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WB and PB Series User`s Manual

1. 1660 480 3000 ib H t 4 2 PB 115 TORQUE 2 HM HB 1 PB 115 TORQUE 4 100 1 2 Pd gt 5 XN 4 2 Q n Lr 1 Kd COR 10 que en EK D af o FC lt T 4 4 Pot 2 1 0 01 1 10 100 1000 10 000 Rotation Speed rpm Figure 2 15 115 Ratings Curve 2390 rpm 7500 rpm 1000 1000 ae 100 Qe i 100 5 RE P E oe 4 aN ous gt ANG Ov e 27 5 225 es g on oO 2 gt we ORANA 27 5 ee ANS 4 of 10 Q 2 sca 10 4 K teri yes At Ou 5 Ne N Ov Xe E P SM 94 nie PM 4 o 1 e e Oua 10 100 1000 10 000 Rotation Speed rpm Figure 2 16 WB 15 Ratings Curve 56 Magtrol WB PB Dynamometers Chapter 2 Installation Mounting
2. 4WB 2 7 8 POWER 1000 1000 278k Pod POWER t 098 5 o 22 D e f 5 swe s e LOS oe 100 4 92 272127 100 T 2 an ot 3 m f e 2 4 KS 5 9 Sf 2 z A Pd ok E RAS E 10 Ve 1 10 100 1000 10 000 100 000 Rotation Speed rpm Figure 2 8 WB 2 7 Ratings Curve 52 Magtrol WB PB Dynamometers Chapter 2 Installation Mounting 320 rpm 3000 rpm i 4 PB 2 7 8 TORQUE 1l 2 PB 2 7 8 TORQUE 1000 1000 1 PB 2 7 8 TORQUE 2 bd 5 5 3 Ost 4 5 9 L Stl love 4 Dou 5 PM Ne Wye 9 41 atl DL 100 Ost 100 x e Q NS e e oon S8 gt 2 1 e a E 2 4 10 10 10 100 100
3. 382 rom 2000 rpm 10 000 100 S Sp I deel deta 4 PB 15 TORQUE Le Let 1000 get et a a 10 2 PB 15 TORQUE n Sd MEPA 1 PB 15 TORQUE e ler Te 5 Pi g g a et o 4 a e 5 l 100 yt tt 4 st 27 5 Ne SS g 99 4 O1 Vet ref 27 We Qo O at Ri 5 PM 4 a 10 0 1 10 10 100 1000 10 000 Rotation Speed rpm Figure 2 17 PB 15 Ratings Curve 57 3 Cooling 3 1 3 1 1 3 1 2 DYNAMOMETER COOLING Proper cooling of the dynamometer is essential to ensure a long operating life and accurate measuring results All Magtrol WB PB Series Dynamometers are water cooled to guaranty the best possible heat dissipation 557 Note PB 2 7 Series Dynamometers are available with a cooling circuit K or without a cooling circuit CONNECTIONS WARNING THE COOLING TUBES MUST HAVE AN INSIDE DIAMETER IN ACCORDANCE WITH THE INDICATIONS ON THE CORRESPONDING DYNAMOMETER DATA SHEETS SEE SECTION 1 2 THEY MUST BE FITTED TO THE DYNAMOMETER USING A METAL RING ALSO CHECK FOR CORRECT WATER FLOW DIRECTION The cooling water input is marked COOLING WATER INLET on the dynamometer housing The o
4. 59 32 EXAMPLE etre etn n etre e ED E On abad iius 59 3 3 CLOSED CIRCUIT COOLING SYSTEMS caecos ceteri nice Xo tL no ace 60 331 EXAMPLE ener dera dra ene qut iniusto etim sang teat ntt diues n Rd ais 60 34 COOLING WATER JISS UBS rhet ies E e EO Oen reo EE equ B teet E NU ee teet ner be tees 61 341 61 342 JHARDNESSs die a patet edt qeu ie uv d e e vt 61 BAS BUEPERING iuge Log aper tr ERE rara dere ec p UO ES 62 344 CONTROLLING THE WATER FLOW CI REPE 62 345 WATER INHIBITORS reo ete e tente ee rh sep eR tee EE ere eU E Uk Ue 62 346 CONDENSATION 63 3 3 COOLING CIRCUL PURGING 2o gt tte te t e PO pe PH PO HE RR COR OPEP 63 Table of Contents Magtrol WB PB Dynamometers 4 CONNECTIONS CONFIGURATION sssssssssssssssssssssssssssssesssstsssssessssssssstesssneessstesssneessaeassanesssnenssess 64 4 1 CONNECTION TO MAGTROL MOTOR TESTING ELECTRONICS essssseeeeeeeeeee nnne eene nnne 64 4 1 1 MANU
5. Pump with water level regulation Water Tank Figure 3 2 Closed circuit Cooling Example 60 Magtrol WB PB Dynamometers Chapter 3 Cooling 3 4 COOLING WATER ISSUES Despite the fact that water is necessary for cooling it represents a risk Rust corrosion erosion and scale deposits have a negative effect on the functioning of the dynamometer 3 4 1 IMPURITIES As a matter of fact running water may contain dust mud calcium or magnesium carbonates calcium or magnesium sulfates silicates iron carbons sulfides or algae and other fungi If the cooling water is not analyzed and treated scale may become deposited on the inside surface of the tubing reducing the heat transfer and the water flow rate A 0 5 mm thick scale deposit reduces the cooling system tubing diameter by 30 A 1 mm thick scale deposit reduces the heat transfer by about 10 which in turn increases the dynamometer temperature The higher water temperature increases the speed of scale depositing Also the warmer the water the faster the corrosion and erosion A water temperature increase of 10 C 50 F multiplies the corrosion effect by a factor of two or even four 3 4 2 HARDNESS The following table indicates the water hardness in German degrees dH The total hardness is defined as the sum of the temporary and the permanent hardness The temporary hardness can be r
6. 3 COOLING Figure 3 1 Open circuit Cooling Example SEES SOSS Figure 3 2 Closed circuit Cooling Example 4 CONNECTIONS CONFIGURATION Tigure d Manual Test CONIGULAL ON isse re estie tecta RED D Ded 64 Figure 4 2 PC Based Test Configuration with M TEST Software eee NEE AE EEE EEEE OVNER 65 Figure 4 3 Tandem Configuration ease so ete ae i e a deor S UE NE SOS EE DH OR ER RE EE 66 Figure 4 4 Supply Cable Between 24 V DC Transformer and DES Power Supply 67 Figure 4 5 Control Signal Cable for WB PB 2 7 and 43 Tandem Dynamometer Clutches Figure 4 6 Control Signal Cable for WB PB 65 115 and 15 Tandem Dynamometer Clutches 2 67 Figure 4 7 Connector Pin Configuration for WB PB 2 7 Dynamometer Power esent 69 Figure 4 8 Connector Pin Configuration for WB PB 43 Dynamometer Power and Temperature Measurement 69 Figure 4 9 Connector Pin Configuration for WB PB 65 115 and 15 Dynamometer Power and Temperature Measurement 69 Figure 4 10 Connector Pin Configuration for WB PB 2 7 43 Dynamometer Torque Signals Figure 4 11 Connector Pin Configuration for WB PB 65 115 and 15 Dynamometer Torque Signals Figure 4 12 Con
7. 1 9 of n 93 t 0 1 100 1000 10 000 100 000 Rotation Speed rpm Figure 2 12 WB 65 Ratings Curve 54 Magtrol WB PB Dynamometers Chapter 2 Installation Mounting 570 rpm 3000 rpm 100 10 10 1 c 2 o 5 5 5 o a 1 0 1 m n 5 a 8 0 1 0 01 10 100 1000 10 000 Rotation Speed rpm Figure 2 13 PB 65 Ratings Curve 2865 rpm 18 000 rpm 100 100 od gt AV Q 5 a we 10 i 10 se Fid 27 le gt xt 5 pan PAN Fd RY e 4 i 9 4 QW 74 1 WV ewe Ne Q 4 Ne a N veto 5 s E 4 P A uw 2 0 1 0 1 100 1000 10 000 100 000 Rotation Speed rpm Figure 2 14 WB 115 Ratings Curve 55 Chapter 2 Installation Mounting Magtrol WB PB Dynamometers
8. o qp rmn Figure 2 2 WB PB 43 Load Cell Locking System 43 Chapter 2 Installation Mounting Magtrol WB PB Dynamometers 2 1 3 WB PB 65 Series WB PB 65 Series Dynamometers are fitted with a mechanical stator assembly locking device protecting the load cell during transport After installing the dynamometer on the test bench proceed as follows and refer to figure 2 3 to unlock the system 1 Loosen the two nuts 2 Unscrew the two screws with three turns 3 Tighten the two nuts IESE Note The screws and nuts for overload protection are adjusted at the factory refer to Chapter 6 Calibration for possible adjustments Figure 2 3 WB PB 65 Load Cell Locking System 44 Magtrol WB PB Dynamometers Chapter 2 Installation Mounting 2 1 4 WB PB 115 Series WB PB 115 Series Dynamometers are fitted with a mechanical stator assembly locking device protecting the load cell during transport After installing the dynamometer on the test bench proceed as follows and refer to figure 2 4 to unlock the system 1 Loosen the two nuts 2 Unscrew the two screws with three turns 3 Tighten the two nuts eS Note The screws and nuts for overload protection and are adjusted in the factory refer to Chapter 6
