfunction has been caused by misuse, alteration, abuse or abnormal conditions of
operation or shipping, Magtrol will repair the product and bill the purchaser for the reasonable cost of repair. If the
product is not covered by this warranty, Magtrol will, if requested by purchaser, submit an estimate of the repair
costs before work is started.
To obtain repair service under this warranty, purchaser must forward the product (transportation prepaid) and a
description of the malfunction to the factory. The instrument shall be repaired at the factory and returned to purchaser,
transportation prepaid. MAGTROL ASSUMES NO RISK FOR IN-TRANSIT DAMAGE.
THE FOREGOING WARRANTY IS PURCHASER’S SOLE AND EXCLUSIVE REMEDY AND IS IN LIEU OF
ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED
WARRANTY OF MERCHANTABILITY, OR FITNESS FOR ANY PARTICULAR PURPOSE OR USE.
MAGTROL SHALL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES OR LOSS WHETHER IN CONTRACT, TORT, OR OTHERWISE.
CLAIMS
Immediately upon arrival, purchaser shall check the packing container against the enclosed packing list and shall,
within thirty (30) days of arrival, give Magtrol notice of shortages or any nonconformity with the terms of the order.
If purchaser fails to give notice, the delivery shall be deemed to conform with the terms of the order.
The purchaser assumes all risk of loss or damage to products upon delivery by Magtrol to the carrier. If a product is
damaged in transit, PURCHASER MUST FILE ALL CLAIMS FOR DAMAGE WITH THE CARRIER to obtain
compensation. Upon request by purchaser, Magtrol will submit an estimate of the cost to repair shipment damage.
70 Gardenville Parkway ! Buffalo, New York 14224
Phone: (716) 668-5555 ! (800) 828-7844 Fax: (716) 668-8705
Web site: www.magtrol.com ! E-mail: [email protected]
MOTOR TESTING EQUIPMENT ! HYSTERESIS BRAKES AND CLUTCHES