Micro Dyne System - Magtrol

User’s Manual

Micro Dyne System

Second Edition, rev C– May 2013

While every precaution has been exercised in the compilation of this document to ensure the accuracy of its contents, Magtrol 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. CopyrightCopyright ©2007–2013 Magtrol, Inc. All rights reserved.Copying or reproduction of all or any part of the contents of this manual without the express permission of Magtrol is strictly prohibited. trADEMArKSNational Instruments™ is a trademark of the National Instruments Corporation.

Purchase Record

Please record all model numbers and serial numbers of your Magtrol equipment, along with the general purchase information. The model number and serial number can be found on either a silver identification plate or white label affixed to each unit. Refer to these numbers whenever you communicate with a Magtrol representative about this equipment.

Model Number: _____________________________

Serial Number: _____________________________

Purchase Date: _____________________________

Purchased From: _____________________________

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Safety Precautions

• Secureallgroundingwirestotheappropriatelocationstoreducethechanceofshockanddamage to the equipment.

• Makesureallwiringandconnectionshavebeenproperlymade.

• AlwayswearsafetyglasseswhenworkingaroundMicroDyneequipment.

• DonotwearlooseclothingortieswhenoperatingtheMicroDyneequipment.

• Ensuremotorundertestisproperlymountedtothemotorfixture.

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The contents of this manual are subject to change without prior notice. Should revisions be necessary, updates to all Magtrol User’s Manuals can be found at Magtrol’s web site at www.magtrol.com/support/manuals.htm.

Please compare the date of this manual with the revision date on the web site, then refer to the manual’s Table of Revisions for any changes/updates that have been made since this edition.

rEviSion DAtE

Second Edition, rev C – May 2013.

tAblE of rEviSionS

Date Edition Change Section(s)02/21/13 2nd Edition, rev. C Chapter 7 Calibration - Watt Meter added. Chapter 705/21/13 2nd Edition, rev. C Calibration commands updated. A.2.809/02/10 2nd Edition, rev. B Step 3 has been removed. It is no longer neccessary to move

the pendulum when installing the circular mass.4.1 step 3

09/02/10 2nd Edition, rev. B Speed Pick-up Connection has been removed from side of electronics box. It is now concealed in the dynamometer housing.

2.2.2

09/02/10 2nd Edition, rev. B Earth ground has been removed from rear of base plate. It is now concealed in dynamometer housing.

2.2.1

09/30/09 2nd Edition, rev. A The number of cycles performed changed from five to ten 6.3.2, step 407/11/08 2nd Edition New calibration software and procedure Chapter 6, A.2.810/21/07 1st Edition, rev. A Added option to print calibration data results at end of

calibration procedure.6.3

06/13/07 1st Edition Finalized version of preliminary manual various

Revisions To This Manual

iii

Table of Contents

SAfEty prECAutionS .........................................................................................................................i

rEviSionS to thiS MAnuAl ...............................................................................................................iiREvISIoN DATE .................................................................................................................................................................II

TAblE oF REvISIoNS ......................................................................................................................................................II

tAblE of ContEntS ..........................................................................................................................iiiTAblE oF FIgURES ......................................................................................................................................................... v

prEfACE .............................................................................................................................................. viiPURPoSE oF ThIS MANUAl .......................................................................................................................................vII

Who ShoUlD USE ThIS MANUAl ............................................................................................................................vII

MANUAl oRgANIzATIoN ...........................................................................................................................................vII

CoNvENTIoNS USED IN ThIS MANUAl ................................................................................................................ vIII

1. introDuCtion ................................................................................................................................11.1 UNPACkINg ThE MICRo DyNE .......................................................................................................................... 1

1.1.1 PACkAgINg .............................................................................................................................................. 1

1.1.2 PARTS lIST ................................................................................................................................................ 1

1.2 DATA ShEET ............................................................................................................................................................ 3

2. inStAllAtion/ConfigurAtion ....................................................................................................82.1 DyNAMoMETER SETUP ....................................................................................................................................... 8

2.1.1 UNloCkINg ThE ShIPPINg/RESTRAININg bolT ........................................................................... 8

2.1.2 DyNAMoMETER lEvElINg ................................................................................................................. 8

2.2 ElECTRICAl CoNNECTIoNS .............................................................................................................................. 9

2.2.1 EARTh gRoUND ...................................................................................................................................... 9

2.2.2 REAR PANEl CoNNECToRS ............................................................................................................... 10

2.3 MoToR PoWER .................................................................................................................................................... 10

2.3.1 PoWER CoNFIgURATIoN oPTIoNS .................................................................................................. 12

2.4 MoToR TESTINg SoFTWARE ............................................................................................................................ 13

2.4.1 SoFTWARE INSTAllATIoN ................................................................................................................. 13

2.4.2 M-TEST CoMMUNICATIoN ................................................................................................................. 13

2.5 CoMMUNICATIoN ChECk ................................................................................................................................. 14

2.6 INITIAl CAlIbRATIoN ....................................................................................................................................... 14

3. tESting ConSiDErAtionS ..........................................................................................................153.1 SAFETy .................................................................................................................................................................. 15

3.2 PoWER DISSIPATIoN ........................................................................................................................................... 15

3.2.1 PoWER AbSoRPTIoN CURvE ............................................................................................................. 16

3.3 ShAFT AlIgNMENT ............................................................................................................................................ 16

3.4 WINDAgE ............................................................................................................................................................... 16

3.5 FRICTIoN ............................................................................................................................................................... 17

3.6 vIbRATIoN ............................................................................................................................................................ 17

3.7 DyNAMoMETER lEvElINg .............................................................................................................................. 17

3.8 CoggINg ............................................................................................................................................................... 17

3.8.1 AvoIDINg CoggINg ............................................................................................................................ 18

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Magtrol Micro Dyne SystemTable of Contents

3.8.2 REMovINg CoggINg .......................................................................................................................... 18

3.9 EDDy CURRENTS ................................................................................................................................................. 18

3.10 TEMPERATURE RISE ........................................................................................................................................... 18

4. tESt SEtup .....................................................................................................................................194.1 ToRqUE CoNFIgURATIoN ................................................................................................................................ 19

4.2 MoToR MoUNTINg ............................................................................................................................................. 20

4.2.1 ShAFT CoUPlINg ................................................................................................................................. 20

4.2.2 ADAPTERS ............................................................................................................................................... 20

4.2.3 ClAMPINg STRAP ................................................................................................................................. 21

4.2.4 STAgE ADjUSTMENT ............................................................................................................................ 21

4.3 SoFTWARE CoNFIgURATIoN ........................................................................................................................... 22

4.3.1 MoToR REvERSAl ............................................................................................................................... 23

5. opErAting prinCiplES ...............................................................................................................255.1 ToRqUE MEASUREMENT .................................................................................................................................. 25

5.1.1 ToRqUE CAlCUlATIoN ..................................................................................................................... 25

5.2 SPEED MEASUREMENT ...................................................................................................................................... 26

5.3 CoNTRollER AND ThE PID looP .................................................................................................................. 26

5.3.1 P (PRoPoRTIoNAl gAIN) .................................................................................................................... 26

5.3.2 I (INTEgRAl) .......................................................................................................................................... 26

5.3.3 D (DERIvATIvE) ..................................................................................................................................... 26

5.3.4 ADDITIoNAl SCAlE FACToR ............................................................................................................ 27

5.3.5 hoW ThE PID looP WoRkS ............................................................................................................... 27

5.3.6 PID EqUATIoNS ..................................................................................................................................... 27

5.4 DC WATTMETER ................................................................................................................................................... 28

6. CAlibrAtion - DynAMoMEtEr ...................................................................................................296.1 CAlIbRATIoN SoFTWARE AND DRIvER INSTAllATIoN .......................................................................... 29

6.1.1 MICRo DyNE CAlIbRATIoN SoFTWARE ......................................................................................... 29

6.1.2 USb DRIvERS ......................................................................................................................................... 29

6.2 CAlIbRATIoN PREPARATIoN ........................................................................................................................... 30

6.3 CAlIbRATIoN PRoCEDURE .............................................................................................................................. 30

6.3.1 SETUP ....................................................................................................................................................... 30

6.3.2 RUN ........................................................................................................................................................... 31

6.3.3 PRINT REPoRT oR SAvE DATA ........................................................................................................... 35

7. CAlibrAtion - WAtt MEtEr ........................................................................................................367.1 CloSED-box CAlIbRATIoN ............................................................................................................................. 36

7.2 CAlIbRATIoN SChEDUlE ................................................................................................................................. 36

7.3 bASIC CAlIbRATIoN PRoCESS ........................................................................................................................ 36

7.3.1 INITIAl CAlIbRATIoN PRoCEDURE ................................................................................................ 36

7.3.2 volTS AND AMPS zERo AND gAIN .................................................................................................. 36

8. troublEShooting .......................................................................................................................38

AppEnDix A: hArDWArE CoMMAnDS ...........................................................................................39A.1 DATA FoRMAT ...................................................................................................................................................... 39

A.1.1 CoDES FoR CR - lF ............................................................................................................................... 39

A.2 MICRo DyNE CoMMAND SET .......................................................................................................................... 39

v

Magtrol Micro Dyne System Table of Contents

A.2.1 CoMMUNICATIoN CoMMANDS ........................................................................................................ 40

A.2.2 RAMP CoMMANDS ............................................................................................................................... 40

A.2.3 SETUP CoMMANDS .............................................................................................................................. 41

A.2.4 SPEED CoMMANDS .............................................................................................................................. 41

A.2.5 ToRqUE CoMMANDS .......................................................................................................................... 42

A.2.6 PoWER ANAlyzER AND RElAy CoMMANDS ................................................................................ 42

A.2.7 MISCEllANEoUS CoMMANDS ......................................................................................................... 42

A.2.8 CAlIbRATIoN CoMMANDS ................................................................................................................ 43

AppEnDix b: SChEMAtiCS ...............................................................................................................44b.1 CoRE bloCk DIAgRAM .................................................................................................................................... 44

b.2 MAIN SChEMATIC ............................................................................................................................................... 45

b.3 DC WATTMETER ................................................................................................................................................... 46

AppEnDix C: CAlibrAtion rECorD .............................................................................................47

SErviCE inforMAtion ......................................................................................................................48RETURNINg MAgTRol EqUIPMENT FoR REPAIR AND/oR CAlIbRATIoN ..................................................... 48

RETURNINg EqUIPMENT To MAgTRol, INC. (UNITED STATES) ............................................................ 48

RETURNINg EqUIPMENT To MAgTRol SA (SWITzERlAND).................................................................. 48

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Magtrol Micro Dyne SystemTable of Contents

tAblE of figurES

1. introDuCtionFigure 1-1 Micro Dyne Accessories ............................................................................................................................2

2. inStAllAtion/ConfigurAtionFigure 2–1 Micro Dyne Dynamometer .......................................................................................................................8Figure 2–4 Electronics Unit Rear Panel ...................................................................................................................10Figure 2–5 Electronics Unit Front Panel ..................................................................................................................11Figure 2–6 Basic Motor Power Circuit .....................................................................................................................11Figure 2–7 Basic System Configuration ....................................................................................................................12Figure 2–8 Relay Configuration ...............................................................................................................................12Figure 2–9 Motor Drive Configuration ....................................................................................................................13

