MODEL 6200 as a stand-alone unit. Includes information on setting power and torque units, torque and speed control and open loop control. Chapter 5: CoMPUTER CoNTRoLLED oPERATIoN -

MODEL 6200

Open LoopDynamometer Controller

User’s Manual

1st Edition rev. A – March 2014

While every precaution has been exercised in the compilation of this document to ensure the accuracy of its contents, Magtrol, Inc. assumes no responsibility for errors or omissions. Additionally, no liability is assumed for any damages that may result from the use of the information contained within this publication. CopyrightCopyright ©2002- 2014 Magtrol, Inc. All rights reserved.Copying or reproduction of all or any part of the contents of this manual without the express permission of Magtrol is strictly prohibited.

trademarksLabVIEW™ is a trademark of National Instruments Corporation.Microsoft® is a registered trademark of Microsoft Corporation.National Instruments™ is a trademark of National Instruments Corporation.Windows® is a registered trademark of Microsoft Corporation.

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: _____________________________

iii

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

2. Check line voltage before operating the 6200.3. Make sure that dynamometers and motors under test are equipped with appropriate safety guards.

Safety Precautions

iv

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

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

revision date

1st Edition rev. A – March 2014

table of revisions

Revisions To This Manual

date edition Change section(s)

03/03/14 1st Edition - rev. A Torque Offset and Gain procedure updated. 6.3.203/03/14 1st Edition - rev. A Basic Calibration Process updated. 6.303/03/14 1st Edition - rev. A Accessory Torque/Speed Output diagram updated. 2.2.1

v

Table of Contents

safety preCautions ....................................................................................................................... iii

revisions to this manual .............................................................................................................. ivREVISIoN DATE ................................................................................................................................................................ IV

TAbLE oF REVISIoNS ..................................................................................................................................................... IV

prefaCe ...............................................................................................................................................viiPURPoSE oF ThIS MANUAL ........................................................................................................................................VII

Who ShoULD USE ThIS MANUAL .............................................................................................................................VII

MANUAL oRgANIzATIoN ............................................................................................................................................VII

CoNVENTIoNS USED IN ThIS MANUAL ................................................................................................................. VIII

1. introduCtion ................................................................................................................................ 91.1 UNPACkINg YoUR 6200 ............................................................................................................................................ 9

1.2 FEATURES oF ThE 6200 ............................................................................................................................................. 9

1.3 DATA ShEET ............................................................................................................................................................... 10

2. Controls ....................................................................................................................................... 122.1 FRoNT PANEL ............................................................................................................................................................ 12

2.1.1 Front Panel Controls and buttons .................................................................................................................. 122.1.2 how to Use Front Panel Controls and buttons .............................................................................................. 13

2.2 REAR PANEL .............................................................................................................................................................. 142.2.1 Rear Panel Functions ...................................................................................................................................... 14

2.3 VACUUM FLUoRESCENT DISPLAY (VFD) ........................................................................................................... 162.3.1 Contrast Settings ............................................................................................................................................ 162.3.2 Displaying Desired Information ..................................................................................................................... 16

3. installation ................................................................................................................................... 93.1 PoWERINg UP ThE 6200 ........................................................................................................................................... 9

3.1.1 Setting Unit for Line Voltage ........................................................................................................................... 93.1.2 hardware Connection ..................................................................................................................................... 103.1.3 Self-Test ......................................................................................................................................................... 10

3.2 bASIC TEST SETUP ................................................................................................................................................... 10

4. manually Controlled operation ....................................................................................... 114.1 SETTINg DESIRED oPERATINg PARAMETERS ................................................................................................. 11

4.1.1 Set Power Display to Desired Units (Watts, hp or Aux.) .............................................................................. 114.1.2 Set Display to Desired Torque Units .............................................................................................................. 114.1.3 Set up System Parameters .............................................................................................................................. 114.1.4 Set Up Pass/Fail Parameters ........................................................................................................................... 114.1.5 Set Up I/o Parameters .................................................................................................................................... 12

4.2 SETTINg DYNAMoMETER LoAD ......................................................................................................................... 12

4.3 USINg INTERNAL MEMoRY .................................................................................................................................. 134.3.1 Storing Data Points ........................................................................................................................................ 134.3.2 Recalling Data Points ..................................................................................................................................... 134.3.3 Exiting the Memory Mode ............................................................................................................................. 134.3.4 Clearing the Memory ..................................................................................................................................... 13

5. Computer Controlled operation ...................................................................................... 145.1 AboUT ThE gPIb INTERFACE ............................................................................................................................... 14

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Magtrol Model 6200 Open Loop Dynamometer ControllerTable of Contents

5.1.1 Installing the gPIb (IEEE-488) Connector Cable ......................................................................................... 145.1.2 Changing the gPIb Primary Address ............................................................................................................ 15

5.2 ChECkINg ThE 6200-To-PC CoNNECTIoN ........................................................................................................ 15

5.3 PRogRAMMINg ........................................................................................................................................................ 16

5.4 6200 CoMMAND SET ................................................................................................................................................ 165.4.1 Command Set for 6200 .................................................................................................................................. 16

5.5 ACQUIRINg SPEED-ToRQUE DATA ...................................................................................................................... 18

5.6 SELECTINg ThE bAUD RATE FoR ThE RS-232 INTERFACE ........................................................................... 19

6. Calibration .................................................................................................................................. 216.1 CLoSED-box CALIbRATIoN ................................................................................................................................. 21

6.2 CALIbRATIoN SChEDULE ...................................................................................................................................... 21

6.3 bASIC CALIbRATIoN PRoCESS ............................................................................................................................. 216.3.1 Initial Calibration Procedure .......................................................................................................................... 216.3.2 Torque offset and gain .................................................................................................................................. 226.3.3 Accessory Torque offset and gain ................................................................................................................ 236.3.4 Auxiliary Input offset and gain..................................................................................................................... 23

6.4 ALTERNATE CALIbRATIoN PRoCEDURE ........................................................................................................... 23

7. troubleshooting ....................................................................................................................... 26

appendix a: labvieW programming examples ..................................................................... 27A.1 SIMPLE READ ............................................................................................................................................................ 27

A.2 CURRENT STAbILIzED ............................................................................................................................................ 28

appendix b: front panel/display menu floW Charts ....................................................... 29b.1 SETUP MENU ............................................................................................................................................................. 29

b.2 PoWER UNITS MENU ............................................................................................................................................... 30

b.3 AUx SETUP MENU .................................................................................................................................................... 30

b.4 ToRQUE UNITS MENU ............................................................................................................................................ 31

appendix C: sChematiCs ................................................................................................................ 32C.1 ENCoDER/SWITCh boARD .................................................................................................................................... 32