9. 73 6 1 2 CALIBRATION WEIGHT 74 6 2 CALIBRATION WITH MAGTROL MOTOR TESTING ELECTRONICS esee 75 6 3 CALIBRATION USING NON MAGTROL ELECTRONIC CONTROL UNITS 75 64 CALIBRATION OP 75 6 4 1 WBIPBASSSBRIBS oro event extera td aen Rt 76 642 WB PB 65 SERIES Eve PETERE 77 6 4 3 WB PB TIS SSBRIBS 5 adea 78 7 MAINTENANCE AND REPAIR sssssssssssssssssssssscsssssssssesssssesssssesssuessssesssseesssneessstesssneessseessstessanesssess 79 IE INAS ND 79 2 REPAIR C 79 7 3 SENDING EQUIPMENT MAGTROL FOR 22 2 79 SERVICE INFORMATION ccsssssssssssssssssssessssssssssessssesssseesssseessscssssseessscsssssesssseesssteessatessstesssseessneessaenses 80 RETURNING MAGTROL EQUIPMENT FOR REPAIR AND OR cete 80 RETURNING EQUIPMENT TO MAGTROL INC UNITED 5 21 80 RETURNING EQUIPMENT MAGTROL SA 80 Magtrol WB PB Dynamometers Table of Contents TABLE OF FIGURE
10. PetedTorque pragToraue Nominal input inertia Rated Rated Fxcitation N m Ib ft kg m Ib ft s kW rpm rpm A 2 WB 65 1 PB 65 25 18 4 0 7 6 19 3 19 x 103 2 35 x 103 12 5730 18 000 5 2WB 65 EK 2 PB 65 50 36 8 1 2 10 62 3 98 103 2 93x103 12 5730 18 000 5 Voltage at 20 C is 30 volts Optical Speed Sensor Cooling Water Consumption Each 65 Series Tandem Dynamometer has an optical speed For all Tandem models 30 l KWh at At 30 Metric sensor with a 60 bit pulse wheel delivered as standard 8 gal kWh at At 86 F US TANDEM TORQUE SPEED POWER CURVES The diagram below shows the characteristic curves for the 65 Series Tandem Dynamometers 570 rpm 5730 rpm 18 000 rpm 100 100 2WB 65 2 651 TORQUE 2WB65 EK 1 PB 65 TORQUE 9 10 21 10 o g 235 7 a 0 o MT 5 No lt We MPO 4 amp 2 55 N 4 v 1 100 1000 10 000 100 000 Rotation Speed rpm 22 Magtrol WB PB Dynamometers Chapter 1 Introduction Tandem Specifications
11. TORQUE SPEED 2 dimensions are in Metric units Dimensions converted to English units have been rounded to 2 decimal places Model units B D E F H J K L M mm 138 98 56 O 815 36 20 190 210 0 64 10 10 543 3864 2209 0 3148 142 079 748 8270 0252 0 39 0 39 162 122 800 5 24 20 1901 20 0 64 10 10 MET 6 38 48 3152 03148 0 0 79 748 8270 0252 0 39 0 39 210 170 1280 885 m 20 190 2100 64 10 10 0 79 7 48 827 0 0252 0 39 0 39 Model units R 5 T V z FF KK Weight mm 80 101 45 90 01 131 220 76 81 160 10 5 3 8kg 3 15 394 177 35471 516 866 0 299 272 063 0 0413 8 38 lb 80 100 45 90 01 131 220 76 69 1610 105 46kg 3 15 394 177 25201 516 8 66 0 299 319 0630 0 413 10 14 80 100 45 01 131 220 76 45 16 9 105 6 2kg DEBA S 3 15 3 94 177 22 516 866 0 299 272 063 0 0413 13670 Chapter 1 Introduction Magtrol WB PB Dynamometers Ordering Information DYNAMOMETER OPTIONS Vertical Mounting V Vertical Mounting is available on the Eddy Current WB Dynamometer only The vertical version has an adapted bearing fitting and its maximum speed is limited Mechanical Rotor Blocking Device MB
12. 2 WB 2 7 8 K 0 30 0 30 3 WB 2 7 8 K 0 45 0 45 4 WB 2 7 8 0 60 0 60 1 PB 2 7 8 0 60 0 60 2 PB 2 7 8 1 20 1 20 4 PB 2 7 8 2 40 2 40 1 WB 43 0 6 1 5 2 43 1 2 3 1 PB 43 2 5 2 PB 43 4 10 1 WB 65 2 10 2 WB 65 4 20 1 65 5 25 2 65 10 50 1 WB 115 10 50 2 115 20 100 20 100 2PB115 40 200 1 WB 15 28 140 2 WB 15 56 280 3 WB 15 84 420 4 WB 15 112 560 60 300 2 15 120 600 4PB15 240 1200 Note A calibration weight adapted specifically for the dynamometer can be ordered directly from Magtrol 74 Magtrol WB PB Dynamometers Chapter 6 Calibration 6 2 CALIBRATION WITH MAGTROL MOTOR TESTING ELECTRONICS When standard Magtrol motor testing electronics are used in the test bench Magtrol DSP Controller and TSC Torque Speed Conditioner the calibration procedure as described in the TSC 401 Instruction Manual should be followed Refer to Section 3 Calibration for dynamometer calibration IESE Note The User s Manuals for all Magtrol products can be accessed downloaded from Magtrol s web site www magtrol com 6 3 CALIBRATION USING NON MAGTROL ELECTRONIC CONTROL UNITS When a Magtrol TSC Torque Speed Conditioner and DSP Controller are not used in the test bench the calibration must be carried out by using the following procedure 1 Mount the calibration arms 2 Adjust the zero 0 on the electronic control unit The dynamometer
13. 0 4754 0 91 0 98 7 87 22 05 23 62 0 43 0 79 1 38 7 09 9 84 1 18 2901 1216 23 25 2501 6101 65010 11 20 35 1801 250 30 0 4754 0 91 0 98 7 87 24 02 25 59 0 43 0 79 1 38 7 09 9 84 1 18 Model units R 5 V X Y AA BB CC DD GG Weight mm 140 0 03 213 524 4h9 15 80 61 240 12 52 43 200 55 ZWB A9 HEK ATEB SIIT 5 513 20 63 0 15741 0 59 3 15 2 40 9 45 0 47 2 05 1 69 7 87 121 25 Ib 5511 0 1563 140 0 03 213 5241 15 61 290 12 52 43 250 65kg 2 WB 43 EK 2 PB 43 PERS in 211 8 39 20 63 0 59 315 2 40 11 42 0 47 2 05 1 69 9 84 143 29 Ib 15 Chapter 1 Introduction Magtrol WB PB Dynamometers Ordering Information DYNAMOMETER OPTIONS High Speed HS WB PB 43 Mechanical Rotor Blocking Device MB For testing small miniature high speed motors Magtrol offers a WB 43 Eddy Current Dynamometer with speed ranges up to 65 000 rpm Industrial Version IS Single WB and PB Dynamometers are also available in an industrial version which includes bearing supports but does not provide a base plate or torque and speed measurement Vertical Mounting V Vertical Mounting is available on the Eddy Current WB Dynamometer only The vertical version has an adapted bearing fitting and its maximum speed is limited Speed Pickup
14. 1 QW 97 e 1 ya ue Q t z S Pi e v Ri Iu 4 0 1 0 1 100 1000 10 000 100 000 Rotation Speed rpm 19 Chapter 1 Introduction Magtrol WB PB Dynamometers Specifications PB 65 POWDER DYNAMOMETER OPERATING PRINCIPLES The PB Powder Dynamometers contain as their name suggests a magnetic powder The electrical current passing through the coil generates a magnetic field which changes the property of the powder thus producing a smooth braking PB DYNAMOMETER RATINGS torque through friction between rotor and stator The Powder Dynamometers PB produce their rated torque at zero speed The element to be tested can be loaded at standstill to determine the starting torque Drag Torque Rated Rated Max Excitation Model Rated Torque De energized Nominalinpul Inertia Power Speed Speed Current N m lb ft N m Ib in kg m Ib ft s kW rpm rpm A 1 PB 65 25 18 4 0 5 4 42 0 92 103 6 78x 10 1 5 570 3000 2 5 2 PB 65 50 36 8 1 0 8 85 1 71 x 103 1 26 x 103 3 570 3000 5 Voltage at 20 C is 30 volts Optical Speed Sensor Cooling Water Consumption Each 65 Series PB Dynamometer has an optical speed sensor For all PB models 30 1 kWh at A 2 30 Metric with a 60 bit pulse wheel delivered as standard For better speed resolution
15. 100 Speed Limit for PB 100 Rotation Speed rpm 1000 0 1 10 000 Power kW 36 Magtrol WB PB Dynamometers Chapter 1 Introduction Specifications SINGLE DYNAMOMETER DIMENSIONS WB PB 15 je A gt removable calibration arm Use outer groove x 510 mm for N m to achieve 500 mm for oe ion in Nm when using Tapping for gu weight kg Center hole calibration arm 3 4 DIN 332 D M16 D Oy 9 DET e TT Xe ge ae 4 ee Prou R p ir E x Q boa Vul N H Er P 65 J gt i Cooling water connection 22 mm 0 87 in NOTE Original dimensions are in Metric units Dimensions converted to English units have been rounded up to 2 decimal places Model unts A D EI F GH JI Kk mm 544 370 1500 4206 53 68 490 590 6500 15 30 75 250 400 1WB15 1PB15 5 91 Meee 2 09 2 68 19 29 23 23 25 59 0 59 1 18 2 95 9 84 15 75
16. TANDEM DIMENSIONS DRIVE SIDE Electromagnetic tooth clutch EK gt WB 65 65 h i D 510 mm for N m 500 mm for mkp 4 Use outer groove to achieve calibration in N m when using weight in kg removable calibration arm WB PB 65 TXOTATION TORQUE SPEED OF Reference surface EE N H P gt Cooling water connection 10 mm 0 39 NOTE Original dimensions are in Metric units Dimensions converted to English units have been rounded up to 2 decimal places Model units A D F G H J K L M N P R 5 370 18h6 36 330 5901 69009 13 50 20 340 380 235 0 02 325 2WB65 EK 1PB65 0 7086 9 260 14 57 0 7083 1 42 12 99 23 23 27 17 0 51 1 97 0 79 13 39 14 96 9 244 12 80 mm 3700 1806 36 330 660 7600 13 50 20 340 380 235 0 02 325 2 WB 65 EK 2 PB 65 Q 0 7086 9 260 14 57 0 7083 1 42 12 99 25 98 29 92 0 511 1 97 0 79 13 39 14 96 9 244 12 80 Model units V X Y AA BB CC DD EE GG QQ Weight mm 1034 6h9 23 105 135 3001 201 60 20155 011 260 15 135 kg 2WB65 EK 1PB65 0 2362 6 106 40 71 0 2351 0 91 4 13 5 311 11 81 0 79 2 36