3. tESting ConSiDErAtionSFigure 3–1 Micro Dyne Power Absorption Curve ....................................................................................................16Figure 3–2 Hysteresis Brake Cross-Section ..............................................................................................................17

4. tESt SEtupFigure 4–1 Dynamometer, Inside View .....................................................................................................................19Figure 4–2 Micro Dyne Motor Fixture......................................................................................................................20Figure 4–3 Motor Fixture Adapters ..........................................................................................................................21Figure 4–4 M-TEST Configure Hardware Window ...................................................................................................22Figure 4–5 M-TEST Power Supply Configuration ....................................................................................................23Figure 4–6 Curve Test Parameters with Motor Reversal ..........................................................................................24

5. opErAting prinCiplESFigure 5–1 Illustrated Torque Principle....................................................................................................................25Figure 5–2 Micro Dyne Rotor ...................................................................................................................................26Figure 5–3 Control Loop and PID System Block Diagram ......................................................................................27

6. CAlibrAtion - DynAMoMEtErFigure 6–1 Hardware Update Wizard .......................................................................................................................29Figure 6–2 Calibration Setup Window ......................................................................................................................30Figure 6–3 Reset ZERO ............................................................................................................................................32Figure 6–4 Dynamometer Calibration ......................................................................................................................32Figure 6–5 Calibration Instruction and Progress Bars ............................................................................................33Figure 6–6 Calibration Complete .............................................................................................................................34Figure 6–7 Final Calibration Window ......................................................................................................................34Figure 6–8 Calibration Report .................................................................................................................................35

vii

purpoSE of thiS MAnuAl

This manual contains all the information required for the setup and general use of Magtrol’s Micro Dyne System. To achieve maximum capability and ensure proper use of the system, please read this manual in its entirety before operating. keep the manual in a safe place for quick reference whenever a question should arise.

Who ShoulD uSE thiS MAnuAl

This manual is intended for bench test operators who are going to use the Micro Dyne System in order to determine the torque and power of a miniature/micro motor in relation to its speed. It is assumed that the user has sufficient knowledge in mechanics and electronics to be able to install/operate the dynamometer and its corresponding electronics unit without risk.

MAnuAl orgAnizAtion

This section gives an overview of the structure of the manual and the information contained within it. Some information has been deliberately repeated in different sections of the document to minimize cross-referencing and to facilitate understanding through reiteration.

The structure of the manual is as follows:

Chapter 1: INTRoDUCTIoN – Contains the technical data sheet for Magtrol’s Micro Dyne System which describes the system and all of its components, and provides detailed technical characteristics. A complete parts list, along with unpacking instructions, is also included in this section.

Chapter 2: INSTAllATIoN/CoNFIgURATIoN – Provides information needed for setup of the Micro Dyne System, primarily electrical connections and power configuration.

Chapter 3: TESTINg CoNSIDERATIoNS – Provides information on a number of factors that must be taken into consideration before running a test, including: safety, power dissipation, and influences that affect the apparent accuracy of the torque readout.

Chapter 4: TEST SETUP – Provides instructions on how to set up a motor test, including dynamometer setup, motor mounting and software configuration

Chapter 5: oPERATINg PRINCIPlES – Information pertaining to the theory of operation including torque measurement, speed measurement and the PID control loop.

Chapter 6: CAlIbRATIoN – Step-by-step instructions for the calibration procedure.

Chapter 7: TRoUblEShooTINg – Solutions to common problems encountered during setup, testing and calibration.

Appendix A: hARDWARE CoMMANDS – Provides command reference tables for users who wish to write their own application.

Appendix b: SChEMATICS – Contains a core block diagram, main schematic and wattmeter schematic.

Appendix C: CAlIbRATIoN RECoRD – Data record for tracking calibration results.

Preface

viii

Magtrol Micro Dyne SystemPreface

ConvEntionS uSED in thiS MAnuAl

The following symbols and type styles may be used in this manual to highlight certain parts of the text:

Note: This is intended to draw the operator’s attention to complementary information or advice relating to the subject being treated. It introduces information enabling the correct and optimal function of the product.

Caution: this is used to draw the operator’s attention to information, direCtives, proCedures, etC. whiCh, if ignored, may result in damage to the material being used. the assoCiated text desCribes the neCessary preCautions to take and the ConsequenCes that may arise if these preCautions are ignored.

WARNING! ThIs INTRoduces dIRecTIves, pRoceduRes, pRecAuTIoNARy meAsuRes, eTc. WhIch musT be execuTed oR folloWed WITh The uTmosT cARe ANd ATTeNTIoN, oTheRWIse The peRsoNAl sAfeTy of The opeRAToR oR ThIRd pARTy mAy be AT RIsk. The ReAdeR musT AbsoluTely TAke NoTe of The AccompANyING TexT, ANd AcT upoN IT, befoRe pRoceedING fuRTheR.

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1. Introduction

1.1 unpACKing thE MiCro DynE

1.1.1 Packaging

your Micro Dyne System was shipped in its own hard-sided carrying case with shock-resistant packing foam. The packaging is designed to protect the instruments during normal handling.

Inspect the contents for any evidence of damage in shipping. In the event of shipping damage, immediately notify the carrier and Magtrol’s Customer Service Department.

Note: Save all shipping cartons and packaging material for reuse when returning the instrument for calibration or servicing.

1.1.2 Parts List

Make sure the case contains all the following:

A. Dynamometer with attached motor fixture

b. Electronics unit

Caution: the dynamometer and eleCtroniCs unit are shipped already ConneCted to one another by a series of Cables (bundled together). use Caution when lifting out of the Case.

C. CD-RoMs

1. M-TEST 5.0 CD-RoM

2. Micro Dyne Supplemental Programs and Utilities CD-RoM

3. Magtrol User Manual CD-RoM

D. bag of cables

1. USb cable

2. Three power supply cables with dual banana plugs on both ends

3. Main IEC power cord

E. A second bag of parts contains the following:

1. Circular weight and fastening (hex key) screw for torque configuration

2. hardware for motor fixturing

a. Two motor fixture adapters

b. Small Allen wrench (hex key)

c. Two small hex screws

3. Three bags of rubber couplings

a. Ten pieces of 0.5 mm inside diameter tubing, each 25 mm in length

b. Ten pieces of 0.8 mm inside diameter tubing, each 25 mm in length

c. Ten pieces of 1.6 mm inside diameter tubing, each 25 mm in length

4. Two calibration weights, one 5 g and one 10 g, tagged and labeled.

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Magtrol Micro Dyne SystemChapter 1 – Introduction

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5. Calibration documentation

a. Calibration certificate for Micro Dyne

b. Calibration test report for wattmeter

c. Calibration test report for dynamometer

6. Accessory tools

a. Tweezers

b. Medium Allen wrench

c. large Allen wrench

d. Five cable ties

Figure 1-1 Micro Dyne Accessories

3

Magtrol Micro Dyne System Chapter 1 – Introduction

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1.2 DAtA ShEEtMicro DyneData Sheet

Micro Dyne Motor Testing System

1 www.magtrol.com

MAGTROL

Features• designedspecificallyforminiatureandmicro

motors

• Torque:Easilyconvertiblefrom2.0mN·mto4.0mN·m(0.28oz·into0.57oz·in)

• Speed:upto100,000rpm

• Power:4W

• Lowinertia

• Soldasacomplete,out-of-the-boxmotortestingsystem.Componentsinclude:

• HysteresisDynamometer:providesprecisetorqueloadingindependentofshaftspeed

• MotorFixture:accommodatesmotorsfrom5mmto30mmindiameter.

• DedicatedElectronics:all-in-onedynamometercontroller,DCwattmeter,powerrelayandUSBinterface

• ComprehensiveMotorTestingSoftware

• Easy-to-usecalibrationsoftware

• Allnecessaryconnectioncables

• Calibrationweights:5gand10g

DesCrIPtIONWith over 50 years’ experience in dynamometer designand torque measurement, Magtrol has revolutionized theindustry.Magtrol’sNEWMicroDyne,capableofmeasuring

extremelylowtorques(2.0mN·mcanberesolvedto0.0004mN·m),isdesignedExCLUSivELyfortestingminiatureandmicro(low-torque)motors.

Fortheutmostconvenience,theMicroDyneispackagedasaCOMPLETEMOTOR TESTiNG SySTEM.Everythingthatisneededtoaccuratelyandefficientlytestminiaturemotorsandmicromotorsisincludedwiththepurchaseof aMagtrolMicroDyne.Theonlycomponentthatneedstobesuppliedbythecustomerisalaptopordesktoppersonalcomputerandmotorpowersupply.

aPPLICatIONsMagtrol motor test systems can be found in test labs, atinspectionstations,andonthemanufacturingfloorsofmostof the world’s leading motor manufacturers. The MicroDynesystem isusedexclusively forclosed-loop testingofminiaturemotorsandmicromotorsusedinlow-torque/high-speedapplications.

Motor sub-types include, but are not limited to, thefollowing:

• BrushedandbrushlessDCmotors• Gearmotors• BrushlessDCservomotors• vibratormotors• Miniatureairmotors

These mini/micro motors are used in a diverse range ofindustriesandproducts,including:

• Medicalandlaboratoryequipment• Roboticsandautomation• Toys• Handheldcommunicationdevices• Audio/videoequipment• Opticsandphotonics• Aerospaceanddefense• Securityandinstrumentation• industrialmachinery

Motor Characteristics

Measured/Calculated:

• Torque

• Speed

• Amps

• Volts

• Horsepower

• Efficiency

• Input Watts

• Output Watts

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Micro Dyne

MAGTROL

System Configuration

BLOCk DIagraM

PC with M‑TEST 7

and calibration software

DSP

Firmware

DSP

Power Supply

Mains(IEC 80 – 240 V AC,

60/50 Hz)

Motor Under Test

motor power

Slotted Disc

brake power

USB cablespeed signal (via fiber optic speed pickup)

torque signalBrake

systeM MODeL

Motor Fixture

motor under test

motor electrical

connectionmotor fixture adjustment knobs (height, width and depth)

Electronic Unitfunctions as a: • Dynamometer Controller • DC Wattmeter • Power Relay • USB Interface

Dynamometer

leveling knobs

motor clamping strap (with knurled cam grip)

voltage sense terminals

motor power IN terminals

motor power OUT terminals

shipping bolt knob

dynamometer shaft

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Micro Dyne

MAGTROL

Dynamometer

T he M ic ro DynedynamometerabsorbspowerwithMagtrol’sun ique HysteresisBr a k i ng Sys t em .Because it does notrequirespeedtocreatet o r q u e , t h edynamometer canconduct a full motorramp—fromfree-runtolockedrotor.

i n a d d i t ion t o ad e d i c a t e d m o t o rf i x t u r e , t h e

dynamometer base plate also includes leveling knobs andmotorpower terminals. Thehousingof thedynamometerprotectsallthemovingpartsofthebrake.

