Dyn-Loc IV Quick Start Guide
Contents
1. a safe speed Be sure that stable speed control of the DUT is achieved After the DUT and dynamometer are rotating and a speed value is displayed on the Dyn Loc IV proceed to Section 9 Enabling the Dyn Loc IV Controller Dyn Loc IV Quick Start Guide V1 0 Fed O Copyright Dyne Systems Inc i 9 ENABLING THE DYN LOC IV CONTROLLER Before enabling the controller for the first time set the over speed trip by using the thumb wheel switches on the back of the Dyn Loc IV Based on DUT performance specifications select an appropriate over speed value Note that the over speed setting is in x100 rpm increments IF STARTING IN TORQUE MODE 1 Press the TORQUE push button this will put the Dyn Loc IV in Torque Control Mode Set the desired Linear Acceleration LAC also known as ramp rate into the active lever wheels Press the LAC SET button to set the Linear Acceleration display units per second value NOTE LAC should be set to match application requirements Set both front lever wheels to different desired torque setpoint values Press the DYNE ON button Observe the Dyn Loc IV should control to the active torque setpoint Ensure accurate and stable control response Press the non illuminated ACTIVE button Observe the Dyn Loc IV should control to the newly active torque setpoint Ensure accurate and stable control response When done press the DYNE OFF button next to the lever wheel switch to unload the devi2. DSUB Connector Male for 4QUAD AMP 205206 9 2 25 Pin DSUB Connector Male for DTC AMP 5205208 1 3 37 Pin DSUB Connector Male for REMOTE AMP 205210 8 4 Male Crimp Pin for DSUB Connector AMP 205089 1 5 Female Crimp Pin for DSUB Connector AMP 205090 1 6 Metalized Plastic Shell for 15 Pin DSUB Connector 3M 3357 6515 1C 7 Metalized Plastic Shell for 25 Pin DSUB Connector 3M 3357 6525 1C 8 Metalized Plastic Shell for 37 Pin DSUB Connector 3M 3357 6537 1C 9 7 Pin Male RPM AMPH MS3106A 16S 1P 10 7 Pin Strain Relief AMPH 97 3057 1008 1 11 6 Pin Male LOAD CELL AMPH MS3106A 14S 06P 12 6 Pin Strain Relief AMPH 97 3057 1007 1 13 9 Pin DSUB Connector Female for Serial Port AMP 205203 1 14 Metalized Plastic Shell for 9 Pin DSUB Connector 3M 3357 6509 1C Dyn Loc IV Quick Start Guide O Copyright Dyne Systems Inc
3. Dyn Loc IV Quick Start Guide V1 0 o Single Ended Encoder Wiring If the system uses an Encoder refer to the table below the Dyn Loc IV User Manual and supplied drawings for wiring details Complete the sensor wiring as indicated Encoder Single Ended Output Belden 9534 Item 2 in Cable table Pin Wire Function G Red Encoder Excitation 12 VDC Black Encoder Excitation Common Shield Not connected on the sensor end D Green Direction Optional Green Channel B Optional White Channel A NOTE Never apply power to the Dyn Loc IV during sensor wiring The cable shield must be connected on the Dyn Loc IV end only leave shields unconnected at the transducer end to avoid ground loop signal problems Single ended encoders require additional hardware adjustments 3 Using the DIP switches listed below select the type of speed feedback input source you are using The following DIP switches are located on the DS501 circuit board bottom center board inside the Dyn Loc IV Setting OFF ON OFF OFF OFF Two wire magnetic pickup ON OFF OFF OFF OFF Encoder pickup non direction sensitive ON OFF ON OFF OFF Encoder pickup with direction bit output Encoder pickup with direction ON OFF OFF ON OFF derived from B channel encoder signal Encoder pickup with direction derived from two channel encoder signal but inverts the direction ON OFF OFF OFF ON Energi
4. Fr Inc Midwest amp Dynamatic Dynamometers TORQUE fon DyneSystemsCo e e e e DYN LOC IV x el MASTER TER RPM TORQUE a Lock 0000 co Za ar 2 Dyn Loc IV QUICK START GUIDE www dynesystems com Phone 1 800 657 0726 Dyn Loc IV Quick Start Guide For Eddy Current Dynamometers This Quick Start Guide helps to get the Dyn Loc IV dynamometer controller configured and running quickly Other Quick Start Guides are available for specific AC dynamometer drive combinations While this Guide helps to get started quickly it is not a substitute for The Dyn Loc IV User Manual Refer to the manual for details not specifically covered in this guide The manual can be found on our web site www dynesystems com NOTE This quick Start Guide applies to units with serial number greater than 748 only Assure that the following required material is on hand before beginning Dyn Loc IV User Manual Various types of multi conductor shielded cable for transducer connections see table at the end of this document Mating MS Series connectors see table at the end of this document Use of this guide requires that the dynamometer be connected to a Device Under Test DUT The DUT must be capable of rotating under the control of a speed control or throttle position control NOTE If the DUT is not operational energizing the eddy current dynamometer is NOT recommended The DUT must be fully operational to carry out the Quick