17. 0 01 mm may be tolerated With magnetic powder dynamometers PB operating at lower maximum speeds a misalignment of up to 0 1 mm is acceptable VIBRATIONS INDUCED BY THE TEST BENCH Vibrations generate premature wear of the bearings Since modifying the motor under test in order to prevent any vibration is not feasible measures will have to be taken to forestall any damage to the dynamometer In order to evaluate motors producing vibrations for instance combustion engines the motors must be mounted on a heavyweight base plate equipped with vibration mounts By doing this the vibrations transmitted from the motor to the dynamometer will be reduced considerably Height differences due to varying motor loading must be taken into account The vibration mounts should not be compressed creating a misalignment between the motor and the dynamometer This would affect the measurement results and damage the dynamometer CAUTION OPERATING AT THE RESONANCE FREQUENCY OF THE MEASURING CHAIN WILL SEVERELY DAMAGE THE DYNAMOMETER 47 Chapter 2 Installation Mounting Magtrol WB PB Dynamometers 2 3 ee COUPLINGS The dynamometer couplings used with the motor under test is an important factor to take into consideration In fact a coupling which is not correctly specified for the application will lead to measuring errors and premature wear of the dynamometer Given the fact that the dynamometer is a precision measuring device hig
18. Bremse in German Wirbelstrom Eddy current bremse brake Eddy currents are circular currents induced in conductors crossing a magnetic field These currents generate electromagnetic forces acting against the movement of the rotor In the WB Eddy current Dynamometer the moving part is a toothed cylindrical rotor The magnetic field is created by coils powered by a DC current source The magnetic flux flows through the rotor teeth not the air gap creating magnetized and non magnetized areas within the stator During rotation the rotor teeth generate Eddy currents in the stator which create a braking force The kinetic heat generated in this process is absorbed by the stator cooling circuit The braking torque depends upon the rotational speed and increases with increasing speed At a standstill the torque is zero To be able to measure a starting torque with this dynamometer it is necessary to block both the stator and the rotor In this case the dynamometer ceases to rotate and the tested motor s torque is integrally transmitted to the dynamometer measuring cell MAGNETIC POWDER DYNAMOMETERS PB Magtrol magnetic powder dynamometers carry the designation of PB which stands for Pulverbremse in German Pulver powder In the PB Magnetic Powder Dynamometer the magnetic field generated by a DC current passing through the coils magnetizes the ferromagnetic powder This powder is located in the gap between the toothed rotor and
19. MAGTROL WB and PB Series Eddy Current and Magnetic Powder Dynamonmeters User s Manual 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 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 COPYRIGHT Copyright 2005 2015 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 Ist Edition rev F September 2015 MAGTROL Safety Precautions dle WARNING ORDER MINIMIZE RISKS IS OF UTMOST IMPORTANCE TO RESPECT THE CURRENT SAFETY STANDARDS WHEN PLANNING CONFIGURING AND OPERATING THE MOTOR TEST SYSTEM Make sure that all Magtrol dynamometers and electronic products are earth grounded to ensure p
20. Place 200 of the calibration weight on the arm on the connector side Adjust the screw so that the display indicates 150 of the nominal torque Tighten the nut Move the 100 calibration weight onto the opposite arm Loosen the nut and adjust the screw to decrease the torque slightly Place 200 of the calibration weight on the arm 10 Adjust the screw so that the display indicates 150 of the nominal torque 11 Tighten the nut 12 Remove the calibration weight and arms 77 Chapter 6 Calibration Magtrol WB PB Dynamometers 6 4 3 WB PB 115 Series Figure 6 4 WB PB 115 Overload Protection Calibration Mount the calibration arms See Section 6 1 1 Calibration Arms Place 100 of the calibration weight on the arm on the connector side Loosen the nut G and adjust the screw to decrease the torque slightly Place 200 of the calibration weight on the arm on the connector side Adjust the screw so that the display indicates 150 of the nominal torque Tighten the nut Move the 100 calibration weight onto the opposite arm Loosen the nut and adjust the screw to decrease the torque slightly ROOM Place 200 of the calibration weight on the arm 10 Adjust the screw so tha
21. September 2015 TABLE OF REVISIONS xe Edition Cmm Diagram torque power for Tandem WB 115 updated Table of Contents 1 INTRODUCTION e 1 11 0 eot to Ehren per oo pr Per ped 1 1 2 DATA SHEBLS 4 ec pe ee BUSINESS MIL 2 1 2 1 WBIPB 2 7 SERIES ss 2 12222 WBIPB AS SERIES oh OR ERE Pret HERE E Cette PITE etu 9 12 3 WB PE 65 SERIES piiriin ure oce cie c D OD HH GIOI e rica fb EE LM FER p E EIS 17 124 115 SERIES entente Rd vete ete aen vb eb er nete 25 123 WB PB ROAST 33 2 INSTALLATION MOUNTING i aiicusikas saxina rk aun asE ck ku tax zn EE RUE DX EE ax MADE REIN cR IE LEE MEE au UE EE 41 2 1 LOCKING THE DYNAMOMETER FOR TRANSPORT iti eiit rte tertie be EH 41 21 WBIPEB 2 7 SERIES ae ede nop ne ate eve tie ote een tot 42 2 12 WB PB43 SERIES occ neo RORIS etit ster 43 2453 WBIPB 6 SERIES earum Hr Hd pire n eben Hp rer ER 44 2 14 WBIPB HS SERIES iie ren on aset ates here ttn 45 2 13 WB PB 15 id 46 2 2 MOUNTING THE DYNAMOMETER TO THE TEST 2 47
22. Calibration for possible adjustments 2 9 2 im 64 Oye _ j Figure 2 4 WB PB 115 Load Cell Locking System 45 Chapter 2 Installation Mounting Magtrol WB PB Dynamometers 2 1 5 WB PB 15 Series WB PB 15 Series Dynamometers are fitted with a mechanical stator assembly locking device protecting the load cell during transport After installing the dynamometer on the test bench proceed as follows and refer to figure 2 5 to unlock the system 1 Screw the nuts on each side of the dynamometer with three turns 2 Unscrew the nuts on each side of the dynamometer until they touch the nuts A minimum clearance of 0 4 mm between the nuts and the dynamometer locking device is requested IESE Note The WB PB 15 Series Dynamometers are not fitted with overload protection systems The load cell is strong enough to cope with any overload occurring during normal dynamometer use Figure 2 5 WB PB 15 Load Cell L
23. ORDERING INFORMATION If one of the listed options is desired please follow the dynamometer model see table above with a dash and then the appropriate suffix as noted in parenthesis For example a Model 1 PB 15 Powder Dynamometer with an optional 6000 bit speed pickup is a 1 PB 15 DG 6000 Example 1 PB 15 DG 6000 Mechanical Rotor Blocking Device MB A mechanical rotor blocking device which allows locked rotor Dynamometer Model Option testing is available for the WB Dynamometer SYSTEM OPTIONS AND ACCESSORIES DESCRIPTION MODEL PART a High Speed Programmable Dynamometer Controller DSP7000 2 Torque Speed Conditioner includes necessary cables TSC 401 121 Power Supply includes necessary cables DES 411 121 High Speed Single Phase Power Analyzer 6510e High Speed Three Phase Power Analyzer 6530 M TEST 7 Motor Testing Software M TEST 7 5 Temperature Testing Hardware HW TTEST Dynamometer Table for with grooved table top 1 amp 2 WB PB 15 Series Dynamometers 005476 Water Cooling Kit for DES 411 121 Power Supply for 2 3 and 4 WB or 2 and 4 PB 15 234 311 900 01 1 D Transformer 24 VDC for electromagnetic clutch of tandem dynamometers 234 31 1 920 01 1 Couplings Thermostatic Sluice Pressure Sensitive Switch On Request Water Cooling System for Brake On Request Calibration Weights On Request 40 2 Installation Mounting 2 1