Electronic Unit

At thehubof theM i c r o D y n es y s t e m i s amultifunctionalelectronic unit.TheunitemploysDSP technologyfor h igh-speeddata acquisitionand complete PC

controlofthedynamometer.AUSBreceptacleenableseasyconnection to a personal computer. An integrated DCwattmeterreadsvoltsandamps,andcalculateswatts;andabuilt-inpowerrelaycontrolsmotorpower(on/off).

The front panel includes the terminals for motor powerin/outandvoltagesensing.LEDpowerandcommunicationindicatorsarelocatedontherearpaneloftheunit.

Motor Fixture

Attachedtothedynamometerbaseplateisamotorfixturedesignedexpresslyformicro/miniaturemotors.ThebaseofthefixturefeaturesanxyZstagewith3-axispositioningforexcellentadjustabilityandmotor centering. With the includedadapters,motorsfrom5mmto30mmindiametercanbeeasilymounted.Thefixtureiskeyedtohelpsecurethemotorundertestandarubberstrapwithknurledcamgripprovidesmotorclamping.

Motor Testing Software

Magtrol’sM-TEST7isas t a t e - o f - t h e - a r tcomprehensive motortestingprogramdesignedforusewithWindows®operating systems forP C - b a s e d d a t aacquisition.Thesoftwaremeasuresandcalculatesa motor’s performance

characteristicsbyemployingtheseuser-configurabletestingmethods:

Ramp: Selectfromaveragerampdown/uporrampdownwithinertiacorrectionfactor.Alsoallowsextrapolationoffree-runandlocked-rotordata,plusinterpolationofspecificspeedortorquedatapoints.

Curve: Testspeed,torque,amps,wattsinput,wattsoutputandopenloopparameters,andcomparesactualvaluestouser-definedlimits.Capableofadjustingsamplingrateandusingsteporrampfromoneloadpointtothenext.

Pass/Fail: Checksamps,inputwatts,speed,torqueandoutputwattsagainstuser-definedvalues.

Thedatageneratedcanthenbestored,displayedandprintedintabularorgraphicformats,andiseasilyimportedintoaspreadsheet.

System Information

Speed Measurement

TheMicroDynecontainsareflectivefiberopticspeedpickup.Eachrotorslotthatpassesbythesensingendofthefiberopticgeneratesanelectronicpulse,which is thenconverted toaspeedreading(inrpm).

Torque Measurement

Ahysteresisbrakeisusedtodeveloparesistancetorotationofamechanicalshaft.Atorsionalforceisproducedbythetestmotor and applied to thebrake’s rotor-shaft assembly.Reaction torque is measured by the angle of the brakependulum assembly and is interpreted by the Micro Dynesystemsoftware(M-TEST7).

OPeratINg PrINCIPLes

systeM COMPONeNts

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Micro Dyne

MAGTROL

SpecificationsDyNaMOMeter

MaximumTorque

NominalInput Inertia

Maximum Kinetic Power MaximumSpeed * Accuracy

5 minute continuous

mN·m kg·cm² W W rpm Torque Speed

4.0 or 2.0 5.43 × 10‑4 4 4 100,000 < 1% of full scale

< 0.02% of reading

Power Absorption Curve

Basedonthemaximumkineticpowerratings,thecurvebelowrepresentsthemaximumpower(heat)thatthedynamometercandissipateovertime. The area under the curve equals themaximumspeed/torquecombinationsforbothamotortestoflessthan5minutes(intermittentduty),andacontinuous-dutymotortest.

DyNAMoMETEr ENvIroNMENTAl rEqUIrEMENTSOperating Temperature 0 °C to +70 °CRelative Humidity < 60% without condensation

EMC In accordance with IEC 61326:2002

MoTor ACCoMMoDATIoNMotor Diameter 5 mm – 30 mmMotor Length 5 mm – 50 mmMotor Shaft Diameter 0.75 mm – 3 mmMaximum Load 100 g

MOtOr FIxture

ADjUSTAbIlITyX/Y/Z Adjustable Range ±5 mm (all axes)Controllable Motion 0.005 mmTravel per Knob Revolution 0.318 mm

eLeCtrONIC uNIt

GENErAl ElECTrICAl CHArACTErISTICSFuse (5 × 20 mm) IEC 315 mA 250 V TPower Requirements 14 VAVoltage Requirements 85 – 264 V AC, 60/50 HzENvIroNMENTOperating Temperature 0 ºC to +70 ºCRelative Humidity < 60% without condensation

TheMicroDyneofferstwodifferenttorqueconfigurationsinoneunit.Dependingonthemotor’smaximumtorquerating,theusercaneasilyswitchbetweenthe2.0mN·mand4.0mN·mtorquesettingsviathedynamometer’srearaccesspanel.Theratingsarethesameforeitherconfiguration.

0

1.0

2.0

3.0

4.0

0 20000 40000 60000 80000 100000

SPEED (rpm)

To

rq

UE

(m

N·m

)

MaximumRated Speed

MaximumRated Torque

PowEr MEASUrEMENT (DC)

Current Input (isolated) ± 5 A ±(0.1% Reading + 0.2% Range)

Voltage Input (isolated) ± 30 VDC ±(0.1% Reading + 0.2% Range)

Conversion Rate 15/second/inputPower Accuracy 0.4% of VA rangeIsolation, to earth 50 V DCIsolation, channel‑to‑channel 100 V DC

* Because the MicroDyne is optimized for high speeds, the lowest measurable speed is 50 rpm. If a motor is operating at less than 50 rpm, the speed measurement will read zero.

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Micro Dyne

Due to the continual development of our products, we reserve the right to modify specifications without forewarning.

www.magtrol.com

MagtrOL INC70 Gardenville ParkwayBuffalo, New York 14224 USAPhone: +1 716 668 5555Fax: +1 716 668 8705E‑mail: [email protected]

MagtrOL saRoute de Montena 771728 Rossens / Fribourg, SwitzerlandPhone: +41 (0)26 407 3000Fax: +41 (0)26 407 3001E‑mail: [email protected]

Subsidiaries in:Germany • France

China • IndiaWorldwide Network

of Sales Agents

Dimensions (mm)

MD

-US

04/1

4

3 DIMENSIONAL VIEWSCALE 1 : 4

72

190

195

245

264

267

THIS DRAWING AND SPECIFICATIONCONTAINS PROPRIETARY INFORMATIONTO MAGTROL INC. ANY DISCLOSUREOR REPRODUCTION OF THIS DOCUMENTWITHOUT WRITTEN AUTHORIZATION FROMMAGTROL INC. IS EXPRESSLY PROHIBITED

DRAWN

CHECKED

DESIGN

DGAJC

DG

09/06/0609/06/06

09/06/06 MAGTROL INC.BUFFALO, NEW YORK 14224-132270 GARDENVILLE PKWY, W.

THIRDANGLEPROJECTION

FINISH:

TITLE:

USED ON:

SIMILAR TO: 005729006542

REVDRAWING NUMBER:

006541 -

1:3 3 OF 3SHEET #SCALE

BSIZE

MATERIAL:

XX.X

UNLESS OTHERWISE SPECIFIED:DIMENSIONS ARE IN MILLIMETERS,DIAMETERS CONCENTRIC: 0.08 TIR,FACES PERPENDICULAR: 0.08INTERPRETATION PER ASMEY14.5M-1994REMOVE ALL BURRS AND BREAKSHARP EDGES 0.13/0.25 X 45°, ALLINSIDE CORNERS TO BE R 0.5 MAX.TOLERANCES:

X.XXANG.

SURFACE FINISH 3.2 µm MAX. U.O.S.

± 0.4± 0.25

± 0.13± 1°

MICRO DYNE ELECTRONICS BOX

DyNaMOMeter

eLeCtrONIC uNIt

BINDING POST FOR MOTOR POWER CONNECTION

LEVELING HARWARE

3 AXIS MOTOR FIXTUREADJUSTABLE ±5mm ON ALL AXES

MOTOR CLAMPING BAND

75SHAFT

HEIGHT

34

113

229

140

POSITION-2: 37.81POSITION-3: 49.24

*Z-AXIS:POSITION-1: 26.38

WIRE BUNDLE

180

*Y-AXIS: 58.4(TO V-BLOCK

VIRTUAL SHARP)

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2.0 h6DETAIL B

SCALE 2 : 3

DYNAMOMETER SHAFT


DRAWN

CHECKED

DESIGN

AJCJEF

KC

09/24/0706/15/06

4/14/06 MAGTROL INC.BUFFALO, NEW YORK 14224-132270 GARDENVILLE PKWY, W.

THIRDANGLEPROJECTION

-FINISH:

-

TITLE

USED ON:

SIMILAR TO: -005784

REVDWG. NO.

006529 B

1:3 6 OF 6SHEET #SCALE

BSIZE

MATERIAL:

.XX.XXX

UNLESS OTHERWISE SPECIFIED:DIMENSIONS ARE IN INCHES,DIAMETERS CONCENTRIC: .003 TIR,FACES PERPENDICULAR: .003INTERPRETATION PER ASMEY14.5M-1994REMOVE ALL BURRS AND BREAKSHARP EDGES .005/.010 X 45°, ALLINSIDE CORNERS TO BE .02 R MAX.TOLERANCES:

FRAC. ANG.

SURFACE FINISH 125 RMS MAX. U.O.S.

± .01± .005

± 1/64"± 1°

MICRO DYNE, DYNAMOMETER ONLY

Weight 4.2 kg 9.3 lb

Weight 1.5 kg 3.2 lb

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2. Installation/Configuration

2.1 DynAMoMEtEr SEtup

Shipping bolt knob

Motor electrical connection

Leveling knobsBubble level

Figure 2–1 Micro Dyne Dynamometer

2.1.1 UnLocking the shiPPing/restraining BoLt

before dynamometer operation, the shipping/restraining bolt must be unlocked. A knob attached to the bolt is located on the top of the dynamometer housing, as shown in Figure 2–1. To unlock, lift up on the knob and turn it 90° to the “Unlock” position.

2.1.2 Dynamometer LeveLing

Simply level the dynamometer with the two leveling knobs at the front of the base plate, using the embedded bubble level as a guide.

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Magtrol Micro Dyne System Chapter 2 – Installation/Configuration

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2.2 ElECtriCAl ConnECtionS

The Micro Dyne is shipped with the dynamometer and the electronics unit already connected to one another by a set of cables. These four cables are bundled together at the dynamometer end, and branch out into the following for connection to the electronics unit:

Connection Cable Attaches to DescriptionEarth ground Mounting plate of speed

pickupProvides safety against electric shock.

Dynamometer brake cable BRAKE Output Delivers power from electronics unit to dynamometer brake.

15-pin instrument cable ENCODER Input Quadrature encoder; reads torque measurement.

2.2.1 earth groUnD

For your safety, the dynamometer has been earth grounded and shipped with the ground strap already in place. This protective wire provides an alternate path to ground in case of short circuits or heavy electrical currents.

The other end of the ground strap should be connected to the metal tab attached to the speed pickup mounting plate, located on the Micro Dyne Electronics Unit. See Figure 2–3 Speed Pickup.