5. Start Guides process in its entirety However connecting and testing of the speed and torque transducers may be carried out without a functional DUT reference sections 3 and 4 of this quick start guide This guide outlines steps needed to bring the Dyn Loc IV to operational status as quickly as possible Execute these steps exactly in the order presented Safety Review Dyn Loc IV Power Connections Speed Transducer Connection amp Configuration Torque Transducer Connection amp Configuration Dyn Loc IV Eddy Current Power Amplifier Connections Water Safeties Interlock Field Current Adjustments Enabling the DUT Enabling the Dyn Loc IV Controller oO On oar onN ae Inc Midwest amp Dynamatic Dynamometers Controls Dynamometers System Integration and Test Cell Automation Dyne Systems Inc W209 N17391 Industrial Drive Jackson Wisconsin 53037 phone 800 657 0726 _website www dynesystems com Dyn Loc IV Quick Start Guide V1 0 1 O Copyright Dyne Systems Inc i 1 SAFETY REVIEW Installing and operating this equipment involves hazards relating to rotating equipment and dangerous electrical voltages To avoid the possibility of serious or fatal injury only qualified persons familiar with industrial electrical power systems should install power wiring Review all safety considerations in the manual before executing any steps in this guide or making any adjustments to the Dyn Loc IV It is recommended that a licen
6. ce under test IF STARTING IN SPEED MODE 1 Dyn Loc IV Quick Start Guide O Copyright Dyne Systems Inc Press the RPM push button this will put the Dyn Loc IV in Speed Control Mode Set the desired Linear Acceleration LAC also known as ramp rate into the active lever wheels Press the LAC SET button to set the Linear Acceleration display units per second value NOTE LAC should be set to match application requirements Set both front lever wheels to different desired speed setpoint values The active setpoint value must match idle base speed of the DUT The inactive setpoint value must be just under the idle base speed of the DUT Press the DYNE ON button Observe the Dyn Loc IV should control to the active speed setpoint This should result in little speed variation and minimal torque application Press the non illuminated ACTIVE button Observe the Dyn Loc IV should control to the newly active speed setpoint Ensure accurate and stable control response When done press the DYNE OFF button next to the lever wheel switch to unload the device under test V1 0 REFERENCE CONNECTORS AND RELATED PARTS CABLE Item Description Manufacturer P N 1 Multi conductor cable 1 twisted pair 22 AWG shielded Belden 8761 2 Multi conductor cable 4 conductors 24 AWG shielded Belden 9534 CONNECTOR COMPONENTS Item Description Manufacturer P N 1 15 Pin
7. d in Section 5 if the dynamometer nameplate calls for more than 16 Amps field current or the field transformer is greater than 277VAC an external ECPAU must be used Exceeding these limitations will damage the Dyn Loc IV Ensure Dyn Loc IV is powered down 2 Determine the appropriate current measurement location for the application a Clamp on a current meter capable of measuring DC current around one of the dynamometer field wires b Voltage measurement from test points TP7 to TP8 on the DS256 board In standard applications 0 01 volts across the resistor is equivalent to 1 amp of field current TP7 and TP8 is equivalent to the voltage across the gold power resistor found on the heat sink 3 Turn the CFB potentiometer fully clockwise 1 2 Amps minimum field current will result 4 Determine the specified field current rating on nameplate for the dynamometer Where applicable use the hot amps lesser value Apply power to the Dyn Loc IV Assure the dynamometer is at a standstill Press the TORQUE push button Set the active lever wheel switches to 9000 Press the DYNE ON push button NOTE If the H20 interlocks are made the control should latch DYNE ON If the DYNE ON lamp drops out check the H20 Interlock If the under speed trip has not been disabled the Dyn Loc should trip after about one second This will cause the OS US RESET push button to light and a high braking condition current limit on the field You wi
8. er strip and are labeled as H20 and I L Safety devices such as pressure flow and temperature dry contacts must be connected in series When adequate coolant pressure and flow is supplied to the dynamometer all these contacts should be closed Without closed water safeties the Dyn Loc IV will not maintain a DYNE ON condition NOTE Only use dry contacts which are contacts not connected to any other circuits or power sources Dyn Loc IV Quick Start Guide V1 0 Copyright Dyne Systems Inc 7 FIELD CURRENT ADJUSTMENTS DYNAMOMETER CURRENT SETTING Dyn Loc IV Quick Start Guide O Copyright Dyne Systems Inc The current limit adjustment is made using the CFB Current Feedback potentiometer on the DS256 circuit board location Dyn Loc IV left side panel This adjustment allows adaptation to a wide range of dynamometer field specifications provides protection for the dynamometer coil and can influence stability of the dynamometer s control NOTE The fuses located on the rear panel of the Dyn Loc IV must be sized to protect the dynamometer coil The minimum fuse size allowed is 2 0A The fuse chosen should provide adequate over current and short circuit protection and be sized based on the field coil current rating on the dynamometer s nameplate The voltage rating of the fuse must exceed the voltage used on the secondary of the field transformer Use the following procedure for eddy current dynamometers only As mentione