C.2 PoWER SUPPLY ......................................................................................................................................................... 32

C.3 DSP & MEMoRY ........................................................................................................................................................ 33

C.4 ANALog I/o ............................................................................................................................................................... 34

serviCe information ...................................................................................................................... 35RETURNINg MAgTRoL EQUIPMENT FoR REPAIR AND/oR CALIbRATIoN ...................................................... 35

Returning Equipment to Magtrol, Inc. (United States) ................................................................................................ 35Returning Equipment to Magtrol SA (Switzerland) ..................................................................................................... 35

vii

Magtrol Model 6200 Open Loop Dynamometer Controller Table of Contents

table of figures

2. Controls ....................................................................................................................................... 12Figure 2–1 Front Panel ............................................................................................................................................... 12Figure 2–2 Secondary Function Menu ........................................................................................................................ 12Figure 2–3 Rear Panel ................................................................................................................................................. 14Figure 2–4 Dynamometer brake output ..................................................................................................................... 14Figure 2–5 Accessory Torque-Speed output ............................................................................................................... 14Figure 2–6 Dynamometer/TSC1 Connector ................................................................................................................ 15Figure 2–7 RS-232C Interface ..................................................................................................................................... 15Figure 2–8 gPIb/IEEE-488 Interface ......................................................................................................................... 15

3. installation ................................................................................................................................... 9Figure 3–1 Cover for Voltage Selector, Fuses ............................................................................................................... 9

5. Computer Controlled operation ...................................................................................... 14Figure 5–1 gPIb (IEEE-488) Interface ....................................................................................................................... 15Figure 5–2 Connector Pin-out .................................................................................................................................... 19

6. Calibration .................................................................................................................................. 21Figure 6–1 Alternative Calibration .............................................................................................................................. 24

vii

purpose of this manual

This manual contains all the information required for the installation and general use of the Model 6200 open Loop Dynamometer Controller. To ensure proper use of the instrument, please read this manual thoroughly before operating it. keep the manual in a safe place for quick reference whenever a question arises.

Who should use this manual

This manual is intended for bench test operators who are going to use the Model 6200 Dynamometer Controller in conjunction with any Magtrol hysteresis Dynamometer or auxiliary instrumentation.

manual organization

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

The structure of the manual is as follows:

Chapter 1: INTRoDUCTIoN - Contains the technical data sheet for the 6200 Dynamometer Controller, which describes the unit and provides its technical characteristics.

Chapter 2: CoNTRoLS - Description of the elements located on the front and rear panels of the unit.

Chapter 3: INSTALLATIoN - Provides setup options available with the 6200 Dynamometer Controller. Illustrates and outlines the hardware connection setup and software configurations for each option.

Chapter 4: MANUALLY CoNTRoLLED oPERATIoN - how to run a test when the 6200 is used as a stand-alone unit. Includes information on setting power and torque units, torque and speed control and open loop control.

Chapter 5: CoMPUTER CoNTRoLLED oPERATIoN - how to run a test when the 6200 is used with a PC. Includes information on gPIb Interface, RS-232 Interface, data format, programming and command set.

Chapter 6: CALIbRATIoN - Provides recommended calibration schedules along with step-by-step instructions for the calibration procedure.

Chapter 7: TRoUbLEShooTINg - Solutions to common problems encountered during setup and testing.

Appendix A: LAbVIEW™ PRogRAMMINg ExAMPLES - Magtrol’s comprehensive motor-test software programs, made specifically to compliment the 6200 Dynamometer Controller.

Appendix b: FRoNT PANEL/DISPLAY MENU FLoW ChARTS - A visual display of various setup procedures.

Preface

viii

Magtrol Model 6200 Open Loop Dynamometer ControllerPreface

Appendix C: SChEMATICS - For Encoder/Switch board, Power Supply, DSP & Memory and Analog I/o.

Conventions used in this manual

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

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

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

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

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Calibration Certificate

1. Introduction

1.2 features of the 6200

• Highquality,easytoreaddisplay-Vacuumfluorescentreadoutwith0.36”(9.1mm)highdigits.

• High-speeddataacquisition-120torqueandspeedreadingspersecondviaIEEE(GPIB)bus.

• Pass/Failtesting-Upperandlowerlimitsareprogrammablefortorque,speed,andauxiliaryinput.

• Currentregulatedsupply-Providesupto1ampoutput.

• Internaldatastorage-Nonvolatilememoryofupto100datapoints.

• Dynamometeroverloadprotection-Maximumpowerlimitcanbeprogrammedtoshutdownifexceeded.

• Twostandardcomputerinterfaces-RS-232andIEEE-488.• Additionalanaloginput-Acceptsany±5VDCtransducer.

• Manytorquemeasurementoptions-IncludesEnglish,metric,andSItorquereadingsasstandard.• Closedboxcalibrationoftorqueandauxiliaryinput-Eliminatesneedtoopenboxforadjustments.

The 6200 is designed to work with any personal computer using an IEEE-488 or an RS-232 interface, or as a stand-alone unit. In a computer-controlled environment, the 6200 provides the following motor testing capabilities:

• Currentregulatedcontrolofdynamometerbrakeforopen-looptesting• Torque(Q)andSpeed(N)dataacquisitionatarateofupto120readingspersecond.

• Saving-Allowsusertosaveprogrammedvalueswithintheirconfigurations.

1.1 unpaCking your 6200Your 6200 was packaged carefully for shipping. Please notify your carrier and Magtrol Customer Service if you believe your unit was damaged in shipping.

1. Save all shipping cartons and packaging material until you inspect the 6200.2. Inspect the 6200 for any evidence of damage in shipping. 3. Make sure the carton contains the following:

MODEL 6200CONTROLLER/DISPLAY

UP DOWNRECALL

SETUP SHIFT

STORE

CLR MENU

DISPLAY

AUX SETUP

TORQUE SET

TORQUE UNITS

BRAKE ON/OFF

POWER UNITS

POWER

POWER/AUX TORQUE SPEED

DECREASE INCREASE

6200 Dynamometer Controller/Readout

Line cord

Magtrol User Manual CD-Rom

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Magtrol Model 6200 Open Loop Dynamometer ControllerChapter 1 – Introduction

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1.3 data sheet

6200Data Sheet

Model 6200 Open-LoopDynamometer Controller

� www.magtrol.com

MAGTROL

Features

• Open-LoopDynamometerControl

• Built-inPass/FailMotorTestingCapability

• Interfaces:RS-232andIEEE-488

• HighSpeedDataAcquisition:120torqueandspeedpointspersecondviaIEEEbus(approx.60/sec.viaRS-232)