The complete earth ground path is as follows:

Dynamometer —> Electronics unit —> Main power cord —> Earth

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Magtrol Micro Dyne SystemChapter 2 – Installation/Configuration

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2.2.2 rear PaneL connectors

Figure 2–4 Electronics Unit Rear Panel

The rear panel connectors, from left to right, are:

Connector Attaches to Connection CablePOWER Input Power source Main power cordBRAKE Output Dynamometer Dynamometer brake cableSPEED Output External speed sensor 6-pin sensor cable USB Port Personal computer USB cable ENCODER Input Dynamometer 15-pin instrument cable

Using the table above, make the necessary connections with the cables provided. As noted in Section 2.2 – Electrical Connections, some of the cables have been installed prior to shipping.

2.3 Motor poWEr

Note: For detailed instructions on motor mounting, refer to Section 4.2.

Using the three power supply cables provided, make the following basic connections. other power configuration options are shown in Section 2.2.1.

Caution: pay attention to whiCh pin on the banana plug is positive and whiCh one is negative. ConneCt to the red (+) and blaCk (–) terminals aCCordingly.

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terminal on Electronics unit Connected to Description

Motor Power In User’s power supply Allows power measurement and on/off switching from electronics unit.

Motor Power Out Motor connection point on dynamometer

Outputs power to the motor. Controlled by relay inside electronics unit which turns motor power on/off.

Voltage Sense Motor connection point on dynamometer

Measures voltage directly from the motor, thus eliminating voltage drop. Results in increased power measurement accuracy and efficiency.

Figure 2–5 Electronics Unit Front Panel

Figure 2–6 illustrates the internal wattmeter and relay layout, showing the complete basic power circuit from power supply to motor.

Motor

+

–

+

–

– +

MOTORPOWER

IN

MOTORPOWER

OUT

VOLTAGESENSE

MOTORPOWER

IN

MOTORPOWER

OUT

A

VCurrentMeter

VoltageMeter

Bananaplugs on

dynamometerpower terminal

MotorpowerSupply

DCSource

Relay

inside Micro Dyne Electronics box

Figure 2–6 Basic Motor Power Circuit

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2.3.1 Power configUration oPtions

2.3.1.1 Basic Configuration

This standard Micro Dyne setup shows a (customer-provided) motor power supply wired to the Micro Dyne Electronics Unit. This setup allows the Micro Dyne’s electronics to control on/off power to the motor under test, and to monitor input power.

(Customer)Motor Power Supply

+–

M-tESt

Micro Dyne Electronics unit

Micro DyneDynamometer

+

–

PC

USB

Motor Power Out

MotorPowerIn

Voltage Sense Leads

MotorLeads

MotorUnderTest

voltAgESEnSE

MotorpoWEr

out

MotorpoWEr

in

Figure 2–7 Basic System Configuration

2.3.1.2 Relay Configuration

To run a motor in both clockwise and counter-clockwise directions, without having to rewire during the middle of a test, a relay card is required. A National Instruments™ PCI relay card (available for purchase from Magtrol) allows for the automatic reversing of motor leads when the motor power supply is connected to the relay card. like the basic system configuration, the Micro Dyne controls on/off power to the motor under test and monitors motor input power. For more information regarding motor reversal, refer to Section 4.3.1.


+–

RelayCard

PC

M-tESt



+

–

Motor Power Out

MotorPower In

Voltage Sense LeadsUSB

MotorLeads

MotorUnderTest

voltAgESEnSE

MotorpoWEr

out

MotorpoWEr

in

Figure 2–8 Relay Configuration

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2.3.1.3 Motor Drive Configuration

This setup allows for the addition of a motor drive unit. The advantage to this is that the Micro Dyne is now measuring the drive/motor efficiencies, instead of the just the motor alone. This is especially beneficial when the motor is dependent on the motor drive for operation. With the power supply unit attached to the Micro Dyne relay, the power to the motor drive can be controlled through M-TEST.

M-tESt



+

–

PC

USBvoltAgESEnSE

MotorpoWEr

out

MotorpoWEr

in

+–+–+–

MotorPower Out

VoltageSenseLeads

MotorLeads

MotorUnderTest


MotorDrive

INOUT

MotorPowerIn

Figure 2–9 Motor Drive Configuration

2.4 Motor tESting SoftWArE

2.4.1 software instaLLation

For detailed installation instructions, refer to Magtrol’s M-TEST 5.0 User’s Manual.

2.4.2 m-test commUnication

In order to use M-TEST with the Micro Dyne, the CoM port to which the USb interface is connected must first be determined.

1. Power up the Micro Dyne.

2. Find the CoM port.

For Windows 95/98/2000: go to Start menu > Settings > Control Panel > System > hardware > Device Manager > Ports. look for the USb Serial Port and note the CoM port number in parenthesis.

For Windows xP: go to Start menu > Control Panel > Switch to classic view > System > hardware > Device Manager > Ports. look for the USb Serial Port and note the CoM port number in parenthesis.

Note: To configure M-TEST for the Micro Dyne, refer to Section 4.3 – Software Configuration.

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2.5 CoMMuniCAtion ChECK

When powering up the Micro Dyne, check to make sure that all four lEDs on the rear panel of the electronics unit (see Figure 2–4) are illuminated according to the table below.

lED Color indicates

USB Yellow Flashing: USB communication is taking place.

24 V Green The 24 volt power is OK.CPU Yellow The power-up sequence has been initiated.5 V Green The 5 volt power is OK.

2.6 initiAl CAlibrAtion

After communication is verified, it is highly recommended to calibrate the dynamometer before performing any tests. Refer to Chapter 6 – Calibration for a detailed procedure.

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3. Testing Considerations

A number of factors must be taken into consideration before running a test, including: safety, power dissipation, and influences that affect the apparent accuracy of the torque readout (such as shaft alignment, windage, friction, vibration, dynamometer leveling, cogging, Eddy currents and temperature rise). The following sections describe these factors, and their effects, in further detail.

Note: If you have not already done so, please take a moment to familiarize yourself with the Micro Dyne System’s technical specifications. See Section 1.2 – Data Sheet.

3.1 SAfEty

WARNING! foR GeNeRAl sAfeTy coNsIdeRATIoNs, pleAse folloW These feW commoN-seNse Rules:

• Makesureallwiringandconnectionshavebeenproperlymade.

• Secureallgroundingwirestotheappropriatelocationstoreducethechanceofshockanddamage to the equipment.

• AlwayswearsafetyglasseswhenworkingaroundMicroDyneequipment.

• DonotwearlooseclothingortieswhenoperatingtheMicroDyneequipment.

• Ensuremotorundertestisproperlymountedtothemotorfixture.

3.2 poWEr DiSSipAtion

All Magtrol dynamometers are power absorption instruments. As a dynamometer loads a test motor, it is absorbing power from the motor into the hysteresis brake. The brake is converting this mechanical energy into heat.

There are finite limits to the amount of energy and resulting temperature rise that any absorption brake can withstand. Excessive power over extended periods of time may result in more obscure damage including breakdown of bearing lubricants and degradation of magnetic coil insulation. Extreme temperatures due to inappropriate operation can not only warp the rotor and surrounding housings, but also alter the magnetic characteristics. Absolute best-case scenario under such circumstances would be a reduced torque output from the brake assembly, if complete dynamometer failure were not realized.

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Magtrol Micro Dyne SystemChapter 3 – Testing Considerations

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3.2.1 Power aBsorPtion cUrve

based on the maximum kinetic power ratings, the curve represented in Figure 3–1 illustrates the maximum power (heat) that the dynamometer can dissipate over time. The area under the curve equals the maximum speed/torque combinations for both a motor test of less than 5 minutes (intermittent duty), and a continuous-duty motor test.

Conditional Environmental ParametersMaximum brake temperature 100 °C (212 °F)Ambient temperature 25±5 °C (77±9 °F)

0

1.0

2.0

3.0

4.0

0 20000 40000 60000 80000 100000

SPEED (rpm)

TO

RQ

UE

(m

N·m

)

MaximumRated Speed

MaximumRated Torque

Figure 3–1 Micro Dyne Power Absorption Curve

3.3 ShAft AlignMEnt

In motor testing, shaft alignment is one of the most important factors to consider. An improper coupling and/or shaft alignment can lead to unwanted side loads and vibration, damaging both the test equipment and motor. To accommodate micro motor sizes, while preventing side loading on the dynamometer shaft, a coupling of small flexible rubber tubing should be used. The friction of the rubber tube on the shaft alone suffices as a clamping agent. Several pieces of rubber tubing, in various diameters, are included with the Micro Dyne for this purpose. Refer to Section 4.2.1 – Shaft Coupling for detailed coupling instructions.

3.4 WinDAgE

Windage is proportional to the square of speed. The air friction is tangential to the surface and impinges upon the stationary field assembly. This acts as viscous drag and becomes part of the motor load and torque reading. There is also a small amount of air dissipated as pumping loss. Since this appears as a load on the motor, not measured by the dynamometer, it becomes a source of error. Considering the size of the parts affected by windage in the Micro Dyne, this source of error will be less pronounced then if similar speeds were seen on larger dynamometers.

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Magtrol Micro Dyne System Chapter 3 – Testing Considerations

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3.5 friCtion

Friction of the carrier bearings is a measurable load. When correctly loaded and lubricated, the friction is insignificant. During actual motor testing there is usually enough system vibration to “settle” negating frictional effects. If excessive drag is present, mechanical realignment may be required. In the design of the Micro Dyne, careful attention was paid to carrier bearing friction for the proper operation of the pendulum assembly; mainly in ensuring the pendulum returned to the zero position within the published error bands.

Note: Friction is the largest source of error in the Micro Dyne but it is relatively small in comparison to the overall range and accuracy (< 1%) of the dynamometer.

3.6 vibrAtion

All rotating dynamometer assemblies are precision balanced. At high speeds, some vibration and noise are inevitable but not necessarily harmful. however, excessive resonant vibrations caused by bent shafts and poor alignment will produce data errors and are a safety hazard.

Caution: severe vibration left unattended Could ultimately lead to permanent damage to the test equipment or the motor under test.

3.7 DynAMoMEtEr lEvEling

An improperly leveled dynamometer will alter the torque calculations in proportion to the deviation from a true level surface. The base plate of the Micro Dyne is equipped with two leveling knobs and an embedded bubble level for easy leveling.

3.8 Cogging

Pole

Case

Rotor Poles

Rotor Assembly

SSS

NN

N

Figure 3–2 Hysteresis Brake Cross-Section

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This cross-section shows (by one tooth) the magnetic relationship of the hysteresis brake elements. If the dynamometer shaft is at rest with the torque applied, and if the torque control is then reduced to zero, a magnetic salient pole will be temporarily imposed on the rotor of the brake.

If the shaft is then rotated slowly, the magnetic poles on the rotor will attempt to align with the adjacent case-pole tooth form. This is often referred to as “cogging”. The action is sinusoidal. First it tries to resist rotation and then, as the rotor passes through the tooth form, it subsequently supports rotation.

The most obvious results of cogging are uncontrolled oscillations within the torque/speed curve. It will become difficult for the motor under test to tune in the PID loop, along with a possible increase in resonant noise from the dynamometer and motor.