9. imal place must be used to match the displayed decimal point location 5 Ensure that the dynamometer and sensor mounting are free of any external forces that could interfere with torque readings Energize both the control and field transformers Calibrate the torque transducer as follows Dyn Loc IV Quick Start Guide Copyright Dyne Systems Inc a Attach the calibration arm to the dynamometer and attach the weight hanger Press and release the AUTO ZERO button on the Dyn Loc IV This will zero the torque display Hang the calibration weights Calculate the calibration torque reading by multiplying the check arm length from the dynamometer nameplate with the amount of weight applied Torque ft lbs Check Arm ft x Weight lbs Configure the active lever wheel for the calculated calibration torque and press the Auto Span button to calibrate Remove the calibration weights Ensure the torque display returns to zero If yes proceed to step g if no return to step b Remove weight hanger and calibration arm Press and release the AUTO ZERO button on the Dyn Loc IV Ensure the torque display value returns to zero if not return to step R Refer to the HELP number descriptions in the Dyn Loc IV User Manual Chapter 9 for HELP XXXX messages appearing on the display during the calibration process When the eddy current dynamometer is absorbing and the system is rotating with positive s
10. ll have one minute to adjust the CFB potentiometer If it times out repress the DYNE ON button o On on 10 Turn CFB potentiometer counter clockwise until you achieve the dynamometer rated field current Do not exceed the field rating 11 Push DYNE OFF push button and OS US RESET push button simultaneously Leave the meter connected for the next test V1 0 ADJUSTING THE FAULT CURRENT The fault current is the current that will be applied to the field if an E stop over speed or under speed occurs The fault current needs to be adjusted for the application adjust the fault current as follows 1 Press the RPM push button to place the controller in RPM mode 2 Press E Stop button NOTE You will have one minute to adjust the Fault Brake pot found on the DS501 board This is the center board found in the bottom of the Dyn Loc The DYNE ON times out after one minute If adjustments are incomplete press the DYNE ON button again Press the E Stop reset button Press DYNE OFF push button and OS US RESET push button simultaneously 8 ENABLING THE DEVIGE UNDER TEST DUT An eddy current dynamometer is an energy absorbing device that is not capable of driving a system The eddy current dynamometer is driven by the DUT typically either an engine or an electric motor Follow these steps in the order presented NOTE Speed control of the DUT is required for the below process Enable the DUT speed control and rotate the system to
11. peed values the torque readings should also be positive If not a wiring error may exist If so swap wires on pins B and C of the 6 pin M S torque connector 8 Refer to the calibration section of the Dyn Loc IV User Manual for additional calibration information NOTE In line torque sensors can be calibrated either with calibration arms and weights or by performing a shunt calibration Refer to Chapter 4 of the Dyne Loc IV User Manual 9 EDDY CURRENT POWER AMPLIFIER CONNECTIONS The internal Eddy Current Power Amplifier ECPAU must be connected to the dynamometer coil F1 F2 and the external field transformer L1 L2 See Section 2 Dyn Loc IV Power Connections The water safeties of the dynamometer must also be wired to the H20 and IL terminals on the barrier strip NOTE The ECPAU internal to the Dyn Loc IV is rated for 277VAC maximum and 16AMPS maximum If dynamometer coil specifications exceed these values an external ECPAU is required contact Dyne Systems for additional information 6 WATER SAFETY INTERLOCK Water safety interlocks on the Dyn Loc IV are critical in detecting a dynamometer coolant loss condition Loss of coolant while the dynamometer is being loaded will result in overheating and likely cause severe damage to the dynamometer The water safeties interlock can be found on the barrier strip on the back of the Dyn Loc IV The water safeties interlock connections are located on the left end of the barri