24. The dynamometer lifespan before overhauling may vary from a few months to a few decades depending on the application but equally depending on the way it has been mounted By mounting the dynamometer as described in the following sections the operating life as well as the measuring precision of the unit may be increased considerably LOCKING THE DYNAMOMETER FOR TRANSPORT Dynamometers are equipped with a load cell for measuring the torque generated by the tested system on the brake The load measuring cell is a precision instrument which must be protected from shocks during transport in order to guaranty the measurement repeatability Therefore all Magtrol WB PB Dynamometers are fitted with a locking system in order to protect the load cell during transport The dynamometer can only be used after removing that model s specific locking device The unlocking procedure is described for each dynamometer model in sections 2 1 1 though 2 1 5 ee Note All dynamometers except the WB PB 2 7 Series have to be mounted on the test bench prior to the removal of the load cell protection device This prevents damage to the load cell transducer during dynamometer installation CAUTION TO PREVENT DAMAGE TO THE LOAD CELL THE DYNAMOMETER MUST BE LOCKED BEFORE MOVING OR SHIPPING 41 Chapter 2 Installation Mounting Magtrol WB PB Dynamometers 2 1 1 WB PB 2 7 Series Before mounting any WB PB 2 7 Series Dynamometer to the test bench
25. as their braking torque is proportional to their speed they cannot be used at low speeds The PB Series Dynamometers feature magnetic powder brakes and are therefore appropriate for low and medium speed testing Due to their design they generate their maximum torque at standstill However their maximum speed is limited to avoid the magnetic powder being centrifuged To combine the advantages of both designs Magtrol offers a tandem mounting of both dynamometer types for applications requiring measurements on a wide range of speeds Chapter 1 Introduction Magtrol WB PB Dynamometers 1 2 5 5 1 2 1 WB PB 2 7 SERIES WB PB 2 7 Series Eddy Current FEATURES e 9 Models with Maximum Torque from 300 mN m to 2400 mN m 42 7 to 340 oz in e Braking Power 20 W to 1 kW e Stable Braking Torque without Shock e Low Moment of Inertia e Low Residual Torque Operation in Either Rotational Direction e Braking Torque Measurement Included e Optional Speed Measurement e Rated Torque Available From Zero Speed Powder Dynamometers Integrated Optical Speed Sensor DESCRIPTION Eddy Current Brake Dynamometers WB series are ideal for applications requiring high speeds and also when operating in the middle to high power range Eddy Current Brakes provide increasing torque as the speed increases reaching peak torque at rated speed The dynamometers have low inertia as a result of small rotor diame
26. condensation generates rust on the internal components which rapidly reduces the operating life of the dynamometer COOLING CIRCUIT PURGING Prior to storing the dynamometer for a long period of time the water remaining in the cooling circuit must be blown out with preferably lubricated compressed air 63 4 Connections Configuration 4 1 CONNECTION TO MAGTROL MOTOR TESTING ELECTRONICS The connection and configuration of the Magtrol DES Power Supply TSC Torque Speed Conditioner and DSP Dynamometer Controller are described in the corresponding User s Manuals for each unit These manuals can be found on Magtrol s User Manual CD ROM delivered with your dynamometer and can also be accessed at Magtrol s Web site www magtrol com Refer to these documents for additional information on connecting the WB PB Series Dynamometer to Magtrol motor testing electronics MaANuAL TEsT CONFIGURATION Ina manual test configuration all test parameters must be manually entered into the DSP Dynamometer Controller Data acquisition is then carried out manually Eddy Current WB OR Powder Brake PB Dynamometer TSC 401 Torque Speed Conditioner DES Power Supply Figure 4 1 Manual Test Configuration 64 Magtrol WB PB Dynamometers Chapter 4 Connections Configuration 4 1 2 Ee PC BASED TEST CONFIGURATION For enhanced motor testing capabilities and full data acquisition Magtrol offers a complete
27. 0 59 5 00 2 36 6 295 15 35 582 02 Ib 31 Chapter 1 Introduction Magtrol WB PB Dynamometers Ordering Information DYNAMOMETER OPTIONS Industrial Version IS Single WB and PB Dynamometers are also available in an industrial version which includes bearing supports but does not provide a base plate or torque and speed measurement Vertical Mounting V Vertical Mounting is available on the Eddy Current WB Dynamometer only The vertical version has an adapted bearing fitting and its maximum speed is limited Speed Pickup DG All models including tandems are equipped with a 60 bit optical speed sensor On PB Dynamometers a 600 bit or 6000 bit speed pickup encoder is available as an option for WB PB 115 DYNAMOMETER MODELS Brake 1 Powder Tandem 1 WB 115 1 115 2 WB 115 EK 1 PB 115 2 WB 115 2 115 2 WB 115 2 PB 115 2 WB 115 2 WB 115 ORDERING INFORMATION If one of the listed options is desired please follow the dynamometer model see table above with a dash and then the appropriate suffix as noted in parenthesis For example a Model 1 PB 115 Powder Dynamometer with an optional 600 bit speed pickup is a 1 PB 115 DG 600 1 PB 115 DG 600 Example low speed applications Dynamometer Model Option Mechanical Rotor Blocking Device MB A me
28. 0 79 6 098 10 24 0 59 297 62 Ib mm 1034 6 91 23 105 135 370 201 60 20 155 01 330 15 150 kg 2 WB 65 EK 2 PB 65 0 2362 6 106 40 71 0 2351 0 91 4 13 5 31 14 57 0 79 2 36 0 79 6 098 12 99 0 59 330 69 Ib 23 Chapter 1 Introduction Magtrol WB PB Dynamometers Ordering Information DYNAMOMETER OPTIONS High Speed HS WB PB 65 Mechanical Rotor Blocking Device MB For testing small miniature high speed motors Magtrol offers a WB 65 Eddy Current Dynamometer with speed ranges up to 50 000 rpm Industrial Version IS A mechanical rotor blocking device which allows locked rotor testing is available for the WB Dynamometer DYNAMOMETER MODELS Single WB and PB Dynamometers are also available in an industrial version which includes bearing supports but does not provide a base plate or torque and speed measurement Vertical Mounting V Vertical Mounting is available on the Eddy Current WB Dynamometer only The vertical version has an adapted bearing fitting and its maximum speed is limited Speed Pickup DG All models including tandems are equipped with a 60 bit optical speed sensor On PB Dynamometers a 600 bit or 6000 bit speed pickup encoder is available as an option for Eddy Current Powder Tandem 1 WB 65 1 PB 65 2 WB 65 EK 1 PB 65 2 WB 65 2 PB 65 2 WB 65 EK 2 PB 65