• HighQuality,Easy-to-ReadVacuumFluorescentReadout:Displaystorque,speed,powerandauxiliaryvalues

• Current-RegulatedSupply:Providesupto1ampoutput

• AdjustableTorqueUnits:English,MetricandSIarestandard

• DynamometerOverloadProtection

• InternalDataStorage:Upto100datapoints

• Auxiliary±5VDCAnalogInput:Foradditionaltransducer

• ClosedBoxCalibration

• RackMounting:19"(482.6mm)withhandles

system conFiguration

DescriptionMagtrol'sModel6200isanOpen-LoopControllerdesignedforusewithanyMagtrolHysteresisDynamometer.Theunitprovidesopen-loopcontrolofthedynamometerviaaninternalcurrent-regulatedpowersupply.Withahigh-qualityvacuumfluorescentreadout,theModel6200displaystorque,speed

andmechanicalpowervaluesofthemotorundertest.Inplaceofmechanicalpower,itcanalsodisplayauxiliarytransducerreadings via the±5VDC analog input. These displayedvaluescanbestoredinternallyoroutputviatheRS-232orIEEE-488interface.

pass/Fail motor testingTheModel 6200 comeswith an easy-to-usemotor testingPass/Fail feature. This feature is ideal for quick pass/fail(go/no go) testing in production and incoming inspectionapplications.

Whenthe6200isoperatedinthePass/Failmode,oneofthreereadingsisusedasthetestedparameter:torque,speedortheauxiliarytransducer.Thetwoparametersnotusedaresetwithuser-definedupperandloweracceptablelimits.Asthemotorisloadedtothetestedparametervalue(forexample,speed),theothertwoparameters(inthiscase,torqueandtransducer)aremeasured. Testresults(fortheother2parameters)areindicatedwitha“PASS” or “FAIL”,or thedisplaycanbetoggledtoshowtheactualvalues.

BRAKE

CTRL OUT DYNAMOMETER

ACCESSORYTORQUE-SPEED

OUTPUT

BRAKE FUSE

AUX.INPUT

RS–232CGPIB/IEEE–488

(5×20mm):

EARTHGROUND

CAUTION: DOUBLE POLE FUSING75VA 50/60 Hz

FUSE (5×20mm):UL/CSA 1.25A 250V SBIEC 1A 250V T

120V UL/CSA 800mA 250V SB240V IEC 315mA 250V TMAGTROL, INC. BUFFALO, NY

MotorUnderTest

Hysteresis Dynamometer

MODEL 6200 CONTROLLER

orDering inFormation6200 Open Loop Dynamometer Controller 120 VAC6200A Open Loop Dynamometer Controller 240 VAC

11

Magtrol Model 6200 Open Loop Dynamometer Controller Chapter 1 – Introduction

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6200

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 saCentre technologique Montena1728 Rossens / Fribourg, SwitzerlandPhone: +41 (0)26 407 3000Fax: +41 (0)26 407 3001E-mail: [email protected]

Subsidiaries in:Great Britain

Germany • FranceChina • India

Worldwide Network of Sales Agents

Specifications

Front panel

6200

-US

03/

06

Set Desired Power Units(W, Hp or AUX)

Set Desired Torque Units(oz.in., oz.ft., lb.in., lb.ft., g.cm, kg.cm, Nmm, Ncm, Nm)

Ready for Rack MountingDisplays Torque, Speed and Mechanical Power Values

InternalMemory

Enables Pass/Fail Testingof Torque, Speed or Auxiliary Input

RS-232 and GPIB/IEEE-488Interfaces for Connection to PC

For Use With Any MagtrolHysteresis Dynamometer

Auxiliary Input Accepts±5 VDC Transducer

Connector for Model 5241 Power Supply(for HD-825 Dynamometer only)

Connector for OptionalMagtrol Readout

rear panel

MEASUREMENT CHARACTERISTICSMaximum Torque 2000 unitsMaximum Speed 99,999 rpm

AccuracySpeed: 0.01% of reading from 10 rpm to 100,000 rpmTorque: 0.2% of range (± 2 V)Aux: 0.1% of range (± 5 V)

ELECTRICAL CHARACTERISTICS

Fuses (5 × 20 mm)

Brake: UL/CSA 1.25 A 250 V SB IEC 1.00 A 250 V TPower (120 V): UL/CSA 800 mA 250 V SBPower (240 V): IEC 315 mA 250 V T

Power Requirements 75 VAVoltage Requirements 120/240 V 60/50 HzMax. Compliance Voltage 45 V DCINPUTS AND OUTPUTSAuxiliary Input ± 5 V DCAccessory Torque/Speed Output

Torque: ± 2 V DCSpeed: 60 TTL pulses/rev, 50% duty cycle

Ctrl Out 0–3 V DCENVIRONMENTOperating Temperature 18 ºC to 25 ºCRelative Humidity < 80%Temperature Coefficient 0.001% of range/°C

DIMENSIONSWidth 19.0 in 483 mmHeight 3.5 in 89 mmDepth

with handles12.4 in13.8 in

315 mm351 mm

Weight 16.37 lb 7.42 kg

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2.1 front panel

The front panel provides a power switch, nine control buttons, a Decrease/Increase Dial, and Vacuum Fluorescent Display (VFD)

model 6200CONTROLLER/DISPLAY

UP DOWNRECALL

SETUP SHIFT

STORE

CLR MENU

DISPLAY

AUX SETUP

TORQUE SET

TORQUE UNITS

BRAKE ON/OFF

POWER UNITS

POWER


DECREASE INCREASE

Figure 2–1 Front Panel

2.1.1 Front Panel Controls and Buttons

The front panel controls and buttons, from left to right, are:

• Powerswitch

• Fivedouble-functioncontrolbutton:

primary function secondary function

BRAKE ON/OFF POWER UNITSUNITS DISPLAY TORQUE UNITSDISPLAY AUX SETUPSTORE CLR MEMRECALL SETUP

• Threesingle-functioncontrolbuttons:

• SHIFT(enablessavingfunctionandsecondaryfunctionsprintedinblueabovecontrolbuttons)

• UP-Leftarrow (moves cursor to the left)

• DOWN-Rightarrow (moves cursor to the right)• Decrease/IncreaseDial(decreasesorincreasestheselectedparameter)

2.1.1.1 Enabling Secondary Functions

To enable the secondary function of the double-function control buttons:1. PresstheblueSHIFTbuttonandreleaseit.Theword“SHIFT”appearsinthedispay:


Figure 2–2 Secondary Function Menu

2. Press any control button to enable the function shown in blue letters above the button:

2. Controls

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Magtrol Model 6200 Open Loop Dynamometer Controller Chapter 2 – Controls

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PoWER UNITS, ToRQUE UNITS, AUx SETUP, CLR MEM oR SETUP3. Press the ShIFT button again to exit the secondary function and return to main menu.