12. sed electrician perform all power connections exceeding 50 Volts 2 DYN LOG IV POWER CONNECTIONS Follow the below steps to connect and supply power to the Dyn Loc IV Dyn Loc IV Quick Start Guide O Copyright Dyne Systems Inc Ensure all incoming power is de energized prior to proceeding Place the Dyn Loc IV controller in a rack or on a suitable surface NOTE The Dyn Loc IV is a rack mountable unit Rack mounting is recommended due to exposed connections on the Dyn Loc IV barrier strip Connect the control transformer secondary typically 120 VAC power wires to terminals L3 and L4 on the barrier strip found on the back of the controller NOTE If the control transformer secondary supplies 230 VAC to L3 and L4 then the 115V 230V switch inside the Dyn Loc IV must be set for 230VAC This switch is located in the back left corner of the bottom circuit board Connect the field transformer secondary typically 240 VAC 277VAC maximum power wires to terminals L1 and L2 on the barrier strip found on the back of the controller NOTE Incoming power to both the control and field transformer primary windings must be fed from the same phase pair Damage may result from improper phasing Energize both the control and field transformers The RPM MASTER EM STOP RESET push buttons digital LED display and ACTIVE button on the front of the controller will illuminate De energize both the control and field transformers If the pu
13. sh buttons and digital LED display illuminate as expected proceed to the next step If not reference the Dyn Loc IV user manual or contact Dyne Systems before proceeding V1 0 3 SPEED TRANSDUCER CONNECTION amp CONFIGURATION Refer to the manual Chapter 8 Section 3 for details on wiring and Chapter 4 Sections 3 and 4 and Chapter 5 Section 11 4 for configuring a speed transducer All speed transducers are terminated at the RPM F B connector located on the back of the Dyn Loc IV A mating 7 pin MS connector is required and can be constructed using items 9 and 10 listed in the Connector Components table at the end of this guide Follow these steps in the order presented 1 Ensure all incoming power is de energized prior to proceeding 2 Determine the type of speed transducer to be used Two types of speed transducers are supported Magnetic Pickup Units MAGPU s and Single Ended encoders A complete list of pin assignments on the RPM F B connector is shown in the Dyn Loc IV User Manual Chapter 8 Magnetic Pickup Unit Wiring If the system uses a Magnetic Pickup refer to the table below the Dyn Loc IV User Manual and supplied drawings for wiring details Complete the sensor wiring as indicated Magnetic Pickup O Belden 8761 Item 1 in Cable table Pin Wire Function A Clear MAGPU B Black MAGPU C Shield Not connected on the sensor end O Copyright Dyne Systems Inc
14. the Dyne Loc IV User manual and supplied drawings for wiring details Complete the sensor wiring as appropriate Belden 9534 Item 2 in Cable table Pin Wire Function A Red Excitation 10 VDC Black Excitation Common Shield Excitation Common Green Input Signal White Input Signal DS105 PC board solder jumpers JP2 installed JP1 not installed In Line Torque Sensor Belden 8761 Item 1 in Cable table Pin Wire Function B Clear Torque Sensor Input Both C and D Black Torque Sensor Input Common D Shield DS105 PC board solder jumpers JP1 installed JP2 not installed Never apply power to the Dyn Loc IV during sensor wiring The cable shield must be connected on the Dyn Loc IV end only leave shields unconnected at the transducer end to avoid ground loop signal problems Additional hardware may be required for In Line torque sensor applications 4 The torque display decimal point location is set from the Dyn Loc IV front panel Access the DIP switches by removing the torque display bezel Set switches 4 and 5 as shown on the table below Torque Display Decimal Place TQ display Switch 5 TQ display Switch 4 TQ Display OFF OFF 00000 OFF ON 0000 0 ON OFF 000 00 ON ON 00 000 NOTE The power display decimal point location matches the torque display decimal point When configuring lever wheel set points torque an implied dec
15. ze both the control and field transformers Test speed transducer by rotating the system by hand if possible A speed reading should appear on the RPM display NOTE If a magnetic pickup is used a minimum speed as a few hundred rpm may be as high required before a RPM reading is displayed Dyn Loc IV Quick Start Guide V1 0 Copyright Dyne Systems Inc 4 TORQUE TRANSDUCER CONNECTION amp CONFIGURATION Refer to the Dyn Loc IV User Manual Chapter 8 Section 2 for details on wiring and Chapter 4 Sections 5 9 for configuring a torque transducer All torque transducers are terminated at the LOAD CELL connector located on the back of the Dyn Loc IV A mating 6 pin MS connector is required and can be constructed using items 11 and 12 liste d in the Connector Components table at the end of this document Follow these steps in the order presented Dyn Loc IV Quick Start Guide O Copyright Dyne Systems Inc Ensure all incoming power is de energized prior to proceeding Determine the type of torque transducer to be used Two types of torque transducers are supported Load Cell and Inline Sensor A complete list of pin assignments on the LOAD CELL connector is shown in the Dyn Loc IV User Manual Chapter 8 Section 2 NOTE Some sensors labeled Inline Torque Sensors should be wired and configured as a Load Cell Contact Dyne Systems for assistance with this configuration Refer to the following tables
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