29. 1574 in 7 95 0 98 4 919 7 80 20 63 5 71 0 1563 0 59 3 15 1 81 6 57 68 34 Ib Shaft of high speed version HS is 20 h6 mm smooth no key with different length Drawing on request or available at www magtrol support salesdrawings htm 13 Chapter 1 Introduction Magtrol WB PB Dynamometers TANDEM OPERATING PRINCIPLES Because the characteristics of the WB and PB dynamometers An electromagnetic clutch is needed for this application are complementary Magtrol is able to offer them mounted which automatically switches off at the maximum speed of in a tandem setup Each dynamometer WB and PB can the PB Powder Dynamometer and automatically switches on autonomously operate according to its own characteristics at zero speed TANDEM DYNAMOMETER RATINGS Drag Torque Rated Rated Max Excitation Model Rated Torque De energized Nominal Input Inertia Power Speed Speed Current N m oz in kg m Ib ft s kW rpm rpm A 2WB 43 EK 1 PB 43 5 3 6 0 13 18 4 4 82 10 3 56 x 10 3 9550 25 000 2 2 WB 43 EK 2 PB 43 10 7 3 0 23 32 5 5 81 x 1041 4 28 x 104 3 9550 25 000 2 Voltage at 20 C is 24 volts Optical Speed Sensor Cooling Water Consumption Each 43 Series Tandem Dynamometer has an optical speed For all Tandem models 30 l KWh at At 30 Metric sensor with a 30 bit pulse
30. 2 24 ALIGNING THE DYNAMOMETERS ON THE TEST 47 222 NIBRATIONS INDUCED BY THE TEST BENCH etos ad ee ae 47 23 c ANEAN TE EEA ERARE evel EEN S ESETE ETE 48 2A MEASURING RANGE EE PER I E E EE E A EE E E 49 2 5 DRAG TORQUE wee pct rre ente i n C D HELD SRE AE EEA IE ED LITE o ia E ob ret 49 2 6 TOLERATED RADIAL AND AXIAL FORCES trn ce ice b eee 49 27 CONNECTING THE COOLING SYSTEM ent reae eg SIDE Deed inb 50 2 9 PROTECTIVE SYSTEMS au 50 2 9 POWER HEAT DISSIPATION rhe ett er rrr to her E Hebe e ERR 52 2 TOTORQUE SPEED POWER CURVES D rre IPLE eds 52 cEMeeB lcm 58 3 DL DYNAMOMETER COO DING xy hene rer e iet be de type eue epo v edet 58 311 CONNECTIONS HD pe rrr Rr OLG 58 3 1 4 WATER FLOW AND PRESSURE D HI e S HE Ec 58 313 COOLING WATER etri steep hne ete eripe enero due tuna eta eee ub tuas ege 58 314 TEMPERATURE SENSOR Ue DOR DRE OEC dide E 58 3 2 OPEN CIRCUDT COOLING SYSTEMS
31. 20 87 787 15362 23 15 9940 4206 68 655 521 15530 17 70 40 460 530 200 390 02 588 4WB15 EK 1PB15 2 2 68 25 79 20 51 61 14 0 67 2 76 1 57 18 11 20 87 7 87 2315 994 0 4206 68 655 521 17030 17 70 40 460 530 200 390 0 2 588 AWB 15 2 8 1S in 3913190 16531 25 79 20 51 67 05 0 0 67 2 76 1 57 18 11 20 87 787 15362 23 15 mm 9940 4206 68 655 590 20030 17 70 40 460 530 200 390 029 588 AWB 15 4 15 in 3901319 18531 268 25 79 23 23 78 86 O 0 67 2 76 1 57 18 11 20 87 787 15362 23 15 Model units T V X Y 00 GG HH JJ Weight 1030 12 48 225 125 544 14 260 117 270 0 1 4054 371 371 485 kg in 40 55 0 47 1 89 8 86 4 92 21 42 0 55 10 24 4 61 15 94 14 61 14 61 1069 24 Ib 1030 12 48 225 125 694 14 260 117 270 01 555 471 421 590 2WB 15 1 PB 15 2 15 2 15 1 55 0 47 1 89 8 86 4 92 27 32 0 55 10 24 4 61 21 85 18 54 16 57 1300 73 Ib 1030 48 225 125 994 14 2601 117 270 01 8551 521 5217 820 2 8 15 4 5 in 4055 0 47 1 89 8 86 4 92 30 13 0 56 10 24 4 61 1063 33 66 20 51 20 51 1807 79 Ib 1030 12 48 225 125 544 14 260 117 270 01 405 471 421 715 40 55 0 47 1 89 8 86 4 92121 42 0 55 10 24 4 61 1 15 94 18 54 16 57 1576 31 Ib 1030 12 48 225 125 694 14 260 117 270 01 5554 5211 521
32. 27 3 18 10 2 34 x 105 750 15 915 50 000 1 5 4 2 7 8 0 60 84 9 12 1 69 14 03 10 5 2 97 x 1075 1000 15 915 50 000 2 0 Voltage at 20 C is 15 volts Optical Speed Sensor Cooling Water Consumption Each 2 7 Series WB Dynamometer has an optical speed sensor For all WB models 30 I kWh at At 30 C Metric with a 30 bit pulse wheel delivered as standard 8 gal kWh at At 86 F US WB TORQUE SPEED POWER CURVES The diagram below shows the characteristic curves for the 2 7 Series Eddy Current Dynamometers 15 915 rpm 50 000 rpm 1000 1000 2 A E E 2025 gt A r1 X 5 91 Ay 2 s ge 4 DeC c amp 100 1 10 heat of i o Pee ss 3 or 2 2 BRN 2 2 d M o e e Vel oe 10 n 10 100 1000 10 000 100 000 Rotation Speed rpm Magtrol WB PB Dynamometers Chapter 1 Introduction Specifications POWDER DYNAMOMETER OPERATING PRINCIPLES The PB Powder Dynamometers contain as their name suggests a magnetic powder The electrical current passing through the coil generates a magnetic field which ch
33. 5 6 49 5 2 00x 10 1 47 x 1071 140 2390 7500 12 Voltage at 20 C is 45 volts Optical Speed Sensor Cooling Water Consumption Each 15 Series WB Dynamometer has an optical speed sensor For all WB models 30 1 kWh at At 30 C Metric with a 60 bit pulse wheel delivered as standard WB TORQUE SPEED POWER CURVES The diagram below shows the characteristic curves for the 15 Series Eddy Current Dynamometers Torque N m 8 gal kWh at At 86 F US Rotation Speed rpm 2390 rpm 7500 rpm 1000 1 1 0 m 1 a lt lt su 45 C We e 4 E 49 QU 4 552 ATTAT 5 o 4 e 47 a A jef ANI let nea 10 Nan ae 10 m lt S N Qe 1 X OR 5 lt 5 1 SN e woe J ae No 9 RK Xs d Ne D 2 oe af 8 uM 4 1 e e 1 10 100 1000 10 000 35 Chapter 1 Introduction Magtrol WB PB Dynamometers Specifications POWDER DYNAMOMETER OPERATING PRINCIPLES The PB Powder Dynamometers contain as their name suggests a magnetic powder The electrical current passing through the coil ge
34. 694 520 3000 4206 22 68 490 590 650 0 15 30 75 250 400 2WB15 2PB15 73220471181 2 tec 0 87 2 68 19 29 23 23 25 59 0 59 1 18 2 95 9 84 15 75 mm 844 670 4500 4206 78 68 840 940 10000 15 30 75 250 400 WB 1 3WB 13 in 33 23 26 38 17 72 3 07 2 68 33 07 37 01 39 37 0 59 1 18 2 95 9 84 15 75 994 820 60010 4206 3 68 840 940 1000 0 15 30 75 250 400 4WB 15 4 PB 15 in 39 13 32 28 23 62 1 0 12 2 68 33 07 37 01 39 37 0 59 1 18 2 95 9 84 15 75 Model units s u z 55 Weight mm 110 300 02 498 1030 0 395 12 48 220 35 265 80 75 37 185kg 1WB 15 1PB 1 zu 5 mn 433 19 61 40 55 0 15 55 0 47 1 89 8 66 1 38 10 43 3 15 2 95 1 46 407 86 0 mm 110 300 02 498 1030 0 395 12 48 220 35 190 75 37 290 2 15 2 1 at 5 m 433 19 61140 55 0 15 55 0 47 1 89 8 66 1 38 7 48 3 15 2 95 1 46 639 34 Ib mm 110 300 02 498 1030 0 395 12 48 220 35 290 75 37 385kg 3WB 15 11 819 in 488 11819 19 61140 55 0 15 55 0 47 1 89 8 66 1381142 3 15 2 95 1 46 848 78 Ib mm 110 300 02 498 1030 0 395 12 48 220 35 215 80 75 37 520 4 15 4 15 4 33 n 19 61 40 55 0 15 55 0 47 1 89 8 66 1 38 8 46 3 15 2 95 1 46 1146 40 Ib 37 Chapter 1 Introduction Magtrol WB PB Dynamometers TANDEM OPERATING PRINCIPLES Because the characteristic
35. 820 4WB 15 1 PB 15 4 15 2 15 17 55 0 47 1 89 8 86 4 92 27 32 0 55 10 24 4 61 TEE 21 85 20 51 20 51 1807 79 Ib 1030 12 48 225 125 994 14 260 117 270 01 855 590 683 1050kg 4WB 15 4PB 15 10 634 40 55 0 47 1 89 8 86 4 92 39 13 0 55 10 24 4 61 33 66 23 23 26 89 2314 85 Ib 10 626 39 Chapter 1 Introduction Magtrol WB PB Dynamometers Ordering Information DYNAMOMETER OPTIONS Industrial Version IS Single WB and PB Dynamometers are also available in an industrial version which includes bearing supports but does not provide a base plate or torque and speed measurement Vertical Mounting V Vertical Mounting is available on the Eddy Current WB Dynamometer only The vertical version has an adapted bearing fitting and its maximum speed is limited Speed Pickup DG All models including tandems are equipped with a 60 bit optical speed sensor On PB Dynamometers a 600 bit or 6000 bit speed pickup encoder is available as an option for low speed applications WB PB 15 DYNAMOMETER MODELS Eddy Current Powder Tandem 1 WB 15 1 15 2 WB 15 1 PB 15 2 WB 15 2 15 2 WB 15 2 PB 15 WB 15 4 15 2 WB 15 4 PB 15 4 WB 15 4 WB 15 1 PB 15 4 15 2 15 4 15 4 15