3.8.1 avoiDing cogging

To avoid magnetic cogging, before the shaft comes to rest, slowly reduce the torque control to zero.

3.8.2 removing cogging

To most effectively remove cogging, once established, reapply current on the dynamometer. Then, slowly ramp the current to zero while maintaining a very low speed (only a few rpms). The current ramp to zero can be increased slightly in speed when the dynamometer rotation is sped up during this process.

3.9 EDDy CurrEntS

There is some Eddy current generation within the brake rotor. These magnetically-induced currents cause an increase in braking torque proportional to speed. While more pronounced in larger dynamometers (which exhibit higher rotor surface velocities), in a pure loading system it becomes a benefit of the dynamometer. Since the Eddy currents effect the rotor surface, this torque is measured by the torque pendulum and becomes another load source (and not a source of error).

3.10 tEMpErAturE riSE

Temperature rise has a more complex effect on hysteresis brake load torque and is difficult to quantify. As the temperature of the brake increases, differential expansions cause dimensional changes that tend to increase torque. Conversely, electrical resistance in the rotor increases with temperature, resulting in decreased Eddy current generation and load, all in a variable frame.

Caution: under no CirCumstanCes should the maximum wattage ratings for the dynamometer be exCeeded. the resulting rise in temperature Can Cause permanent damage to the rotating assembly, inCluding altering the magnetiC properties of the rotor itself.

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4. Test Setup

4.1 torquE ConfigurAtion

The Micro Dyne can be configured to either a 4 mN·m or 2 mN·m torque scale. The Micro Dyne is shipped as the 2 mN·m configuration. To convert it to 4 mN·m, follow the procedures below.

1. locate the small parts bag labeled 4 m·Nm configuration components.

Pendulum

Circular weight for4 mN·m torque scale

Figure 4–1 Dynamometer, Inside View

2. Attach the circular weight with the provided flat head cap screw, using the provided Allen wrench included with the 4 m·Nm configuration components.

3. Calibrate the dynamometer with the 10 gram calibration weight. Refer to Chapter 6 for complete calibration instructions.

Note: Re-calibration is necessary after every conversion between the 2 mN·m and 4 mN·m torque configurations.

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4.2 Motor Mounting

Clamping strap

Horizontal adjustment knob

Vertical adjustment

knob

Depth adjustment

knob

Knurled cam grip

Figure 4–2 Micro Dyne Motor Fixture

4.2.1 shaft coUPLing

If the motor shaft diameter is 0.5 mm to 1.6 mm, it is highly recommended to use one of the provided rubber couplings to adapt the motor shaft to the 2.0 mm Micro Dyne Dynamometer shaft.

1. Trim the tubing to allow about 2 mm of tubing over the dynamometer shaft and 3 mm of tubing over the motor shaft.

2. Place the tubing snugly around the dynamometer shaft, being careful not to bend the shaft.

3. After the motor is mounted, as described in Sections 4.2.2, 4.2.3 and 4.2.4, place the other end of the rubber tubing around the motor shaft.

4.2.2 aDaPters

When testing motors with diameters less than 20 mm, the appropriately-sized adapter must be used.

Motor Diameter Adapter5 mm – 10 mm V-Adapter I

10 mm – 20 mm V-Adapter II20 mm – 30 mm No adapter necessary

Attach the adapters to the fixture using the provided hex screws and Allen wrench. The threaded holes are found in the groove of the v-adapters.

Note: The adapter should be secured in place but be careful not to overtighten.

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Magtrol Micro Dyne System Chapter 4 – Test Setup

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Motor Fixture with

V-Adapter I

Motor Fixture without adapter

Motor Fixture with

V-Adapter II

Adapter

Figure 4–3 Motor Fixture Adapters

4.2.3 cLamPing straP

1. Place the motor under the rubber strap.

2. Tighten by pulling on the strap. A knurled cam will lock the strap in place when the strap is let go.

3. To release the motor, rotate the cam upward and the strap will loosen.

Note: Ideally, the clamping strap should be secured at the middle of the motor.

4.2.4 stage aDjUstment

For precise motor alignment, the stage of the motor fixture may be axially adjusted using the three colored adjustment knobs.

Knob Color Axis Adjustment DirectionRed X Horizontal (side-to-side positioning)Yellow Y Vertical (shaft height)Green Z Depth (of motor to input shaft of

dynamometer)

Note: The entire motor fixture can also move (as one unit) along the length of the dynamometer base plate, in line with the bolt pattern. The fixture is locked in place by screwing into the tapped holes with the provide hex key screws.

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4.3 SoftWArE ConfigurAtion

This section only provides very basic instructions for setting up M-TEST to run with the Micro Dyne. For detailed information about selecting, configuring and running a test, refer to Magtrol’s M-TEST 5.0 User’s Manual.

1. Power up the Micro Dyne.

2. Start M-TEST.

3. open the Configure hardware window.

Figure 4–4 M-TEST Configure Hardware Window

4. Enter the following settings:

a. Under Dynamometer Controller, select “Micro Dyne” for the Model.

b. For the Interface, select the CoM port where the USb interface is connected (as determined in Section 2.4.2 – M-TEST Communication).

c. Under Power Measurement, select “Micro Dyne” as the Device.

Note: For increased power measurement capabilities, other power analyzers (such as Magtrol’s 6510e or 6530) may be used in conjunction with the Micro Dyne. If applicable, the supplemental power analyzer should be selected as the “Device.” If using a third-party measurement device not found on the list, by selecting “None”, M-TEST will no longer be responsible for measuring the input power.

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Magtrol Micro Dyne System Chapter 4 – Test Setup

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4.3.1 motor reversaL

If it is desired to perform a motor test in both clockwise and counter-clockwise directions, a relay card is required. Motor direction is configured in M-TEST and requires a power supply supported by M-TEST. Supported power supplies are found in the Device text box, under the Power Supply options in the Configure hardware window. See Figure 4–5.

4.3.1.1 Reversing Motor Direction Before Test is Run

To reverse the motor direction and keep the direction of rotation constant throughout the entire test, use the Configure hardware window for motor reversal setup.

1. open the Configure hardware window.

2. Under Power Supply, click on the Device text box and scroll through for a list of supported power supplies.

3. After selecting a power supply, set the voltage and current output for that voltage supply. If a negative voltage is entered, M-TEST switches relays to change the polarity of the motor voltage and, in turn, reverses the direction of rotation (for a DC motor).

-

Figure 4–5 M-TEST Power Supply Configuration

4.3.1.2 Automatic Reversal of Motor Direction During Test

Curve tests and Pass/Fail tests allow for reversing the motor direction during a test.

Note: because Ramp tests do not allow motor voltage control, the motor must ramp up and down in the same direction for the entire test. To reverse the direction of rotation for a ramp test, after running the first test, enter a negative power supply voltage in the Configuration hardware window (as described in Section 4.3.1.1) and then run the test a second time.

1. If not already done so, select a power supply supported by M-TEST in the Configure hardware window.

2. open the Configure Test window. If Curve Test or Pass/Fail Test is selected, an extra column in the Control Data table, under Test Parameters, labeled “volts” should appear.

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3. To have the motor direction reversed during a test, simply enter a negative voltage, as shown in Figure 4–6.

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5. Operating Principles

5.1 torquE MEASurEMEnt

An innovative approach to measuring small torques is implemented in the Micro Dyne. The design employs a very small pendulum and brake assembly hung in a precision-machined carrier. The basic concept, a textbook physics problem, is described below.

θ

mpg

p sin (θ)

Brake

Pendulum

mpg

p cos (θ)

mpg

p

Lp

Torque = Lcm

mg sin (θ)

Symbol representsLp the length to the center of mass of the pendulum

mpgp the force applied by the mass and gravity

mpgp sin (θ) the force in the radial direction

Figure 5–1 Illustrated Torque Principle

5.1.1 torqUe caLcULation

At calibration time, a known mass at a known distance is applied to the pendulum system and a precise calibration is accomplished.

Lpmpgp sin (θ) = Lcmcgc cos (θ)

Symbol representsLc the length from the center to the calibration weight

mcgc the force applied by the known mass and gravity

The coefficient Lpmpgp is calculated and stored. Torque data is calculated using this coefficient, along with position data.

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Magtrol Micro Dyne SystemChapter 5 – Operating Principles

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5.2 SpEED MEASurEMEnt

The Micro Dyne contains a reflective fiber optic speed pickup. As each rotor slot passes by the sensing end of the fiber optic, an electronic pulse is generated, which is then converted to a speed reading (in rpm). The incoming pulses from the speed pickup can be resolved down to 5 hz or 5 pulses per second. With 6 slots on the rotor, this results in a minimum speed setting of 50 rpm. (The speed reading will drop to zero at 50 rpm.)

Note: The rotor/speed measuring mechanism of the Micro Dyne has been optimized for motors running from 10,000 rpm to 100,000 rpm.

Figure 5–2 Micro Dyne Rotor

5.3 ControllEr AnD thE piD loop

The Micro Dyne has PID adjustment capability for both the speed and torque modes to provide the best system response. The PID loop comprises the following three variables:

P = proportional gainI = integralD = derivative

other important variables include:

• Setpoint-desiredloadorspeed• Error-differencebetweenthesetpointandtheactualmeasurement• Additionalscaling–usedtobroadentherangeofthecontrolloop

5.3.1 P (ProPortionaL gain)

With proportional gain, the controller output is proportional to the error or to a change in measurement. Deviation from the set point is usually present. Increasing the proportional gain will make the PID loop unstable. Increasing the integral value will eliminate this instability. For best loop control, set the proportional gain as high as possible without causing the loop to become unstable.

5.3.2 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 set point. If the response becomes oscillatory, increase the derivative value.

5.3.3 D (Derivative)

With derivative, the controller output is proportional to the rate of change of measurement or error. Derivative can compensate for a changing measurement. Derivative takes action to inhibit more rapid changes of the measurement than proportional gain.

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5.3.4 aDDitionaL scaLe factor

The Additional Scale Factor (PS, IS and DS) is a multiplier of the P, I or D term. Due to the fact there are so many different motor combinations, this multiplier is needed to extend the range of the PID. The letters represent the following values:

A = 0.001 D = 0.05 g = 1 * The default multipliers are g, g, and g

b = 0.005 E = 0.10 h = 5

C = 0.010 F = 0.50 I = 10

Using the multiplier, PID values from 0.001 (0.001 × 1%) to 990 (10.0 × 99%) may be inputted.

5.3.5 how the PiD LooP works

The following diagram demonstrates the correlation between the variables in the PID loop.