2.1.2 How to use Front Panel Controls and Buttons

2.1.2.1 Controls/Single-Function Buttons

button to use function

POWER Press I to turn power ON. Press O to turn power off.

Turns power ON or OFF.

SHIFT Press this button and release; then press desired control button.

Enables the function written in blue above control button.

UP/LEFT Press. Increases magnitude of change when adjusting a numerical value (speed, torque or max. speed).

DOWN/RIGHT Press. Decreases magnitude of change when adjusting a numerical value (speed, torque or max. speed).

DECREASE/INCREASE DIAL

Turn clockwise or counterclockwise.

Increases or decreases the parameter selected.

2.1.2.2 Double-Function Buttons

button to use function

POWER UNITS Press SHIFT and release; then press this button

Sets power display to WATTS, HP or AUX input.

BRAKE ON/OFF Press. Toggles brake ON or OFF.TORQUE UNITS Press SHIFT and release; then

press this buttonEnables you to set desired unit of measure. Press UP or DOWN button to see options. Press SHIFT to enable option.

UNITS DISPLAY Press. Shows power units, torque units and percent of full scale current output.

AUX SETUP Press SHIFT and release; then press this button

Enables you to set the scaling of the auxilary input.

DISPLAY Press. When in the PASS/FAIL mode, shows actual value of parameter.

CLR MEM Press SHIFT and release; then press this button

Clears the data memory. Resets next memory location to 0.

STORE Press. Stores data into next available memory location.

SETUP Press SHIFT and release; then press this button

Enables user to select SYSTEM, PASS/FAIL and I/O menus.

RECALL Press. Displays memory contents beginning at last stored value.

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Magtrol Model 6200 Open Loop Dynamometer ControllerChapter 2 – Controls

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2.2 rear panel

The rear panel provides connectors and receptacles for connecting to appropriate equipment. Refer to figures 3, 4 and 5 in this chapter for detailed drawings of the brake

BRAKE

CTRL OUT DYNAMOMETER

ACCESSORYTORQUE-SPEED

OUTPUT

BRAKE FUSE

AUX.INPUT RS–232C

GPIB/IEEE–488

(5×20mm):

EARTHGROUND

CAUTION: DOUBLE POLE FUSING75VA 50/60 Hz

FUSE (5×20mm):UL/CSA 1.25A 250V SBIEC 1A 250V T

120V UL/CSA 800mA 250V SB240V IEC 315mA 250V TMAGTROL, INC. BUFFALO, NY

Figure 2–3 Rear Panel

2.2.1 rear Panel FunCtions

The rear panel, from left to right, provides the following functions:

bRAkE Connect dynamometer brake cable here.

Figure 2–4 Dynamometer Brake Output

bRAkEFUSE

Contains brake fuse (5 x 20 mm)(UL/CSA 1.25A 250V Sb)(IEC 1A 250V T)

CTRL oUT Connect to Model 5241 Power Amplifier when using hD-825 Dynamometer.

ACCESSoRYToRQUE/SPEEDoUTPUT

Connect accessory output cable here (optional).

7 6

3 1

5 42

7. D.P.6. TACH. COMMON5. N/C4. TORQUE COMMON3. D.P.2. TORQUE OUTPUT1. TACH. SIGNAL

Figure 2–5 Accessory Torque-Speed Output

Caution: For use with Magtrol readouts only. ConneCting another deviCe to this output May Cause equipMent Failure.

CurrentRegulation

+35VFused

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Magtrol Model 6200 Open Loop Dynamometer Controller Chapter 2 – Controls

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gPIb/IEEE-488 Use this socket for gPIb cable (meets IEEE-488 specifications).

24. SIGNAL GROUND23. ATN-COM22. SRQ-COM21. IFC-COM20. NDAC-COM19. NRFD-COM18. DAV-COM17. REN16. D815. D714. D613. D5

12. SHIELD11. ATN10. SRQ 9. IFC 8. NDAC 7. NRFD 6. DAV 5. E01 4. D4 3. D3 2. D2 1. D1

14 3 2

13141516

6 5

1718

7

19

811 10 9

20212223

12

24

Figure 2–8 GPIB/IEEE-488 Interface

PoWER Attach power cord here.

EARTh gRoUND Attach earth ground here.

AUx INPUT Connect auxiliary instrument signal cable here.

DYNAMoMETER Connect dynamometer signal cable here.

14. TORQUE SIGNAL13. TORQUE COMMON12. D.P.11. N/C10. TACH. SIGNAL 9. D.P. 8. COMMON

7. TACH. +5.0 VDC 6. ISOLATED -22 VDC 5. ISOLATED +22 VDC 4. ISOLATED -22 VDC 3. ISOLATED +22 VDC 2. N/C 1. N/C

14 3 2

891011

6 5

1213

7

14

Figure 2–6 Dynamometer/TSC1 Connector

RS-232C Use this socket for RS-232 connector cable

5. GND

1.

6.

9. N/C

3. RX

8.

2. TX

4.

7.

14 3 25

69 8 7

Figure 2–7 RS-232C Interface

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Magtrol Model 6200 Open Loop Dynamometer ControllerChapter 2 – Controls

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2.3 vaCuum fluoresCent display (vfd)

The VFD provides information about the control functions, the motor under test, and an auxiliary input device (if connected). The displays, from left to right, are:

• POWER(expressedinhorsepowerorwatts)/AUXINPUT• TORQUE• SPEED• MemoryIndicator

2.3.1 Contrast settings

The 6200 is shipped with the Contrast Setting at zero (lowest) in order to prolong display life. If it is necessary to increase the Contrast for improved readability, execute the following steps:

1. Press ShIFT.2. Press CoM SETUP button.

3. Select CoNTRAST until desired brightness is reached.

4. Press ShIFT to return to main menu.

Note: Make sure the lowest possible setting is used to achieve desired result. Using a setting higher than necessary may cause display segments to burn-in over a period of time, resulting in uneven illumination from segment to segment.

2.3.2 disPlaying desired inFormation

2.3.2.1 Local Control1. Press ShIFT and release; then press PoWER UNITS to see UNITS displayed.

2. Press UP or DoWN to scroll through available choices.

3. Press ShIFT to exit.

4. Press ShIFT and release; then press ToRQUE UNITS to see UNITS displayed.

5. Press UP or DoWN to scroll through options for units.6. Press ShIFT to exit.

7. Press RECALL to view memory contents; last in = first out.


2.3.2.2 Remote Control

Referto“6200CommandSet”inChapter4-The6200withaPCforalistofcommandsrecognizedby the 6200.