36. AGGRESSIVE AND LEADS TO CORROSION DUE TO A HIGH CONTENT OF FREE CARBON DIOXIDE FILTERING In order to avoid clogging of the cooling system due to sand mud rust or other substances the installation of a filter at the water inlet is recommended Solid substances conveyed by the cooling water should not exceed 250 microns As a rule the filter should remove approximately 98 of the substances above 250 microns of diameter CONTROLLING THE WATER FLow Rate An excessive deposit of minerals may be avoided by limiting consumption to the absolute minimum necessary for the dynamometer braking power dissipation This may be performed by installing a thermostatic valve on the water outlet and by adjusting it just below the cutoff temperature of the dynamometer safety thermostat approximate setting 50 C or 120 F This valve must constantly guaranty a flow rate in order to get enough water flowing to the dynamometer safety thermostat Water INHIBITORS In order to prevent scale from forming in closed circuit cooling circuit systems it is sometimes necessary to use water inhibitors which must be effective against rust corrosion and mineral deposits The use of strong alkaline substances or certain acids may be risky and dangerous during manipulations These substances can attack the different metals of the dynamometer and may even be toxic to the operator e Chromates should not be used as they cannot avoid mineral deposits and do not prote
37. Controller Figure 4 3 Tandem Configuration In tandem the unique features of each type of dynamometer brake are utilized allowing nominal braking torque to be applied to the unit under test from zero speed to maximum rotation Each dynamometer WB and PB can also autonomously operate according to its own characteristics Tandem Dynamometers are available on a number of PB WB combinations Refer to the corresponding data sheets in Section 1 2 for speed and torque ratings of each tandem configuration Note The parametrization of the tandem dynamometers is quite complicated In order to get the maximum torque and to be able to use the system at its fullest capacity complete Magtrol measuring chain as illustrated in Figure 4 3 is required ELECTROMAGNETIC CLUTCH To couple both dynamometers together in a tandem configuration a toothed electromagnetic clutch is required This clutch is delivered as standard with all Magtrol tandem dynamometers When the speed of the PB Dynamometer is at zero the electromagnetic clutch is engaged Conversely the clutch disengages when the PB Dynamometer has reached its maximum speed This function is automatic when a Magtrol DSP Controller is used See Note in Section 4 2 66 Magtrol WB PB Dynamometers Chapter 4 Connections Configuration 4 2 2 TRANSFORMER CONNECTION A transformer converts the power supplied by the DES into a 24 V DC current in order to energize the electro
38. Rotation Speed rpm 38 Magtrol WB PB Dynamometers Chapter 1 Introduction Tandem Specifications WB PB 15 TANDEM DIMENSIONS DRIVE SIDE Electromagnetic tooth clutch EK T removable calibration arm Use outer groove to achieve ii lt 510 mm for N m calibration in Nm 5 500 mm for when using WB 15 BEES gt PB 15 weight in kg 1 1 D Ai hoa priri prin baad 2 t Inlet Y DD M Es Cooling water connection 2 22 0 87 NOTE Original dimensions are in Metric units Dimensions converted to English units have been rounded up to 2 decimal places Model units D R 5 694 0 4206 68 355 371 12530 17 70 40 460 530 200 390 0 2 588 Dude Em LEADS laze 2 68 13 98 14 61 49 33 0 67 2 76 1 57 18 11 20 87 7 87 23 15 6940 4206 68 355 371 14030 17 70 40 460 530 200 390 029 588 2WBIS EK 2PB15 2732 9 2 68 13 98 14 61 55 24 0 67 2 76 1 57 18 11 20 87 7 87 23 15 69410 4206 68 355 521 17030 17 70 40 460 530 200 390 0 2 588 20 8 15 4 IST in 2739 0 18531 268 139812051 67 05 0 0867 2 76 1 57 18 11
39. Software is a state of the art motor testing program for Windows based data acquisition Used with a Magtrol DSP7000 Programmable Dynamometer Controller Magtrol M TEST 7 Software provides the control of any Magtrol Eddy Current or Powder Brake Dynamometer and runs test sequences in a manner best suited to the overall accuracy and efficiency of the Magtrol Motor Test System The data that is generated by Magtrol s Motor Testing Software can be stored displayed and printed in tabular or graphic formats and can be easily imported into a spreadsheet Written in LabVIEW M TEST 7 has the flexibility to test a majority of motor types in a variety of ways Because of LabVIEW s versatility obtaining data from other sources e g thermocouples controlling motor power and providing audio visual indicators is relatively easy Magtrol s M TEST 7 Software is ideal for simulating loads cycling the unit under test and motor ramping Because it is easy to gather data and duplicate tests the software is ideal for use in engineering labs Tests can be programmed to run on their own and saved for future use allowing for valuable time savings in production testing and incoming outgoing inspection Magtrol WB PB Dynamometers Chapter 1 Introduction System Configurations WB PB 2 7 SINGLE DYNAMOMETER CONFIGURATIONS The Dynamometers can be complemented by various electronic modules such as the DES 410 Power Supply TSC 401 Torque
40. Torque from 1 5 N m to 10 1 1 lb ft to 7 3 Ib ft e Braking Power 0 5 kW to 3 kW e Stable Braking Torque without Shock e Low Moment of Inertia e Low Residual Torque e Operation in Either Rotational Direction e Braking Torque Measurement Included e High Rotational Speed e Rated Torque Available From Zero Speed Powder Dynamometers e Integrated Optical Speed Sensor DESCRIPTION Eddy Current Brake Dynamometers WB series are ideal for applications requiring high speeds and also when operating in the middle to high power range Eddy Current Brakes provide increasing torque as the speed increases reaching peak torque at rated speed The dynamometers have low inertia as a result of small rotor diameter Brake cooling is provided by a water circulation system which passes inside the stator to dissipate heat generated by the braking power The water cooling in the WB provides high continuous power ratings max 3 kW Powder Brake Dynamometers PB series are ideal for applications operating in the low to middle speed range or when operating in the middle to high torque range Powder Brakes provide full torque at zero speed and are water cooled allowing for power ratings up to 1 kW Both WB and PB Dynamometers have accuracy ratings of 0 3 to 0 5 full scale depending on size and system configuration APPLICATIONS Mounted on test benches WB PB 43 Series Dynamometers allow performance and reliability testing on d
41. excitation must be stopped Note Unlike all other Magtrol WB PB Dynamometers the WB PB 2 7 Series Dynamometers are not fitted with a thermostat This function is defeated by a short between terminal 1 and 2 68 Magtrol WB PB Dynamometers Chapter 4 Connections Configuration 045350 Qu N C N C Supply Supply Figure 4 7 Connector Pin Configuration for WB PB 2 7 Dynamometer Power Am 05 50 Temperature A Temperature B Supply Supply B c Figure 4 8 Connector Pin Configuration for WB PB 43 Dynamometer Power and Temperature Measurement A Supply B Temperature B C Supply D Temperature A Figure 4 9 Connector Pin Configuration for WB PB 65 115 and 15 Dynamometer Power and Temperature Measurement 69 Chapter 4 Connections Configuration Magtrol WB PB Dynamometers 4 3 2 TORQUE SIGNAL CONNECTION The torque signal is supplied by a load cell fitted with a bridge strain gauge Signal N C Signal Supply N C Supply Figure 4 10 Connector Pin Configuration for WB PB 2 7 and 43 Dynamometer Torque Signals o gie eS Note The use of shielded cable is mandatory Connect cable shielding to the connector housing Signal Signal C Supply D Supply E Shield Figure 4 11 Connector Pin Configuration for WB PB 65 115 and 15 Dynamometer Torque Signals Note The use of shielded cable is mandatory Connect cable s