Derivative Proportional

Integral

Set Point

Reading

-

e(t) Yd(t) Yp(t)

Yi(t)

Yt(t)Ys(t)

+ +Scale

0 to 120,000 rpm0 to 20 kHz

PowerWattmeter

0 to 1

BrakeCoil

FilterFilter Position

Filter SpeedFilter

0 to 75°0 to 6826 counts

TORQUE

SPEED (rpm)

Figure 5–3 Control Loop and PID System Block Diagram

5.3.6 PiD eqUations

Where Skp, Ski and Skd are factory-determined system coefficients…

yd(t) = (e(t) - e(t-3) + 3 * [e(t-1) - e(t-2)]) * (10/Skd) * D% * DS

yp(t) = (e(t) + yd(t)) * (10/Skp) * P% * PS

yi(t) = yi(t-1) + [e(t) + yd(t)] * (10/Ski) * I% * IS

yt(t) = yp(t) + yi(t)

ys(t) = Scale * yt(t)

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5.4 DC WAttMEtEr

The data acquisition stage in the hardware of this DC power measurement instrument is very simple. The input voltage is divided by an amplifier circuit and applied directly to a lTC2515 A/D converter. The input is differential and isolated from the amps circuitry. The input current is applied to a shunt resistor and the resulting voltage is amplified and applied directly to a lTC2515 A/D converter. The input is differential and isolated from the voltage circuitry. The wattage presented is a multiplication of the amps and voltage. See Section B.3 – DC Wattmeter Schematic.

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MA

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6. Calibration - Dynamometer

6.1 CAlibrAtion SoftWArE AnD DrivEr inStAllAtion

6.1.1 micro Dyne caLiBration software

1. Insert the “Micro Dyne Calibration And Driver Disk” into your CD-RoM drive.

2. The calibration software installer will start automatically.

6.1.2 UsB Drivers

1. Connect Micro Dyne USb cable to PC.

2. Connect power to Micro Dyne and turn on. (Windows will detect the Micro Dyne as an unknown USb device until drivers are loaded.)

3. Install the appropriate drivers by directing the automatic hardware Update Wizard to the “USb Driver” directory of the Micro Dyne Calibration and Driver Disk.

Note: If a problem arises with the automatic driver installation, continue to step 4 and proceed with manual installation.

4. go to Start menu > Control Panel > Performance and Maintenance > System

5. Under the hardware tab, select device manager6. Expand the “other devices” folder

7. Right-click dlp-usb245m8. Select update driver9. When the hardware Update Wizard opens, click Install from a list, or specific location

(Advanced).10. In the hardware Update Wizard, locate the USb Driver directory of the Micro Dyne

Calibration and Driver Disk and follow the prompts until installation is complete.

Figure 6–1 Hardware Update Wizard

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6.2 CAlibrAtion prEpArAtion

A detailed description of the electrical, mechanical and software setup for calibration is conveniently located within the Calibration Software. In the calibration software setup window (next to Setup help), click INsTRucTIoNs.

Caution: read and follow the on-sCreen instruCtions Carefully before Continuing with the Calibration proCedure.

6.3 CAlibrAtion proCEDurE

The Micro Dyne Calibration Software walks the user through every step in the calibration process. Simply follow the instructions and prompts that appear on the screen.

6.3.1 setUP

Start the Micro Dyne Calibration Software by opening the micro dyne calibration software from the Start menu. The calibration setup window will appear.

Figure 6–2 Calibration Setup Window

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Open/Print Button Access previously saved calibration data with option to reprint calibration report.

Calibrate Button Perform calibration

Model Number Enter model number; default is “Micro Dyne”

Serial Number Enter serial number; default is blank

Condition Select from list; options are “New Unit” (default), “Recal after repair” and “Recal as received” Selection will appear on calibration report.

Nominal Value Select torque value in mN·m from “2.000” (default) or “4.000”

Exact Mass of Calibration Weight Enter mass of calibration weight (in grams) as printed on tag. Required for calibration to proceed.

VISA Resource Name Selectable from all detected COM ports of PC. To identify Micro Dyne COM port, click Setup Help inStruCtionS.

Initialize Communication button/indicator

Click to initialize communication with Micro Dyne. Unit information will be displayed (see Detected Unit Info) and indicator will turn green.

Setup Help Instructions button Provides a detailed description of the electrical, mechanical and software setup required for calibration.

Technician Enter calibration technician’s name

Date Current date is automatically entered.

Remarks Entered remarks will appear on calibration report.

Detected Unit Info Displays data about Micro Dyne unit after communication is successfully initialized. (See Initialize Communication button/indicator.)

Yellow Message Box A note reminding which calibration weight to use will be displayed, depending on the nominal torque value selected: • For 2 mN·m range, use 5 g weight • For 4 mN·m range, use 10 g weight

6.3.2 rUn

1. After completing all required setup data, click calibrate to begin calibration. Carefully follow the instructions given in the bar at the top of the screen.

Note: Calibration Constants are displayed for units with firmware version 2.4 or later.

The Reset zERo dialog box will appear.

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Figure 6–3 Reset ZERO

2. To zero the pendulum at its current rest state (without weights), click send Zero.

Note: If reading in dialog box is more than a few counts away from zero (after clicking “Send zero” once), click send Zero again before continuing.

3. The next prompt asks the user to hang the calibration weight, starting with the right side. Carefully hang the appropriate calibration weight from the calibration peg, as show in Figure 6–4. Tweezers have been included in the accessory tool bag for your convenience.

Pendulum

Calibration weight

Calibration

Figure 6–4 Dynamometer Calibration

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4. Continue to follow the instructions in the bar at the top of the screen, alternating between hanging the weight on opposite sides of the pendulum and removing the weight. An example of the screen display during this process is shown in Figure 6–5.

Instruction bar

Progress bar

Figure 6–5 Calibration Instruction and Progress Bars

This entire cycle will be performed a total of ten times. After each cycle, the message/instruction bar will display the status of the calibration routine. The blue progress bar will also update.

5. When the calibration is complete, a dialog box appears prompting the user to write calibration constants to the unit (to be saved in the Micro Dyne’s internal firmware).

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Figure 6–6 Calibration Complete

6. After calibration, the obtained data will be displayed as passed or failed.

PASS!, hit CONTINUE to report or STOP to exit

Figure 6–7 Final Calibration Window

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7. If calibration passed:

To view/print a calibration report or save calibration data, click continue and proceed to Section 6.3.3.

To quit the Micro Dyne Calibration program without printing the results or saving the data, click stop.

If calibration failed:

Click stop or continue to quit program.

6.3.3 Print rePort or save Data

After clicking “Continue” at the completion of a calibration procedure, the calibration report will be displayed in the window and a dialog box will appear with the option of printing the report.

Figure 6–8 Calibration Report

Whether “ok” is selected, or “Cancel”, the Save As dialog box will appear next in order to save the calibration data.

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7. Calibration - Watt Meter

7.1 CloSED-box CAlibrAtion

The Micro Dyne 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.

The unit 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.

7.2 CAlibrAtion SChEDulE

Calibrate the Micro Dyne:

• Afteranyrepairsareperformed.

• Atleastonceayear;morefrequentlytoensurerequiredaccuracy.

7.3 bASiC CAlibrAtion proCESS

The basic calibration process consists of two procedures which must be performed in the following order:

1. Initial Procedure

2. zero for both volts and Amps

3. volts gain

4. Amps gain

Items needed for calibrating the Micro Dyne:

• Externalvoltagereferenceof0to30voltsDC

• Currentreferenceof0to5ampsDC

• Digitalmultimeter(DMM)

both measuring instruments should have a accuracy of 0.005% or better.

7.3.1 initiaL caLiBration ProceDUre

1. Allow the Micro Dyne to stabilize in an environment with:

• Anambienttemperatureof18°Cto25°C.

• Relativehumiditylessthan80%.

2. Turn on the Micro Dyne.

3. Allow the Micro Dyne to warm up for at least 30 minutes.

7.3.2 voLts anD amPs Zero anD gain

1. Send the command CAl to the unit via the serial port.

2. The response will be zERo.

3. Apply 0.0000 volts to the volts input/0.0000 amps to the amps input.

4. Send the command zERo.

5. The response will be FSv=x.xxxx

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6. Apply 30 volts to the input (this can vary a few mv but must be measured accurately).

7. Send the command FS=x.xxxx (where x.xxxx is your meter reading).

8. The response will be FSA=x.xxxx.

9. Apply 5 amps to the amps input (this can vary few mA but must be measured accuratly).

10. Send the FSA=x.xxxx (where x.xxxx is your meter reading).

11. Unit will respond CAl CoMPlETE.

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8. Troubleshooting

If you require additional assistance, please contact Magtrol Customer Service at 1-716-668-5555.

problem reason SolutionSpeed MeasurementSpeed is erratic or there is no speed reading.

Speed pickup is in incorrect mode.

Switch speed pickup to SHS Mode.

CalibrationMicro Dyne revision is not displayed in the calibration software window.

Lost communication with electronics unit.

Check USB connections.

Calibration Error message appears at completion of calibration procedure.

Pendulum not fully returning to zero after the weight is removed

Make sure the dynamometer is level and restart calibration procedure.

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Appendix A: Hardware Commands

Although most motor tests can be performed with M-TEST, the following command reference tables are included for users who wish to write their own application.

A.1 DAtA forMAt

Speed-torque data is a fixed-length string in ASCII format with a floating point decimal. Use the following string format:

SdddddTdddd.R(cr)(lf)

or

SdddddTdddd.l(cr)(lf)

Where…

S = Speed in rpm. (No leading zeroes are used.)

d = Decimal digit 0 through 9.

T = Torque in mN·m. (The torque value always contains a decimal point.)

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 Micro Dyne will return:

S 1725T22.60R

by manipulating the string, the speed-torque and shaft direction (if required) can be extracted. Then separate numerical variables can be assigned to them for data processing.

a.1.1 coDes for cr - Lf

bASiC hEx DECCr = CHR$(13) 0D 13lf = CHR$(10) 0A 10

A.2 MiCro DynE CoMMAnD SEt

When entering a command code:

1. Type all characters in uppercase ASCII format.

2. End all commands with a CR-lF (hex 0D-0A).

3. Do not string multiple commands together in one line.

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Magtrol Micro Dyne SystemAppendix A: Hardware Commands

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The character # represents a floating-point numerical value following the command. leading zeroes are not required.

a.2.1 commUnication commanDs

Command Code function Explanation

*IDN? Returns Magtrol Identification and software revision.

Example: “MD 1.4 FP 2” Micro Dyne REV 1.4 and FPGA REV 2

B0 Brake Off. ---B1 Brake On. ---OD Returns speed-torque value. Output Data prompt to return data string with

this format:SxxxxxTxxxxxRcrlf

orSxxxxxTxxxxxLcrlf

R or L is the shaft direction indicator, as viewed looking at the dynamometer shaft where: R = right; clockwise (CW) L = left; counterclockwise (CCW)

a.2.2 ramP commanDs

Command Code

function Explanation

DILXX.XX Sets dynamic scale coefficient. When using dynamic scaling, XX.XX is multiplied by the I term to give the end I value.

DPLXX.XX Sets dynamic scale coefficient. When using dynamic scaling, XX.XX is multiplied by the P term to give the end P value.

DS# Enable or disables dynamic scaling.

Values for # are: 0 = disable 1 = enable

PD# Program Down: Sets ramp down rate to #rpm per second and starts ramp.

Specify speed range (F#) AND a stop speed (S#) before using this command. This command programs a decreasing shaft speed at a rate of #rpm per second.

PR • Resets ramp up or down. • Sets speed to maximum speed.• Turns brake off.

This command resets the ramp function, halting the ramp’s progress, and returns the motor to free run.