2.3.2.3 Auxiliary Input1. Press ShIFT and release; then press AUx SETUP.

2. Rotate Decrease/Increase Dial to select scale.3. Press ShIFT to exit.

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3. Installation

Note: before installing the 6200, you should become familiar with the front and rear panels, as outlined in Chapter 2–Controls.

3.1 poWering up the 6200

WARNING! To Reduce The RIsk of elecTRIc shock, mAke suRe The 6200 Is eARTh GRouNded befoRe sTARTING!

3.1.1 setting unit For line Voltage

The 6200 will operate with either of the following power sources:

• 120V50/60Hz

• 240V50/60Hz

1. Find the line cord receptacle on rear panel. The line cord is a detachable NEMA Standard 3 wire.

2. Make sure the selector matches the power source (numbers should match the line voltage).

If not:

• Locatethepowerentrymodule.

• Removethelinecord.

• Insertascrewdriverintotheslotandopenthecover.

• Slidethevoltageselectorsothedesiredlinevoltageappearsinthewindow.

• Installtheappropriatefusesforthatvoltage.

Figure 3–1 Cover for Voltage Selector, Fuses

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3.1.2 Hardware ConneCtion

Do not overload or stall the motor. Prolonged overload can cause the motor to overheat.

Note: Note: To make sure that the 6200 is operational, a Magtrol dynamometer with a test motor installed must be connected to the 6200. It is not required that the 6200 be connected to a computer.

1. Connect the 6200 to the dynamometer using the following cables:

• 14-pinsignalcable

• 2-pinbrakepowercable

2. Turn on 6200 power.

3.1.3 selF-test

After turning the power on to the 6200, the display panel will show all segments of the VFD (series of rectangles), indicating that the 6200 is downloading the program.

When the program download is complete, themessage“MAGTROL6200”appears.

3.2 basiC test setup

1. After the Model Display wappears, press the UNITS DISPLAY button and set current output to 0% with Decrease/Increase Dial.

2. Start the test motor.

3. Allow the motor speed to stabilize at its no-load speed for a few seconds.

4. Press the bRAkE oN/oFF button to oN.

5. Turn the Decrease/Increase Dial clockwise.

desired results:

• Thetorquereadingwillincrease.

As brake power is applied, load is applied to the motor. The applied torque increases as the Decrease/Increase Dial is turned clockwise. For most motors, loading is indicated by motor speed reduction.

8. Reduce the torque load to zero by turning the Decrease/Increase Dial counterclockwise.

desired results: • Thetorquereadingwilldecrease.

9. Press the bRAkE oN/oFF button to oFF.

10. Turn off power to the test motor.

Note: If the desired results did not occur, please see Chapter 7 –Troubleshooting.

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4. Manually Controlled Operation

4.1 setting desired operating parameters

Note: See Appendix b: Front Panel/Display Menu Flow Charts.

4.1.1 set Power disPlay to desired units (watts, HP or aux.)1. Press and release ShIFT.

2. Press PoWER UNITS.

3. Press UP or DoWN to scroll through choices.


4.1.2 set disPlay to desired torque units

1. Press and release ShIFT.

2. Press ToRQUE UNITS.

3. Press UP or DoWN until you see the desired unit of measure.


4.1.3 set uP system Parameters


2. Press SETUP.

3. Press ShIFT.

4. Press UP or DoWN until you see the desired unit of input torque.

5. Press ShIFT.

6. Press UP or DoWN until selection matches encoder installed on dynamometer. (60-bit = standard)

7. Press ShIFT.

8. Use the UP or DoWN buttons and the Decrease/Increase Dial to adjust the maximum power setpoint for the dynamometer in use.


4.1.4 set uP Pass/Fail Parameters


2. Press SETUP.

3. Press the DoWN button once.

4. Press ShIFT.

5. Press UP or DoWN to turn oN or oFF Torque PASS/FAIL testing.

6. If oN, press ShIFT.

7. Use the or DoWN buttons and the Decrease/Increase Dial to adjust the high limit for Torque.

8. Press ShIFT.

9. Use the or DoWN buttons and the Decrease/Increase Dial to adjust the low limit for Torque.

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10. Press ShIFT.

11. Press UP or DoWN to turn oN or oFF Speed PASS/FAIL testing.


13. Use the UP or DoWN buttons and the Decrease/Increase Dial to adjust the high limit for Speed.

14. Press ShIFT.

15. Use the UP or DoWN buttons and the Decrease/Increase Dial to adjust the low limit for Speed.

16. Press ShIFT.

17. Press UP or DoWN to turn oN or oFF Auxiliary Input PASS/FAIL testing.


19. Use the UP or DoWN buttons and the Decrease/Increase Dial to adjust the high limit for Auxiliary Input.

20. Press ShIFT.

21. Use the UP or DoWN buttons and the Decrease/Increase Dial to adjust the low limit for Auxiliary Input.


4.1.5 set uP i/o Parameters


2. Press SETUP.

3. Press the DoWN button twice.

4. Press ShIFT.

5. Press UP or DoWN until you see the desired contrast level.

6. Press ShIFT.

7. Press UP or DoWN until you see the desired gPIb address.

8. Press ShIFT.

9. Press UP or DoWN until you see the desired RS-232 baud rate.


4.2 setting dynamometer load

1. Press the UNITS DISPLAY button.

2. Use the Decrease/Increase Dial to adjust the current output to 0%.

3. Use the bRAkE oN/oFF button to turn the brake oN.

4. Start the motor under test.

5. Use the UP or DoWN buttons and the Decrease/Increase Dial to adjust the loading on the motor.

Caution: do not exCeed the Capabilities oF the dynaMoMeter or the power sourCe in use. Motors draw very large Currents when held at loCked rotor, and overheating May result. when using open loop Current Control, induCtion Motors Cannot be tested beyond breakdown, exCept at loCked rotor.

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4.3 using internal memory

4.3.1 storing data Points

1. Press and release SToRE. The VFD will indicate SToRE followed by a number. This indicates the memory location that contains the data.

2. Continue pressing SToRE at each desired point.

4.3.2 reCalling data Points

1. Press and release RECALL. The VFD will indicate RECALL followed by a number. This number indicates the memory location that is being displayed. The order of recalled data isLASTIN=FIRSTOUT(LIFO).A“M”alsoappearstotherightoftheSPEEDdisplayto let the user know that the displayed data is from memory and not real time data.

2. Continue pressing RECALL until all the desired data is retrieved. once data has been recalled, it is lost from internal memory.

4.3.3 exiting tHe memory mode


4.3.4 Clearing tHe memory


2. Then press CLR MEM.

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5. Computer Controlled Operation

The 6200 can be used with a personal computer to control a dynamometer and to transmit data from motor testing directly to the computer.