42. in low speed applications Magtrol offers a 600 bit or 6000 bit speed pickup encoder as an option 8 gal kWh at At 86 F US PB TORQUE SPEED POWER CURVES The diagram below shows the characteristic curves for the 65 Series Powder Dynamometers 100 10 Torque 0 1 10 570 rpm 3000 rpm 10 1 a o z o a 0 1 m 5 o o o 0 01 100 1000 10 000 Rotation Speed rpm 20 Magtrol WB PB Dynamometers Chapter 1 Introduction Specifications WB PB 65 SINGLE DYNAMOMETER DIMENSIONS T removable calibration arm 510 mm for N m Use outer roove to 500 mm 2chieve calibration I 00 gt N m when using weight in kg r Tapping for calibration arm Center hole DIN 332 D M5 D H gt J Reference surface Cooling water connection 10 mm 0 39 in NOTE Original dimensions are in Metric units Dimensions converted to English units have been rounded up to 2 decimal places Model units B D E F G H J K L M N 3001 225 11210 1816 22 36 2601 310 34210 111 17 17 2
43. mN m kg m Ib ft s kW rpm rpm rpm A 1WB 43 1 5 15 2 12 1 21 104 8 92 105 1 5 9550 50 000 65 000 1 2 WB 43 3 0 2 2 30 4 24 2 17 x 10 1 60 x 104 3 9550 50 000 65 000 2 Voltage at 20 C is 24 volts Optical Speed Sensor Cooling Water Consumption Each 43 Series WB Dynamometer has an optical speed sensor For all WB models 30 1 kWh at At 30 C Metric with a 30 bit pulse wheel delivered as standard 8 gal kWh at At 86 F US WB TORQUE SPEED POWER CURVES The diagram below shows the characteristic curves for the 43 Series Eddy Current Dynamometers 1 9550 50 000 rpm 4 5 1 14 1 5 5 4 2 A 4 a WwW S ae D m S Tr z Qe ai 5 x 5 ae o EX Q a Va 3 4 X o 0 1 4 l 0 1 100 1000 10 000 100 000 Rotation Speed rpm 11 Chapter 1 Introduction Magtrol WB PB Dynamometers POWDER DYNAMOMETER OPERATING PRINCIPLES The PB Powder Dynamometers contain as their name torque through friction between rotor and stator The Powder suggests a magnetic powder The electrical current passing Dynamometers PB produce their rated to
44. 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 2 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 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 i
45. of dynamometer brake are utilized allowing the unit under test to be applied with nominal braking torque from zero speed to maximum rotation The Tandem Dynamometers are available on a number of WB PB combinations Powder Brake Eddy Current Brake Dynamometer PB Dynamometer WB g 0 TSC 401 TSC 401 Torque Speed Torque Speed Conditioner Conditioner H Speed d Torque Excitation i DES Power Supply Excitation DES Power Supply SS DSP7002 Dynamometer Controller PC 5 USB 34 Magtrol WB PB Dynamometers Chapter 1 Introduction Specifications WB 15 EDDY CURRENT DYNAMOMETER OPERATING PRINCIPLES The WB Eddy Current Dynamometers develop their full power at high rotation speeds The 15 Series is particularly intended WB DYNAMOMETER RATINGS for motors which rotate at high speeds up to 7500 rpm The braking torque depends on the rotation speed Drag Torque Rated Rated Max Excitation Model Rated Torque De energized Nominal input Inertia Power Speed Speed Current Ib ft N m Ib in kg m Ib ft s kW rpm rpm A 1WB 15 140 103 1 4 12 3 5 00 x 1021 3 68 10 35 2390 7500 4 2WB 15 280 206 2 8 24 7 1 00 x 10 7 37 x 10 70 2390 7500 7 5 3WB 15 420 309 4 2 37 1 1 50x 10 1 10x 10 105 2390 7500 10 4WB 15 560 413
46. series are ideal for applications requiring high speeds and also when operating in the middle to high power range Eddy Current Brakes provide increasing torque as the speed increases reaching peak torque at rated speed The dynamometers have low inertia as a result of small rotor diameter Brake cooling is provided by a water circulation system which passes inside the stator to dissipate heat generated by the braking power The water cooling in the WB provides high continuous power ratings max 140 kW Powder Brake Dynamometers PB series are ideal for applications operating in the low to middle speed range or when operating in the middle to high torque range Powder Brakes provide full torque at zero speed and are water cooled allowing for power ratings up to 48 KW Both WB and PB Dynamometers have accuracy ratings of 0 396 to 0 5 full scale depending on size and system configuration APPLICATIONS Mounted on test benches WB PB 15 Series Dynamometers allow performance and reliability testing on driving elements such as electric motors combustion engines servomotors geared motors reduction gears pneumatic equipment hydraulic transmission systems starter motors electromagnetic clutches gas turbines and turbocompressors Magtrol offers three types of dynamometer brakes to absorb load Hysteresis Eddy Current and Magnetic Powder Each type of Dynamometer has advantages and limitations and choosing the correct one wil
47. shaft must rotate freely the motor must be disconnected 3 Hang the calibration weight from one of the calibration arms IESE Note Use outer groove to achieve calibration in N m when using weight in kg Adjust the electronic control unit to obtain the reading of the nominal dynamometer torque 5 Move the calibration weight to the opposite calibration arm The reading on the electronic unit should be the same difference lt 1 If this is not the case remove the weights and return to step 2 6 Remove the calibration arms 6 4 CALIBRATION OF OVERLOAD PROTECTION 887 Note WB PB 15 Series Dynamometers do not have overload protection Calibration of the overload protection for WB PB 43 65 and 115 Series Dynamometers is performed at the factory However it may be necessary to periodically check or confirm the protection of the measuring cell by following the procedures outlined in Sections 6 4 1 through 6 4 3 eS Note This does not apply to WB PB 2 7 Series Dynamometers as the overload stop is fixed and requires no setting 75 Chapter 6 Calibration Magtrol WB PB Dynamometers CAUTION FOR OVERLOAD CALIBRATION OF WB PB 43 65 AND 115 SERIES DYNAMOMETERS READINGS OF 150 OF THE NOMINAL TORQUE ARE ONLY POSSIBLE IF THE MEASURING SYSTEM OPERATES WITHOUT SATURATION WITH A COMPLETE DSP CONTROLLED MAGTROL SYSTEM WB PB DYNAMOMETER DSP DYNAMOMETER CONTROLLER DES POWER SUPPLY AND TSC TorQuE SPEED COND
48. system which includes a DSP High Speed Programmable Dynamometer Controller and M TEST Motor Testing Software Communication between the DSP Controller and PC running the M TEST Software is carried out by a GPIB or RS 232 interface board and corresponding connection cable Eddy Current WB OR Powder Brake PB Dynamometer TSC 401 Torque Speed Conditioner Figure 4 2 PC Based Test Configuration with M TEST Software Note Magtrol s M TEST Software is a state of the art motor testing program for Windows based data acquisition Used with the Magtrol DSP7000 Controller Magtrol M TEST 5 0 Software provides the control of any Magtrol Dynamometer and runs test sequences in a manner best suited to the overall accuracy and efficiency of the Magtrol Motor Test System This complete system is the ideal solution for performing complete test cycles on all types of rotating systems Please contact Magtrol for additional information on this type of configuration 65 Chapter 4 Connections Configuration Magtrol WB PB Dynamometers 4 2 4 2 1 ee TANDEM DYNAMOMETER CONFIGURATION The tandem configuration combines the advantages of both the WB Eddy current and PB magnetic powder dynamometers by coupling them in series Powder Brake Dynamometer PB cj Eddy Current Brake Dynamometer WB 5 401 TSC 401 Torque Speed Torque Speed Conditioner Conditioner DSP7002 Dynamometer