PU# Program Up: Sets ramp up rate to #rpm per second and starts ramp.

Specify speed range (F#) AND a start speed (S#) before using this command. This command increases the shaft speed at a rate of #rpm per second.

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Magtrol Micro Dyne System Appendix A: Hardware Commands

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a.2.3 setUP commanDs


R Resets as follows:• Brake OFF.

Use this command to cancel any previous commands.

RQ1 Resets quadrature counter. Use this command to reset torque count to zero.

a.2.4 sPeeD commanDs


F# Sets maximum speed to # rpm. Sets a speed range for the controller. Must be specified before using the speed or ramp mode. Sets the range of the PID calculation.

N • Resets speed point to maximum speed.• Sets speed mode OFF.• Sets brake OFF.

Use this command, sent alone, to reset any previous speed-stabilized setting to the maximum speed range.

N# • Sets speed point to #.• Sets brake ON.

Use this command to load the motor under test to a specific speed value #. Issue a speed range command (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.

ND# Sets speed derivative to #. Derivative value (#) can be any number from 0 to 99.

NDS# Sets scaling factor. Values for # are: A (0.001) D (0.05) G (1) B (0.005) E (0.10) H (5) C (0.01) F (0.50) I (10)

NI# Sets speed integral to #. Integral value (#) can be any number from 0 to 99.

NIS# Sets scaling factor. Values for # are: A (0.001) D (0.05) G (1) B (0.005) E (0.10) H (5) C (0.01) F (0.50) I (10)

NP# Sets speed proportional to # gain.

Proportional gain value (#) can be any number from 0 to 99.

NPS# Sets scaling factor. Values for # are: A (0.001) D (0.05) G (1) B (0.005) E (0.10) H (5) C (0.01) F (0.50) I (10)

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Magtrol Micro Dyne SystemAppendix A: Hardware Commands

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a.2.5 torqUe commanDs


Q • Resets torque to 0.0.• Turns torque mode OFF.• Turns brake OFF.

Resets any previous torque-stabilized command, and returns the motor to free run.

Q# • Sets torque point to #. • Turns brake ON.

Closed-loop command with its own set of PID parameters. Units are in mN·m.

QD# Sets torque derivative to #. Derivative value (#) can be any number from 0 to 99.

QDS# Sets scaling factor. Values for # are: A (0.001) D (0.05) G (1) B (0.005) E (0.10) H (5) C (0.01) F (0.50) I (10)

QI# Sets torque integral to #. Integral value (#) can be any number from 0 to 99.

QIS# Sets scaling factor. Values for # are: A (0.001) D (0.05) G (1) B (0.005) E (0.10) H (5) C (0.01) F (0.50) I (10)

QP# Sets torque proportional gain to #.

Proportional gain value (#) can be any number from 0 to 99.

QPS# Sets scaling factor. Values for # are: A (0.001) D (0.05) G (1) B (0.005) E (0.10) H (5) C (0.01) F (0.50) I (10)

a.2.6 Power anaLyZer anD reLay commanDs


OA1,0 Reads amps. ---OV1,0 Reads volts. ---OW1,0 Reads watts. ---PWR0 Switches off the power relay. ---PWR1 Switches on the power relay. ---

a.2.7 misceLLaneoUs commanDs


I# Sets current output to #. The Micro Dyne power supply outputs a fixed value of current. Use any value (#) between 0 and 99.99%. (99.99% = FS).

SAVE Saves present configuration of unit to non-volatile memory. ---

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Magtrol Micro Dyne System Appendix A: Hardware Commands

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a.2.8 caLiBration commanDs


CAL Sets unit into calibration mode. See Chapter 6 - Calibration - Dynamometer and Chapter 7 - Calibration - Watt Meter

CGL Returns average gain after calibration on left side. (Available with firmware revisions 2.4 and above.)

Output, floating point

CGR Returns average gain after calibration on left side. (Available with firmware revisions 2.4 and above.)


CZL Returns average of zero calibration reading on left side. (Available with firmware revisions 2.4 and above.)


CZR Returns average of zero calibration reading on right side. (Available with firmware revisions 2.4 and above.)


FSA=X.XXX Calibrate full scale amps to this value.

See Chapter 6 - Calibration - Dynamometer and Chapter 7 - Calibration - Watt Meter

FSV=X.XXX Calibrate full scale volts to this value.


ZERO Sets the offset to the value at the input.


GL=xxxx Sets average gain after calibration on left side.

Input, floating point

GR=xxxx Sets average gain after calibration on right side.


ZL=xxxx Sets average of Zero calibration reading on left side.


ZR=xxxx Sets average of Zero calibration reading on right side.


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Appendix B: Schematics

b.1 CorE bloCK DiAgrAM

1

1

2

2

3

3

4

4

5

5

6

6

D D

C C

B B

A A

U178B212_CORE_DSP_REVB

RAM128K x 24

GSI GS73024AB3.3V

FLASH1M x 8

SST SST39LF0803.3V

DSP

MOTOROLA DSP56303GC1003.3V

FPGA

ACTEL APA0752.5V

119 PBGA48 FBGA

196 PBGA 144 BGA

2.5V REG

JTAG-1 JTAG-2

XTAL8 MEG

RESET

EEPROM

93C66A

RS232

DRIVER

JP1JP2

CORE BLOCK3.3V

D[D0..D23]D[D0..D23]

3.3V

GA1GA2GA3

GA4GA5GA6GA7GA8

GA9GA10GA11GA12

GA13GA14GA15

GA16

GA17GA18GA19

GA20GA21GA22

GA23GA24GA25

GA26GA27GA28

GA29GA30GA31

GA32

GA33

GA34GA35GA36

GA37

GA38GA39 GA40GA41

GA42GA43GA44

GA45

GA46GL4 GA48

A[A0..A19]

WRRD

RS TXDRS RXD

RESETMODA

MODBMODCMODD

PC0

PC1PC2

PC3

PC4PC5

PB2PB3PB4PB5

PB6

PB7PB8

PB9PB10

PB11

PD0

PD1PD2

PD3

PD4PD5

GA49GA50GA51GA52GA53GA54GA55GA56GA57RESET

AA2TIO0TIO1TIO2

COREV(3.3)

D0D1D2D3D4D5D6D7D8D9D10D11D12D13D14

D15

A0A1A2A3

A[A0..A19]

13579

1113151719212325272931333537394143454749515355575961636567697173757779

2468101214161820222426283032343638404244464850525456586062646668707274767880

SAMTEC# BSE-040-01-F-D-A

JP1

CONN_80PIN_080

13579

1113151719212325272931333537394143454749515355575961636567697173757779

2468101214161820222426283032343638404244464850525456586062646668707274767880


JP2

CONN_80PIN_080

3.3V

MT2

MOUNT HOLE .128" DIA

MT1

1

Magtrol Inc.70 Gardenville Pkwy.Buffalo NY, 14224USA

3

CORE BOARD

78B212 B

TITLE

SIZE DWG NO. REV.

Sheet of

CCAGE CODE

03692SCALE: NONE

SCHEMATIC,APPROVED BY:

DRAWN BY:

DATE:

DATE:

3/13/06

2/22/04

PJ

SDS


CHECKED BY: DATE:3/13/06DG

REVISIONSREV DESCRIPTIONDATE ECN

TP17TP16 TP18 TP19

81 8283 8485 8687 8889 9091 9293 9495 9697 9899 100101 102103 104105 106107 108109 110111 112113 114115 116117 118119 120121 122123 124125 126127 128129 130131 132133 134135 136137 138139 140141 142143 144145 146147 148149 150151 152153 154155 156157 158159 160

2.5V

1

1

2

2

3

3

4

4

5

5

6

6

D D

C C

B B

A A

U178B212_CORE_DSP_REVB

RAM128K x 24

GSI GS73024AB3.3V

FLASH1M x 8

SST SST39LF0803.3V

DSP

MOTOROLA DSP56303GC1003.3V

FPGA

ACTEL APA0752.5V

119 PBGA48 FBGA

196 PBGA 144 BGA

2.5V REG

JTAG-1 JTAG-2

XTAL8 MEG

RESET

EEPROM

93C66A

RS232

DRIVER

JP1JP2

CORE BLOCK3.3V

D[D0..D23]D[D0..D23]

3.3V

GA1GA2GA3

GA4GA5GA6GA7GA8

GA9GA10GA11GA12

GA13GA14GA15

GA16

GA17GA18GA19

GA20GA21GA22

GA23GA24GA25

GA26GA27GA28

GA29GA30GA31

GA32

GA33

GA34GA35GA36

GA37

GA38GA39 GA40GA41

GA42GA43GA44

GA45

GA46GL4 GA48

A[A0..A19]

WRRD

RS TXDRS RXD

RESETMODA

MODBMODCMODD

PC0

PC1PC2

PC3

PC4PC5

PB2PB3PB4PB5

PB6

PB7PB8

PB9PB10

PB11

PD0

PD1PD2

PD3

PD4PD5

GA49GA50GA51GA52GA53GA54GA55GA56GA57RESET

AA2TIO0TIO1TIO2

COREV(3.3)

D0D1D2D3D4D5D6D7D8D9D10D11D12D13D14

D15

A0A1A2A3

A[A0..A19]

13579

1113151719212325272931333537394143454749515355575961636567697173757779

2468101214161820222426283032343638404244464850525456586062646668707274767880


JP1

CONN_80PIN_080

13579

1113151719212325272931333537394143454749515355575961636567697173757779

2468101214161820222426283032343638404244464850525456586062646668707274767880


JP2

CONN_80PIN_080

3.3V

MT2

MOUNT HOLE .128" DIA

MT1

1

Magtrol Inc.70 Gardenville Pkwy.Buffalo NY, 14224USA

3

CORE BOARD

78B212 B

TITLE

SIZE DWG NO. REV.