5.1 about the gpib interfaCe

Magtrol instruments use the gPIb (IEEE-488 Standard) for computer-to-instrument interfacing because:

• TheGPIBparallelinterfaceisfasterthanserialinterfaces.

• TheGPIBenablestesterstoaccessupto15instrumentsononeport.Becausetypicalmotor testing requires that at least five separate parameters must be synchronized, a system of easy, fast access to more than one instrument is essential.

• TheGPIBhasrigiddataformattingandhardwarestandards.Thesestandardshelpto

ensure that all functions will work properly when the hardware and software are installed.

Note: The gPIb interface is not standard on most computers. An interface card and driver software must be installed. Magtrol recommends National Instruments Corporation hardware and software.

• AnIEEE-488cablemustbeinstalledbetweenthecomputerandthe6200.

5.1.1 installing tHe gPiB (ieee-488) ConneCtor CaBle

Caution: Make sure both the CoMputer and the 6200 are turned oFF beFore installing the gpib ConneCtor Cable.

1. Connect one end of a high-quality, double-shielded cable to the 6200 gPIb connector.

2. Connect the other end to the gPIb interface in your PC.

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D5

D6

D7

D8

REN

DAV-COM

NFRD-COM

NDAC-COM

IFC-COM

SRQ-COM

ATN-COM

SIGNAL GROUND

IEEE-488 INTERFACE

D1

D2

D3

D4

EO1

DAV

NFRD

NDAC

IFC

SRQ

ATN

SHIELD

1 13

2 14

3 15

4 16

5 17

6 18

7 19

8 20

9 21

10 22

11 23

12 24

Figure 5–1 GPIB (IEEE-488) Interface

5.1.2 CHanging tHe gPiB Primary address

Each instrument serviced by the gPIb has its own Primary Address code, which enables the computer to obtain readings from the instrument. The factory default setting on the 6200 is 15.

Some PC interfaces can access from one to fifteen 4-bit primary addresses. other interfaces can access as many as thirty-one 5-bit primary addresses. The 6200 uses the 4-bit format.

1. Press the ShIFT button and release.

2. Press SETUP.

3. Press DoWN twice.

4. Press ShIFT twice.

5. Press or DoWN until you see the desired gPIb address.

6. Press ShIFT twice to exit.

5.2 CheCking the 6200-to-pC ConneCtion

Note: Make sure that the 6200 and its host computer are communicating before acquiring data.

1. Make sure the primary address is set correctly for the 6200.

2. Set the input variable to 15 characters (13 variable characters and the two required data terminationcharactersCRandLF.(See“Programming”inthischapter.)

3. Issueoutputdatacommand“OD”andread15charactersaccordingtotheinstructionsforyour gPIb interface.

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desired results: • Torque/speed data will be returned

Note: If the desired results did not occur, Please see Chapter 7 - Troubleshooting.

5.3 programming

Note: Check the manual provided with your software for full instructions.

1. Use the following information to answer the formatting questions asked when installing your gPIb software.

• AllGPIBdataacquisitionsystemsrequirestheuseofdataterminationcharacters.The6200 uses the gPIb standard termination characters “Carriage Return (CR)-Line Feed (LF).”Providetheminthatorder.

Codes for CR - LF

basiC hex deC

Cr = CHR$(13) 0D 13

lf = CHR$(10) 0A 10

2. Set the timeout for at least one second, if you are asked to set a communication fault delay timeout.

• Ifthecommunicationfaultdelaytimeoutistooshort,orifthecomputerresetstheinterface too quickly, the host instrument may stop responding.

5.4 6200 Command set

When entering a command code:

1. Type all characters in uppercase ASCII format.

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

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

Thecharacter#representsafloatingpointnumericalvaluefollowingthecommand.Leadingzeroes are not required.

5.4.1 Command set For 6200

Command Category

Command Code

function explanation

Communications H Sets high data acquisitionrate (120 samples per second)

The Controller/Readout outputs data at 120 S/s (Using an RS-232 interface, the rate is 60 S/s.)

Communications L Sets low data acquisition rate (3.8 samples per second)

The Controller/Readout outputs data at 3.8 S/s (default rate).

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Command Category

Command Code


Communications OA Prompts to return to auxiliary input data string

“Output Auxiliary” prompt to return the value at the AUX INPUT x AUX SCALING factor.

Communications OD Prompts to return speedtorque-direction data string

“Output Data” prompt to return data string with this format:

SxxxxxTxxxxxRcrlf or SxxxxxTxxxxxLcrlf

R or L is the shaft direction indicator, as viewed looking at the dynamometer shaft, where:

R = right; clockwise (CW)L = left; counterclockwise (CCW)

The speed will equal the displayed value and the torque will be in the same units as displayed on the front panel.

Setup M1 Enables front panel controls

Use this command to enable front panel control of most functions.

Setup M0 Locks out front panelcontrols

Use this command to lock out the front panel controls, so that the Controller/Readout settings can be changed only by using the computer with either the GPIB (IEEE-488) or the RS-232 interface.note: The brake ON/OFF switch on the front panel still functions.

Setup R Resets as follows:• Manual control ON• Low data acquisition rate• Brake OFF

Use this command to cancel any previous commands.note: These settings are the power-on default settings.

Setup UA# Sets auxiliary input scaling to #

This command sets the scaling factor for the auxiliary input to # units/volt. The range is 0.0 to 10000.0. Programmed value # is not saved atpower down.

Setup UE# Sets encoder pulse count to #

This command selects the pulse count option for speed transducing. The pulse count defaults to 60-bit if out of range. The standard encoder supplied with all Magtrol Load Cell Dynamometers is 60 pulses/revolution. Optional 600 and 6000 pulse encoders are available for low-speed applications.Codes for pulse count # are:0 = 60-bit1 = 600-bit2 = 6000-bitProgrammed value # is not saved at power down.

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Command Category

Command Code


Setup UI# Sets dynamometer torque units to #

note: For Hp and watts calculations to be correct, the correct dynamometer torque units must be specified. Values for # are:0 = oz.in. 5 = kg.cm.1 = oz.ft. 6 = N.mm.2 = lb.in. 7 = N.cm.3 = lb.ft. 8 = N.m.4 = g.cm.Torque units default to 0 (oz.in.) if out of range. Programmed value # is not saved at power down.

Setup UR# Sets readout torque units to #

This command sets the torque unit conversion for the torque readout.Values for # are:0 = oz.in. 5 = kg.cm.1 = oz.ft. 6 = N.mm.2 = lb.in. 7 = N.cm.3 = lb.ft. 8 = N.m.4 = g.cm.Torque unit conversion defaults to 0 (oz.in.) if out of range. Programmed value # is not saved at power down.

