Magtrol DSP6000 User Manual

Model DSP6001High Speed ProgrammableDynamometer ControllerUser’s Manual

viiiMagtrol Model DSP6001 Dynamometer ControllerTable of ContentsFigure 5–4 High Initial P Setting for Torque Control ...

88APPENDICESAppendix C: Front Panel/Display Menu Flow ChartsMODEL DSP6001DYNAMOMETER CONTROLLERPOWERPOWERBRAKE STATUS SET POINT SET POINT P I DTORQUE

89Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2 SECONDARY KEY FUNCTIONSC.2.1 power UnitS

90Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.4 aUx SetUp MenUAUXSETUPSHIFTCLOSELOOP ON

91Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.5 CoM SetUp MenUCOMSETUPSHIFTRS-232BAUDBI

92Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.1 MaxPower Setup MenuSHIFTDYNOSETUPMAXP

93Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.2 Dynamometer Configuration Menu Note:

94Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.2A Hysteresis Dynamometer Setup MenuINP

95Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.2C Aux Setup MenuSHIFTSCALEFACTOR0.000–

96Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.2F Eddy-Current Dynamometer with Eddy-C

97Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.2G Powder Brake Dynamometer with Powder

ixPrefacePURPOSE OF THIS MANUALThis manual contains all the information required for the installation and general use of the Model DSP6001 Dynamometer

98Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.2H Eddy-Current Dynamometer with Powder

99Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.3 Encoder Setup MenuENCODERSDYNOSETUPSH

100Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.4 Alarm Setup MenuAIR FLOWALARMALARMSD

101APPENDICESAppendix D: Remote Configuration Flow ChartsD.1 ADVANCED CONFIGURATIONCommand - ALL0Turn off all alarms while configuring unit Command -

102Magtrol Model DSP6001 Dynamometer ControllerAppendix D: Remote Configuration Flow ChartsAPPENDICESD.2 PRE-TESTSTARTCommand - UR# Select torque read

103Magtrol Model DSP6001 Dynamometer ControllerAppendix D: Remote Configuration Flow ChartsAPPENDICESD.3 RAMPCommand - F Set max speed (calculation p

104Magtrol Model DSP6001 Dynamometer ControllerAppendix D: Remote Configuration Flow ChartsAPPENDICESD.4 SPEEDSTARTCommand - N# Set speed pointCommand

105Magtrol Model DSP6001 Dynamometer ControllerAppendix D: Remote Configuration Flow ChartsAPPENDICESD.5 TORQUESTARTCommand - Q#Set speed pointComman

106Magtrol Model DSP6001 Dynamometer ControllerAppendix D: Remote Configuration Flow ChartsAPPENDICESD.6 MISCELLANEOUSCommand - DIR#Selects quadrature

107APPENDICESAppendix E: SchematicsE.1 DYNAMOMETER POWER SUPPLYA_GNDA_+5VDL71uHL81uHTP12TP180.1uFC131+5VD+5VA1uHL31uHL2TP11uFC3+5VDTP2AGND$G_DGND$G_D

xMagtrol Model DSP6001 Dynamometer ControllerPrefaceChapter 10: TROUBLESHOOTING - Solutions to common problems encountered during setup and testing.

108Magtrol Model DSP6001 Dynamometer ControllerAppendix E: SchematicsAPPENDICESE.2 DYNAMOMETER DSP & MEMORYPSC_1200R7434C100+25V13456789102J10111

109Magtrol Model DSP6001 Dynamometer ControllerAppendix E: SchematicsAPPENDICESE.3 DSP DYNAMOMETER ANALOG I/OJ6121FUSEF1HEADER_SIP2A1A2A3A4A5J12A7A8A

110APPENDIXAPPENDICESAppendix F: Additional Scale Factor TableThe Additional Scale Factor Table is the same as the M-TEST Defaults file, which contains

111IndexAAccessory Torque-Speed Output 12,37,80Additional Scale Factor 42,110Advanced Configuration 101Air Flow Alarm 56AlarmCommands 69Operation

112Magtrol Model DSP6001 Dynamometer ControllerIndexGPIB 65Integral 40,42LLabVIEW Programming Examples 83Line Voltage 15MMaximum Speed Alarm 53Ma