Sheet of

CCAGE CODE

03692SCALE: NONE

SCHEMATIC,APPROVED BY:

DRAWN BY:

DATE:

DATE:

3/13/06

2/22/04

PJ

SDS


CHECKED BY: DATE:3/13/06DG

REVISIONSREV DESCRIPTIONDATE ECN

TP17TP16 TP18 TP19

81 8283 8485 8687 8889 9091 9293 9495 9697 9899 100101 102103 104105 106107 108109 110111 112113 114115 116117 118119 120121 122123 124125 126127 128129 130131 132133 134135 136137 138139 140141 142143 144145 146147 148149 150151 152153 154155 156157 158159 160

2.5V

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Magtrol Micro Dyne System Appenidix B: Schematics

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b.2 MAin SChEMAtiC

1 23

J5

BRAK

E

BAN

ER

RS T

XDRS

RXD

RS T

XDRS

RXD

RESE

T

RESE

T

QU

AD1_

AQ

UAD

1_B

QU

AD1_

IND

TACH

2

+24V

24V

COM

GAT

EFI

BER-

OPT

IC C

ABLE

S TO

DYN

O

1 2 3 4 5 6 7 89 10 11 12 13 14 15

17 16

J3 D C

onne

ctor

15

ENCO

DER

/B

ENCO

DER

B

ENCO

DER

/A

ENCO

DER

A

IND

EX

IND

EX /

BRAK

E CI

RCU

IT

D0

24

D1

23

D2

22

3V3O

UT

6

BOAR

D ID

1

GND

2

RESE

T#3

RESE

TO#

4

GND

7

SLEE

P8

SND

/WU

P9

VCC-

IO10

EXTV

CC11

PORT

VCC

12

GND

5D

321

D4

20

D5

19

D6

18

D7

17

RD#

16

WR

15

TXE#

14

RXF#

13

DLP

-USB

245M

U2

USB

D[D

0..D

23]

D[D

0..D

23]

D0

D1

D2

D3

D4

D5

D6

D7

D8

D9

D10

D11

D12

D13

D14

D15

A0A1A2A3

A[A0

..A19

]A[

A0..A

19]

QU

AD1_

A

QU

AD1_

B

QU

AD1_

IND

15KR710

0R3

15K

R6

100

R4

3.3

OH

MS

R10

100

R5

+3.3

V

+5.0

V

+24V

0.1u

FC1

1

120

pFC8

0.1u

FC1

2

+5.0

V

D0

D1

D2

D3

D4

D5

D6

D7

D[D

0..D

7]

TXE#

RXE#

+3.3

V

TXE#

RXE#

1 2 3

P1BR

OW

N W

IRE

BLU

E W

IRE

WH

ITE

WIR

E

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79

2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80

81 83 85 87 89 91 93 95 97 99 101

103

105

107

109

111

113

115

117

119

121

123

125

127

129

131

133

135

137

139

141

143

145

147

149

151

153

155

157

159

82 84 86 88 90 92 94 96 98 100

102

104

106

108

110

112

114

116

118

120

122

124

126

128

130

132

134

136

138

140

142

144

146

148

150

152

154

156

158

160

JP1

JP2

CORE

BO

ARD

J1

+3.3

V+3

.3V

.1C7

FERR

ITE

L5

.1C547

UF

C6

AC(L

)1

AC(N

)2

V+4

V-3

FG5

DCD

C2AC

(N)

EART

H

AC(L

1)

FERR

ITE

L1

220U

FC4

FERR

ITE

L2

FERR

ITE

L3

FERR

ITE

L6

MT5

MT6

MT3

MT4

MT2

MT1

.01

C1TP

1

TP2

TP3

TP4

TP5

AC(L

)1

AC(N

)2

V+4

V-3

DCD

C1 24V

FERR

ITE

L4

+5V

+5.0

V

+3.3

V

+24V

USB

CPU

47U

FC2

1A2

2Y5

2B7

2A6

EN4

1Y3

1B1

DS3

4LV8

6TM

U3A

3B9

3Y11

4B15

3A10

4Y13

4A14

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U3B

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6TM

TACH

2

123456

J4 RS23

2

VCC

5

VOU

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C2-

3

C1-

1

C1+

2

C2+

4G

ND

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DN

7

LTC1

263

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Volta

ge R

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ator

+5.0

V

10U

FC1

3

VB8

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7

COM

3

VCC

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BF

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2

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0

+12V

+24V

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210

KR1

21KR1

1+3.3

V

PWM

_DRI

VE

G

D

S

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V

+3.3

V

FEM

ALE

LAST

DES

IGN

ATO

RS U

SED

:R1

4, C

18, L

6

1 2 43 5 6 7 8LE

D 1

LED

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3

LED

4

YELL

OW

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GRE

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02-1

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V DEC

UP

U3

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T2

1

GN

D

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17U

1

25V

35V

35V

10V

+12V

1A

+5.0

V

PWM

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VE

24V

COM

24V

COM

24V

COM

RESE

T

TIO

0

CPU

USB

PB2

PB3

CPU

USB

10KR1

10K

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+24V

24V

COM

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12

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SWIT

CH P

USH

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1 2 3 4 5 6 7 8

P2 Hea

der 8

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K

PVCS

SDO

ASD

OV

WAT

TMET

ER I

NPU

TRE

LAY

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OA

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1.0

OH

MS

R9 1W 50V

1%

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110

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(TO

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D)

(BO

TTO

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ED)

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PB9

PB10

TIO

1

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1

TIO

1

GA1

GA2

GA3

GA4

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PB4

PB5

PB7

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8

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5

TO 7

8P21

6 BO

ARD

ASS

EMBL

Y

46

Magtrol Micro Dyne SystemAppenidix B: Schematics

AP

PE

ND

ICE

S

b.3 DC WAttMEtEr

11

22

33

44

55

66

DD

CC

BB

AA

1

Mag

trol

70 G

arde

nVill

e Pkw

y.Bu

ffalo

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1

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ME

TER

IN

PUT

78B2

16B

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E

SIZE

DW

G N

O.

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.

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tof

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GE

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: NO

NE

SCH

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ATI

C,

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ED B

Y:

DRA

WN

BY

:

DA

TE:

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TE:

7/21

/06

06/0

9/06

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DG

THIS

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WIN

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Y IN

FOR

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GN

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2

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3

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4

IN+

5

IN-

6

GN

D7

GN

D8

GN

D9

GN

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GN

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GN

D16

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LTC

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1

VIN

2

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GN

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OU

T6

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7N

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IS8-

3

.1C5.1C6

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3 V

olts

0 to

3 v

olts

in

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6 57 U

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91

10.0

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0

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GN

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2

OV

3

+V4

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C1D

CDC

NK

E

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TP5

TP4

TP6

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A V

5 V

IN

GN

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116

46 8

1311 9

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5

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2

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3

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IN+

5

IN-

6

GN

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GN

D8

GN

D9

GN

D10

CS11

SDO

12SC

K13

Fo14

GN

D15

GN

D16

U7

LTC

2415

NC1

1

VIN

2

SHD

N3

GN

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5V

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3

3 V

olts

0 to

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olts

in

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15.0

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3

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TP10

2 31

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91

5 V

IN

1N91

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1

1 2345

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15

5 V

D V

GN

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2

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3

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C2D

CDC

NK

E

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10U

FC1

0

FERR

ITE

L4

FERR

ITE

L3

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5 V

A A

5 V

IN

GN

D A

A

5 V

D A

GN

D D

A

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10U

FC9

5 V

A A

5 V

A A

GN

D A

AG

ND

A A

GN

D A

A

GN

D A

A

GN

D A

A

GN

D A

V

5 V

A V

5 V

A V

GN

D A

V

GN

D A

VG

ND

A V

GN

D A

V

5 V

D A

1 2345

U9

PS91

15G

ND

D A

1 2345

U10

PS91

15

470

R13

1KR14

GN

D D

A

12

U5A

MM

74H

C14M

470

R6

5 V

IN

470

R83

4

U5B

MM

74H

C14M

1 2345

U11

PS91

15

5 V

D V

1 2345

U12

PS91

15G

ND

D V

1 2345

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PS91

15

470

R25

5 V

IN

98

U5D

MM

74H

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470

R18

1110

U5E

MM

74H

C14M

470

R20

1KR26

GN

D D

V

12345678

P1

RELA

Y

RELA

Y

5 V

IN

5 V

A V

GN

D A

V

8 4

U1C

OP2

91

5 V

A A

GN

D A

A

5 A

MPS

RA

TIN

GD

ESIG

N F

OR

7.5

30 V

OLT

S RA

TIN

GD

ESIG

N F

OR

50

4 5

1 2 3

Q2

TIN

Y_L

OG

IC(N

C7SZ

14)

4 5

1 2 3

Q3

TIN

Y_L

OG

IC(N

C7SZ

14)

5 V

D A

5 V

D V

2 W

ATT

S0.

01 O

HM

S

1%

MO

TOR

POW

ER IN

MO

TOR

POW

ER O

UT

VO

LTA

GE

SEN

SE

CLKSDOVSDOAPVCS

10U

FC3

1.1C3

2

FERR

ITE

L5FE

RRI

TEL6

IC1IC2IC3IC4IC5

IMPE

D C

HIP

, 1K

OH

M 3

00m

A

BRE

LEA

SE T

O P

ROD

UCT

ION

2/19

/07

-

TO 7

8P21

3 BO

ARD

ASS

EMBL

Y

47

AP

PE

ND

ICE

S

Appendix C: Calibration Record

DAtEDynAMoMEtEr MoDEl/SEriAl #

AppliED torquE

inDiCAtED torquE

Error tEStEr

48

Service Information

rEturning MAgtrol EquipMEnt for rEpAir AnD/or CAlibrAtion

before returning equipment to Magtrol for repair and/or calibration, please visit Magtrol’s Web site at http://www.magtrol.com/support/rma.htm to begin the Return Material Authorization (RMA) process. Depending on where the equipment is located and which unit(s) will be returned, you will be directed to either ship your equipment back to Magtrol, Inc. in the United States or Magtrol SA in Switzerland.

returning Equipment to Magtrol, inc. (united States)

When returning equipment to Magtrol, Inc.’s factory in the United States for repair and/or calibration, a completed Return Material Authorization (RMA) form is required. 1. visit Magtrol’s Web site at http://www.magtrol.com/support/rma.htm to begin the RMA process.2. Complete the RMA form online and submit.

3. An RMA number will be issued to you via e-mail. Include this number on all return documentation.

4. Ship your equipment to: MAgTRol, INC. 70 gardenville Parkway buffalo, Ny 14224 Attn: Repair Department

5. After Magtrol’s Repair Department receives and analyzes your equipment, a quotation listing all the necessary parts and labor costs, if any, will be faxed or e-mailed to you.

6. After receiving your repair estimate, provide Magtrol with a P.o. number as soon as possible. A purchase order confirming the cost quoted is required before your equipment can be returned.

returning Equipment to Magtrol SA (Switzerland)

If you are directed to ship your equipment to Switzerland, no RMA form/number is required. just send your equipment directly to Magtrol SA in Switzerland and follow these shipment instructions:

1. Ship your equipment to: MAgTRol SA After Sales Service Route de Montena 77 1728 Rossens / Fribourg Switzerland

vAT No: 485 572

2. Pleaseuseourforwarder:TNT•1-800-558-5555•AccountNo154033 only ship ECoNoMIC way (3 days max. within Europe)

3. Include the following documents with your equipment: • DeliverynotewithMagtrolSA’saddress(aslistedabove)

• Threeproformainvoiceswith: • YourVATnumber • Value-forcustomspurposesonly • Descriptionofreturnedgoods • Originofthegoods(ingeneral,Switzerland) • Noticedfailures4. A cost estimate for repair will be sent to you as soon as the goods have been analyzed. If the repair charges

do not exceed 25% the price of a new unit, the repair or calibration will be completed without requiring prior customer authorization.

www.magtrol.comTesting, Measurement and Control of Torque-Speed-Power • Load-Force-Weight • Tension • Displacement

MAgTROl InC70 Gardenville ParkwayBuffalo, New York 14224 USAPhone: +1 716 668 5555Fax: +1 716 668 8705E-mail: [email protected]

MAgTROl SARoute de Montena 771728 Rossens / Fribourg, SwitzerlandPhone: +41 (0)26 407 3000Fax: +41 (0)26 407 3001E-mail: [email protected]

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Documents

Micro Dyne System - Magtrol