Misc. X Prompts to return % current output

This command returns the % current value in the format “I##.##”. The value will be between 0 (no loading) and 99.99 (full loading).

Misc. I# Sets current output to #

The power supply outputs a fixed value of current. Use any value # between 0 and 99.99%. (99.99% = 1 Amp.)

5.5 aCQuiring speed-torQue data

Speed-torquedataisafixed-lengthstringinASCIIformatwithafloatingpointdecimal.Usethefollowing string format:

SdddddTdddd.R[cr][lf]

or

SdddddTdddd.L[cr][lf]

where . . .

S = speed in RPM. No leading zeroes are used.

d = decimal digit 0 through 9

T = torque in units selected during setup. The torque value always contains a decimal point.

L = counterclockwise dynamometer shaft rotation (left)

R = clockwise dynamometer shaft rotation (right)

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. = decimal point. The decimal point location depends on the specific dynamometer and torque range in use.

Note: The [cr} and [lf] characters will not display.

example:

If a motor is running at 1725 RPM clockwise, with the dynamometer loading the motor to 22.6 oz.in., the 6200 will return:

S 1725T22.60R

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

5.6 seleCting the baud rate for the rs-232 interfaCe

The 6200 communicates with the host computer through a Db-9 interface connector. The connector pin-out is:

2-Rx, 3-Tx, 4-DTR, 5-gND. No other pins are connected.

1 2 3 4 5

6 7 8 9

RXTX

DTRGND

Figure 5–2 Connector Pin-Out

The 6200 is equipped with an RS-232 (serial) interface. To select the baud rate:

1. Press ShIFT and release.

2. Press SETUP button.

3. Press DoWN twice.

4. Press ShIFT three times.

5. Press the UP or DoWN buttons to cycle through the following available baud rates:

300 2400 9600

600 4800 19200

1200

6. Press ShIFT to Exit

other important communication parameters are:

•NoParity

•8DataBits

•1StopBit

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To wire your own serial communications cable, use the following wiring diagram:

A cable may also be purchased from your local electronics store. A Radio Shack #26-152 cable and #26-264 null modem adapter are known to work. The null modem adapter must be used on the computer end of the cable.

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6. Calibration

6.1 Closed-box Calibration

The 6200 features closed-box calibration. The advantage of closed-box calibration is that the user does not have to disassemble the case or make mechanical adjustments. however, the calibration of the Accessory Torque output must be done internally with offset and gain trim pots.

The Torque readout and Auxiliary Input can be calibrated using external reference sources. Correction factors for offset and gain are stored in nonvolatile memory. They remain in effect until the user or the calibration house updates them.

The front panel displays the actual values for the zERo and gAIN correction factors. Record these values before calibration. In the unlikely event of a Controller/Readout failure, it can re-initialized by pressing and holding the SToRE and RECALL buttons while turning the power on. All internal memory and setups will be lost. After re-initializing, reprogram the gAIN and zERo values into memory.

6.2 Calibration sChedule

Calibrate the 6200:

• Afteranyrepairsareperformed.

• Atleastonceayear;morefrequentlytoensurerequiredaccuracy.

6.3 basiC Calibration proCess

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

1. Initial Calibration Procedure

2. Torque offset and gain

3. Speed Verification

4. Accessory Torque output offset and gain

5. Auxiliary Input offset and gain

Items needed for calibrating the 6200:

• Externalvoltagereferenceof0to5voltsDC

• Digitalmultimeter(DMM)

• Functiongeneratorwithsquarewave,TTLoutput

both instruments should have a VDC accuracy of 0.05% or better.

6.3.1 initial CaliBration ProCedure

Note: Record the actual correction factors displayed before proceeding with calibration.

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1. Allow the 6200 to stabilize in an environment with:

• Anambienttemperatureof18°Cto25°C.

• Relativehumiditylessthan80%.

2. Turn on the 6200.

3. Allow the 6200 to warm up for at least 30 minutes.

4. Enable the calibration mode as follows:

a. Turn instrument power oFF.

b. Press in and hold the UP and DoWN buttons simultaneously.

c. Turn instrument power oN.

d. Continue pressing the UP and DoWN buttons until the display shows the software revision date then release.

e. Press the ShIFT button once.

Note: To exit CALIbRATE mode without making any changes, press the ShIFT button 6 times.

6.3.2 torque oFFset and gain

1. Connect the external voltage reference common to Pin 13 and Pin 4 of the dynamometer input connector.

2. Connect the external voltage reference high to Pin 14 of the dynamometer input connector.

3. Apply +2.000 VDC.

4. Press the DISPLAY button.

5. Adjust the gain by turning the Decrease/Increase Dial until the displayed voltage equals the reference voltage.

Note: The magnitude of change per revolution can be increased by pressing the UP button or decreased by pressing the DoWN button.

6. Apply 0.000 VDC.


8. Adjust the Decrease/Increase Dial until the display indicates 0 mVDC.

9. Repeat steps 3 through 8 to complete this procedure.

10. Press ShIFT.

11. Record the T-zERo correction factor for future reference.

12. Press ShIFT.

13. Record the T-gAIN correction factor for future reference.

14. Speed Verification:

a. Connect the function generator output to Pin 10 of the dynamometer input connector.

b. Connect the function generator common to Pin 8 of the dynamometer input connector.

c. Apply a square wave, TTL signal of 1000 hz.

d. Verify the 6200 Speed readout displays 1000 +/- 0.01% of applied frequency.

e. Apply several additional frequencies (10 khz, 50 khz) and verify the Speed readout displays the applied frequency +/- 0.01%.

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6.3.3 aCCessory torque oFFset and gain

1. Connect the DMM common to Pin 4 of the Accessory Torque-Speed output connector.

2. Connect the DMM high to Pin 2 of the Accessory Torque-Speed output connector

3. Apply 0.000 VDC

4. Adjust R24 (oFFSET) on the circuit board for 0 mVDC on the DMM.


6. Adjust R25 (gAIN) on the circuit board for +2.000 VDC on the DMM.

6.3.4 auxiliary inPut oFFset and gain

1. Press ShIFT button once. Display indicates AUx INPUT calibration as follows:

2. Connect the external voltage reference to the Auxiliary Input bNC connector.


4. Press DISPLAY button.



6. Apply 0.000 VDC.

7. Press UNITS DISPLAY button.

8. Adjust the Decrease/Increase Dial until the display indicates 0 mVDC.

9. Repeat steps 3 through 8 to complete this procedure.

10. Press ShIFT.

11. Record the A_zERo correction factor for future reference.

12. Press ShIFT.

13. Record the A_gAIN correction factor for future reference.

14. Press the ShIFT button once to return to default display.

6.4 alternate Calibration proCedure

The 6200 can also be calibrated by using a certified dynamometer, calibration beam, and weight instead of an external voltage reference.