113Magtrol Model DSP6001 Dynamometer ControllerIndexTesting Instrumentation Setup 17Timeout 69TorqueConfiguration 105Torque Commands 74Torque Contr

114Service InformationRETURNING MAGTROL EQUIPMENT FOR REPAIR AND/OR CALIBRATIONBefore returning equipment to Magtrol for repair and/or calibra

www.magtrol.comTesting, Measurement and Control of Torque-Speed-Power • Load-Force-Weight • Tension • DisplacementMAGTROL INC70 Gardenville ParkwayBuf

1GENERALINFORMATIONCalibration Certificate1. Introduction1.2 NEW FEATURES OF THE DSP6001Magtrol’s new Model DSP6001 Dynamometer Controller is an upg

2Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – IntroductionGENERALINFORMATION1.3 DATA SHEETDSP6001Data SheetDSP6001 High-Speed Programmable

3Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – IntroductionGENERALINFORMATION2DSP6001MAGTROLSpecificationsFRONT PANELREAR PANELSet Desired P

4Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – IntroductionGENERALINFORMATION3DSP6001MAGTROLSystem ConfigurationsMotorUnderTestOPTIONAL:±10

5Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – IntroductionGENERALINFORMATION4DSP6001MAGTROLSystem ConfigurationsDYNAMOMETER / TSC1AUX / TSC

6Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – IntroductionGENERALINFORMATION5DSP6001MAGTROLDYNAMOMETER / TSC1AUX / TSC2SUPPLY 2SUPPLY 1RS-2

7Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – IntroductionGENERALINFORMATIONDSP6001Due to the continual development of our products, we res

1st Edition, revision J – March 2010While every precaution has been exercised in the compilation of this document to ensure the accuracy of its conten

8GENERALINFORMATION2. Controls2.1 FRONT PANELThe front panel provides a power switch, nine control buttons, a Decrease/Increase Dial, and Vacuum Flu

9Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – ControlsGENERALINFORMATION2. Press any control button to enable the function shown in blue l

10Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – ControlsGENERALINFORMATION2.2.3.2 Double-Function ButtonsButton To Use FunctionPOWER UNITS

11Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – ControlsGENERALINFORMATION2.3.1 contraSt SEttingSThe DSP6001 is shipped with the Contrast S

12Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – ControlsGENERALINFORMATION2.4 REAR PANELThe rear panel provides connectors and receptacles

13Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – ControlsGENERALINFORMATIONDYNAMOMETER/TSC1Connect dynamometer signal cable here.14. TORQUE

14Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – ControlsGENERALINFORMATIONSUPPLY 2 Connect WB/PB DES supply for TSC2. 3. CLUTCH 8. W FLOW_2

15SETUP3. Installation/Configuration Note: Before installing the DSP6001, you should become familiar with the front and rear panels, as outlined in

16Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.1.2 SeLf-teStAfter turning the power on to the DSP6001, the

17Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2 TESTING INSTRUMENTATION SETUPThe DSP6001 has the abil

i1. Make sure that all Magtrol dynamometers and electronic products are earth-grounded, to ensure personal safety and proper operation.2. Check lin

18Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.1 DynaMoMeter ConfigUration MenUTo reach the dynamometer

19Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.2 HyStereSiS DynaMoMeter SetUp3.2.2.1 Hardware Connectio

20Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.3 HyStereSiS DynaMoMeter witH torqUe tranSDUCer SetUp3.2.

21Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.3.2 Software Configuration1. Turn on the DSP6001 and proc

22Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.4 HyStereSiS DynaMoMeter witH aUxiLiary inStrUMentation S

23Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.4.2 Software Configuration1. Turn on the DSP6001 and proc

24Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.5 HyStereSiS DynaMoMeter witH eDDy-CUrrent or powDer Brak

25Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.5.2 Software Configuration1. Turn on the DSP6001 and proc

26Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.6 eDDy-CUrrent or powDer Brake DynaMoMeter SetUp3.2.6.1

27Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.7 eDDy-CUrrent or powDer Brake DynaMoMeter witH torqUe tr

iiThe contents of this manual are subject to change without prior notice. Should revisions be necessary, updates to all Magtrol User’s Manuals can be

28Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.8 eDDy-CUrrent or powDer Brake DynaMoMeter witH aUxiLiary

29Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.9 two eDDy-CUrrent/powDer Brake DynaMoMeterS (inDepenDent

30Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.9.2 Software Configuration1. Turn on the DSP6001 and proc

31Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.10 two eDDy-CUrrent/powDer Brake DynaMoMeterS (tanDeM Set

32Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.10.2 Software Configuration1. Turn on the DSP6001 and pro

33Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.11 eDDy-CUrrent DynaMoMeter witH powDer Brake DynaMoMeter

34Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP8. Press SHIFT 2 times to get to the TSC2 Powder Brake Setup

35Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.12 in-Line torqUe tranSDUCer CroSS Loop fUnCtion3.2.12.1

36Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP8.a. If choosing a Hysteresis or Powder Brake Type, press SHIF

37Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.4 TORQUE/SPEED ANALOG OUTPUTSTorque and Speed DAC Outputs p

iiiTable of ContentsSAFETY PRECAUTIONS ...

38SETUP4. Digital FiltersThe Digital Filters of the DSP6001 are used to remove undesired noise from the TSC inputs. This noise could be conducted fro

39Magtrol Model DSP6001 Dynamometer ControllerChapter 4 – Digital FiltersSETUP4.2 FILTER SETUPNote: Filter setup should take place after hardware in

40SETUP5. PID Settings5.1 ABOUT THE PID LOOPThe DSP6001 has PID adjustment capability for both the speed and torque modes to provide the best system

41Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUP5.3 HOW THE PID LOOP WORKSThe following diagram demonstrates the correlati

42Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUP5.3.3 eqUationSWhere Skp, Ski and Skd are system coefficients…Yd(t) = (e(t)

43Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUP5.4.1.3 Setting Additional Scale Factor for D (Derivative)1. Starting fro

44Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUPFigure 5–3 Initial P Setting for Torque Control at 25%Figure 5–4 High Ini

45Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUPa. If the response was too slow, increase the I term in 1-5% increments an

46Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUP5.5.3 Setting tHe piD for SpeeD ControL1. With the motor and brake OFF, s

47Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUPFigure 5–8 Initial I Setting for Speed Controlc. If there is too much ove

ivMagtrol Model DSP6001 Dynamometer ControllerTable of Contents3.3 SPEED ENCODER SETUP ...

48Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUP5.5.4 Setting tHe piD for raMp DownIt is nearly impossible to select a PID

49Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUPFigure 5–11 Ramp Down High IRamp shows higher value for I term. Note “bum

50SETUP • OPERATION6. Alarm System6.1 GENERAL INFORMATIONNew to the DSP6001 is a built-in alarm system, designed to caution the user when problems o

51Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATIONThe relay contacts are made accessible on the Accessory Torque/

52Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.1.3 aLarM priorityWhile in an alarm condition, a higher prio

53Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.2.2 power aLarM aCtionWhen the power exceeds that of the max

54Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.3.2 MaxiMUM SpeeD aLarM aCtionA. If speed is greater than

55Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATIONPOWERBRAKE STATUS SET POINT SET POINT P I DTORQUE SPEED STATUSF

56Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.5 AIR FLOW ALARM• Usedtoindicatealackofairowfroma

57Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.6 WATER FLOW ALARM• Usedtoindicatelackofwaterow• O

vMagtrol Model DSP6001 Dynamometer ControllerTable of Contents6.6 WATER FLOW ALARM ...

58Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.7 EXTERNAL ALARM• Usedtoshutdownsystembasedonadditio

59Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.8 TEMPERATURE ALARM• Toalertuserwhendynamometergetsto

60Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.9 ELECTRICAL ALARM• UsedtoprotecttheDESsupply• Monito

61OPERATION7. Manually Controlled Operation Note: Using the DSP6001 without a computer will limit its testing capabilities.7.1 HOW TO CHOO

62Magtrol Model DSP6001 Dynamometer ControllerChapter 7 – Manually Controlled OperationOPERATION7.2 HOW TO SET DESIRED POWER UNITS To select the desi

63Magtrol Model DSP6001 Dynamometer ControllerChapter 7 – Manually Controlled OperationOPERATION Note: If the response is too slow or oscillatory, a

64Magtrol Model DSP6001 Dynamometer ControllerChapter 7 – Manually Controlled OperationOPERATION4. Press the SHIFT button to exit the MAX SPEED funct

65OPERATION8. Computer Controlled OperationThe DSP6001 can be used with a computer to control a dynamometer and to transmit data from the motor testi

66Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.1.2 CHanging tHe gpiB priMary aDDreSSEach instrumen

67Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION Note: If the desired results did not occur, p

viMagtrol Model DSP6001 Dynamometer ControllerTable of Contents9.3.2 TSC1 Offset and Gain ...

68Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.4 DATA FORMATSpeed-torque data is a fixed-length str

69Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.5.1.2 Codes for CR - LFBASIC HEX DECCR = CHR$(13) 0

70Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.6.2 CoMMUniCation CoMManDSCommand CodeFunction Expl

71Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.6.3 raMp CoMManDSCommand CodeFunction ExplanationDI

72Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.6.4 SetUp CoMManDSCommand CodeFunction ExplanationA

73Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATIONCommand CodeFunction ExplanationUA# Sets auxiliary inp

74Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.6.5 SpeeD CoMManDSCommand CodeFunction ExplanationF

75Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.6.7 MiSCeLLaneoUS CoMManDCommand CodeFunction Expla

76MAINTENANCE9. Calibration9.1 CLOSED-BOX CALIBRATIONThe DSP6001 features closed-box calibration. The advantage of closed-box calibration is that t

77Magtrol Model DSP6001 Dynamometer ControllerChapter 9 – CalibrationMAINTENANCEPOWERBRAKE STATUS SET POINT SET POINT P I DTORQUE SPEED STATUSFigure 9

viiMagtrol Model DSP6001 Dynamometer ControllerTable of ContentsTABLE OF FIGURES2. CONTROLSFigure 2–1 Front Panel ...

78Magtrol Model DSP6001 Dynamometer ControllerChapter 9 – CalibrationMAINTENANCE9.3.3 tSC2 offSet anD gain1. Connect the external voltage reference

79Magtrol Model DSP6001 Dynamometer ControllerChapter 9 – CalibrationMAINTENANCE15. N/C14. CURRENT SET POINT (ANALOG 0V)13. +5.0 VDC COM12. SUPPLY +24

80Magtrol Model DSP6001 Dynamometer ControllerChapter 9 – CalibrationMAINTENANCE8. Connect volt meter to Pin 3 (negative) and Pin 1 (positive) of ACC

81Magtrol Model DSP6001 Dynamometer ControllerChapter 9 – CalibrationMAINTENANCE9.3.6 DeCiMaL point CHeCk1. Connect a 0.5 VDC source to pins 14 (TOR

82MAINTENANCE10. TroubleshootingIf you require additional assistance, please contact Magtrol Customer Service at 1-716-668-5555.Problem Reason Soluti

83APPENDICESAppendix A: LabVIEW Programming Examples0 [0..1]1 [0..1]Magtrol offers a comprehensive motor testing software program to satisfy most of y

84Magtrol Model DSP6001 Dynamometer ControllerAppendix A: LabVIEW Programming ExamplesAPPENDICES0 [0..2]1 [0..2]1 [0..2]2 [0..2]A.2 TORQUE STABILIZE

85Magtrol Model DSP6001 Dynamometer ControllerAppendix A: LabVIEW Programming ExamplesAPPENDICESA.3 SPEED STABILIZED0 [0..2]1 [0..2]2 [0..2]2 [0..2]

86APPENDICESAppendix B: Inertia CorrectionB.1 INERTIAL EFFECT ON MOTOR TEST DATAA major advantage of the DSP6001 is its ability to obtain full motor

87Magtrol Model DSP6001 Dynamometer ControllerAppendix B: Inertia CorrectionAPPENDICESB.2.1 key ConDitionS• Select appropriate value. The test poin