Note: Magtrol suggests you do NoT use this method. by using the alternate calibration procedure, you are calibrating the 6200 to a specific dynamometer, not to a reference standard. If you connect the 6200 to a different dynamometer, the resulting torque reading may be incorrect.

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1. Connect the chosen dynamometer to the 6200 using the 14-pin signal cable and the 2-pin brake cable.

2. Attach the calibration beam to the dynamometer shaft.

3. Enter the calibration mode.

4. Press the bRAkE oN/oFF button oN to apply full loading to the dynamometer.

5. hang the weight on the calibration beam pin and level the beam as illustrated in the following

diagr

Torque = Weight (W) × Distance (D)

Weight (W) = Torque / Distance (D)

d

W

CW CCW

t t

Figure 6–1 Alternative Calibration

6. Press the DISPLAY button.



8. Remove the weight for zERo adjustment.


10. Adjust the Increase/Decrease Dial until the display indicates 0 mVDC.

Note: The mV output of the dynamometer will be equivalent to the Weight times Distance on the calibration beam, disregarding any decimal point.

example Magtrol’s hD-400-6 Dynamometer has a full-scale torque of 40.0 oz·in. The distance

from the center of the dynamometer shaft to the pin on the calibration beam is 5 inches. Placing an 8 oz. weight on the pin will produce a torque of 40.0 oz·in. The mV output of the dynamometer will be equivalent to 8 oz. multiplied by 5 inches, yielding an output signal of 400 mV.

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11. Repeat steps 5 through 10.

12. After completing calibration, press bRAkE oN/oFF button oFF to remove loading from the dynamometer.

13. Remove the calibration beam from the dynamometer shaft.

14. Proceed with desired motor testing.

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7. Troubleshooting

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

problem reason solutionMechanical power reads much higher or lower than expected.

Torque units are incorrect. Set torque input units to match the specifications on dynamometer nameplate.

No GPIB communication. Setup error and/or hardware fault.

Check:• GPIB address of Controller.• GPIB cable - should be functioning and attached to Controller and computer interface card.

No RS-232 communication.

Setup error and/or hardware fault.

Check:• Baud rate of Controller.• Pinout of serial cable.• Cable attachment to Controller and serial interface port of computer.

Dynamometer shaft does not turn smoothly when BRAKE is OFF.

Salient poles were set up on the rotor by having brake current applied with no shaft rotation.

Start the motor and bring up to speed. Press BRAKE button ON. Adjust output current up to a value at least 25% of the maximum torque rating of the dynamometer in use (if possible). Reduce output current to 0.

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Appendix A: LabVIEW Programming Examples

Magtrol offers a comprehensive motor testing software program to satisfy most of your programming needs. To order your software, call Magtrol Sales at 1-716-668-5555.

a.1 simple read

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a.2 Current stabilized

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Appendix B: Front Panel/Display Menu Flow Charts

Thefollowingflowchartsareareferencefornavigatingthroughthekeysetupfunctionsofthe6200OpenLoopDynamometer Controller. For step-by-step setup instructions, refer to the corresponding chapters in this manual.

b.1 setup menu

I/O:

CONTRAST: 0 - 3

GPIBADDRESS: 0 - 15

RS-232BAUD:

300

600

1200

2400

4800

9600

19200

AUX P/F: OFF

ON: HIGH LIMIT: 0 - 99999EXIT

LOW LIMIT: 0 - 99999

SPEED P/F: OFF

ON: HIGH LIMIT: 0 - 99999


TOR�UE P/F: OFF

ON: HIGH LIMIT: 0 - 99999


SETUP: PASS/FAIL:

S�STEM:

INPUTUNITS:

��

��

��

��

��

��

N��

N��

N��

60 ��

6000 ��

ENCODER: 600 ��

MAXPOWER:

0 - 99999

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b.2 poWer units menu

b.3 aux setup menu

Hp

W

AUX

POWER UNITS:

AUX SETUP: SCALE:0 - 10000

UNITS/VOLT

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b.4 torQue units menu

oz.in.

oz.ft.

lb.in.

lb.ft.

g.cm

kg.cm

N.mm

N.cm

N.m

TORQUEUNITS:

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Appendix C: Schematics

C.1 enCoder/sWitCh board

C.2 poWer supply

(ROTARY ENCODER)

SPKR1

(PB0)(PB1)(PB2)(PB3)(PB4)(PB5)(PB6)(PB7)(PB8)(PB9)

(PB10)(AUDIO)

(+ 5V)(GND)

J11234567891011121314

R7R6R5R4R3R2R1 R8 R9 R10 R11

C1

22K 22K 22K 22K 22K 22K 22K 22K 22K 22K 22K

SW10

SW9SW8

SW7SW6

SW5SW4

SW3SW2

SW1

AB

BR1

BR2

BR3

PD05

PD05

PE05

C194700

C254700

C230.1

C220.1

C210.1

C181000

C171000

C230.1

C21.0

C201

C240.1

U1LM340T5

IN OUTCOM

U8LM320T5

IN OUTCOM

COM

+25V

+35V

-25V

L3

1uH

L2

1uH

L1

1uH

+5VD +5VA

-5VA

d

R21

R22

5.1K

5.1K

R233.3K

14A-56-28

14A-30-515

1

3

4

6

7

9

10

12

1

3

4

6

12

11

9

7

8

TX1

TX2

J112345

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C.3 dsp & memoryu

12

u1

0u

11

u7

i/o

3i/

o2

i/o

4a

5

13

14

i/o

0i/

o1

10

9 11

4 3

a2

5a

3a

4

8a

0a

167

a1

0

a7

at

28C

16e

-20s

CC

e

i/o

7a

8a

9

oe

We

i/o

5a

6i/

o6

16

15

17

21

19

18

202 1

23

22

r2

02

2k

r4

32

2k

u2

0a

37

4h

C0

01 2

u1

9

y2

y3

13

12

15

14

3 6

y1

b g1

C

1a

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Magtrol Model 6200 Open Loop Dynamometer ControllerAppendix C: Schematics

AP

PE

ND

ICE

S

C.4 analog i/o

35

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]

subsidiaries in:Germany • France

China • IndiaWorldwide Network

of Sales Agents

Documents

MODEL 6200 as a stand-alone unit. Includes information on setting power and torque units, torque and speed control and open loop control. Chapter 5: CoMPUTER CoNTRoLLED oPERATIoN -