49. water cooled allowing for power ratings up to 3 kW Both WB and PB Dynamometers have accuracy ratings of 0 3 to 0 5 full scale depending on size and system configuration APPLICATIONS Mounted on test benches WB PB 65 Series Dynamometers allow performance and reliability testing on driving elements such as electric motors combustion engines hand held power tools windshield wiper motors servomotors fans geared motors reduction gears pneumatic equipment hydraulic Magtrol offers three types of dynamometer brakes to absorb load Hysteresis Eddy Current and Magnetic Powder Each type of Dynamometer has advantages and limitations and choosing the correct one will depend largely on the type of testing to be performed With over 50 models to choose from Magtrol Sales professionals are readily available to assist in selecting the proper Dynamometer to meet your testing needs Model I WB 65 HS Eddy Current Dynamometer transmission systems motors for domestic appliances starter motors gas turbines and turbocompressors MOTOR TESTING SYSTEMS Magtrol s M TEST 7 Software is a state of the art motor testing program for Windows based data acquisition Used with a Magtrol DSP7000 Programmable Dynamometer Controller Magtrol M TEST 7 Software provides the control of any Magtrol Eddy Current or Powder Brake Dynamometer and runs test sequences in a manner best suited to the overall accuracy and efficiency of the Magtrol Mo
50. 0 0 1 325 1038 0 250 1009 38 125 30 235 55 80 130 2 115 2 1151 7 878 0 3937 2 95 7 870 12 80 40 870 9 84 0 3932 1 50 4 92 1 18 9 25 2 17 3 15 286 60 Ib 29 Chapter 1 Introduction Magtrol WB PB Dynamometers Tandem Specifications WB PB 115 TANDEM OPERATING PRINCIPLES Because the characteristics of the WB and PB dynamometers An electromagnetic clutch is needed for this application are complementary Magtrol is able to offer them mounted which automatically switches off at the maximum speed of in a tandem setup Each dynamometer WB and PB can the PB Powder Dynamometer and automatically switches on autonomously operate according to its own characteristics at zero speed TANDEM DYNAMOMETER RATINGS TR Rated Torque pe energized Nominal Input Inertia Power Speed Speed Current Ib in kg m Ib ft s kW rpm rpm A 2WB 115 EK 1 PB 115 100 73 7 3 26 5 4 18 x 102 3 08 x 102 30 2865 15 000 5 2WB 115 EK 2 PB 115 200 147 5 5 44 2 5 44 102 4 01 x 1021 30 2865 15 000 5 2 WB 115 2 WB 115 200 147 5 2 17 7 5 51 x 1021 4 07 x 102 60 2865 15 000 5 Voltage at 20 C is 30 volts Optical Speed Sensor Cooling Water Consumption Each 115 Series Tandem Dynamometer has an optical speed For all Tandem models 30 I kWh at At 30 Metric sensor with a 60 bit p
51. 0 10 000 100 000 Rotation Speed rpm Figure 2 9 PB 2 7 Ratings Curve 9550 rpm 50 000 rpm 4 a uumumummuummuum 2 4 d Ki 1 um 2 5 KD a 4 lt r e D o 95 a E RS OY m 4 S Or gt 5 S4 S 2 N 2 Qe S ov g 0 1 4 i 0 1 100 1000 10 000 100 000 Rotation Speed rpm Figure 2 10 WB 43 Ratings Curve 53 Chapter 2 Installation Mounting Magtrol WB PB Dynamometers 955 rpm 4000 rpm 100 10 1 2 LJ 9 5 e 1 0 1 en 5 zal 0 1 0 01 10 100 1000 10 000 Rotation Speed rpm Figure 2 11 PB 43 Ratings Curve 5730 rpm 30 000 rpm 100 100 i eer ere e oS 418 T E os z 4 Ne 4 5 QV o o eos red 2 1 o XN e Sw SAP 1 2 e a V o N Ne
52. 100 1000 10 000 Rotation Speed rpm 28 Magtrol WB PB Dynamometers Chapter 1 Introduction Specifications WB PB 115 SINGLE DYNAMOMETER DIMENSIONS T removable calibration arm Use outer 1 groove to 510 mm for N m achieve d X 500 mm for calibration in U when using weight in kg Tapping for calibration arm 4 Center hole DIN 332 D M8 D Reference surface Cooling water connection 15 mm 0 59 in NOTE Original dimensions are in Metric units Dimensions converted to English units have been rounded up to 2 decimal places Model units A D 390 280 1662 32h6 40 54 360 430 4700 11 201 40 200 280 1 57 2 13 14 17 16 93 18 5010 0 43 0 79 1 57 7 87 11 02 500 390 2760 32h6 15 54 360 430 4700 11 201 40 200 280 2 115 2 115 19 69 15 3510 87 2 2 0 59 2 13 14 17 16 93 18 50 0 0 43 0 79 1 57 7 87 11 02 Model units Q R S T U V X Y 2 DD 55 Weight 75 200 0 1 325 1038 0 250 1019 38 125 30 197 55 80 80 kg 1WB115 1PB115 7 878 0 3937 in 2 95 7 870 12 80 40 87 0 9 84 0 3932 1 50 4 92 1 18 7 76 2 17 3 15 176 37 Ib mm 75 20
53. 221 800 8n5 24 20 190 21010 64 10 2 WB 2 7 8 K 2 PB 2 7 8 K 482316 9 0 3148 0 94 0 79 7 48 8 27 0 252 0 39 0 39 mm 186 146 10440 86 12 20 190 2010 64 10 SINE oK in 7 32 575 4 0919 0 3148 047 0 79 748 8270 0 252 039 0 39 mm 210 1701 1280 8n5 20 190 21010 64 10 LAPB SUR Boal 02149 0 79 748 8270 0 252 0 39 0 39 Model units S 2 Weigh 80 100 45 90 01 152 220 7 6 48 81 16 0 105 42kg in 3 15 3 94 1 77 3547 5 98 866 0 299 1 89 3 19 0 63 0 413 9 26 Ib mm 80 100 45 90 01 152 220 76 48 160 105 5 3kg 3 547 5 98 8 66 0 299 1 89 2 72 0 63 0 413 11 68 80 100 45 90 01 152 220 7 6 48 57 160 105 6 4 in 345 3 94 1 77 3547 5 98 8 66 0 299 1 89 2 24 0 63 0 413 14 11 Ib 80 100 45 90 01 152 220 7 6 48 45 160 105 7 5kg 3547 5 98 8 66 0 299 1 89 1 77 0 63 0 413 16 58 Ib Magtrol WB PB Dynamometers Chapter 1 Introduction Dimensions FEST DYNAMOMETERS WITHOUT COOLING CIRCUIT A removable calibration arm Calibration in N m with weight in kg rc FF 102 mm for N m 4 Tapping for calibration arm
54. 50 Weera a 0 87 1 42 10 24 12 2 13 46 0 43 0 67 0 67 9 84 mm 3701 295 182 0 1816 22 36 330 3801 429 11 17 17 250 2WB65 2PB65 457 4161 717 ree 0 87 1 42 12 99 14 96 16 22 0 43 0 67 0 67 9 84 Model unts P R S T U V 2 Weight 282 25 150 01 240 1034 0 180 619 23 105 50 128 55kg 1WB65 1PB65 5 909 0 2362 in 1110 0 98 29001 9 45 4071 O 7 09 0239 0 91 4 13 1 97 5 04 121 25 Ib 282 25 150 0 1 2401 1034 0 180 6h9 23 105 501 128 70 kg 2WB 65 2 PB65 5 909 0 2362 11 10 0 98 5 902 9 45 40 71 7 09 0 2351 0 91 4 13 1 97 5 04 154 32 Ib Shaft of high speed version HS is 0 25 h6 mm smooth no key with different length Drawing on request or available at www magtrol support salesdrawings htm 21 Chapter 1 Introduction Magtrol WB PB Dynamometers TANDEM OPERATING PRINCIPLES Because the characteristics of the WB and PB Dynamometers An electromagnetic clutch is needed for this application are complementary Magtrol is able to offer them mounted which automatically switches off at the maximum speed of in a tandem setup Each dynamometer WB and PB can the PB Powder Dynamometer and automatically switches on autonomously operate according to its own characteristics at zero speed TANDEM DYNAMOMETER RATINGS
55. A mechanical rotor blocking device which allows locked rotor testing is available for the WB Dynamometer WB PB 2 7 DYNAMOMETER MODELS Eddy Current cooling Circuit Cooling Circuit 2WB27 8K 1PB27 8K 1 2 7 8 3WB2 7 8K 2 2 7 8 2 PB 2 7 8 4 WB 27 8 4PB27 8K 4 PB 2 7 8 ORDERING INFORMATION If one of the listed options is desired please follow the dynamometer model see table above with a dash and then the appropriate suffix as noted in parenthesis For example a Model 1 WB 2 7 8K Eddy Current Dynamometer with a maximum speed rating of 70 000 rpm is a 1 WB 2 7 8K HS Example 1 WB 2 7 8K HS Dynamometer Model Option SYSTEM OPTIONS AND ACCESSORIES DESCRIPTION MODEL PART a High Speed Programmable Dynamometer Controller DSP7000 2 Torque Speed Conditioner includes necessary cables TSC 401 111 Power Supply includes necessary cables DES 410 111 High Speed Single Phase Power Analyzer 6510e High Speed Three Phase Power Analyzer 6530 M TEST 7 Motor Testing Software M TEST 7 9 i Temperature Testing Hardware HW TTEST Couplings Thermostatic Sluice Pressure Sensitive Switch On Request Water Cooling System for Brake On Request Calibration Weights On Request Magtrol WB PB Dynamometers Chapter 1 Introduction 1 2 2 WB PB 43 Series WB PB 43 Series Eddy Current FEATURES e 4 Models with Maximum
56. AL 5 E AEE E EA EEE EEE oos Eae FERT IEEE S 64 41 22 PC BASED TEST CONFIGURATION un gena 65 4 2 TANDEM DYNAMOMETER CONFIGURATION wuuu 66 4 2 1 ELECTROMAGNETIC CLUTCH 66 4 22 202225 rto eo Ea eset ee E FE EET T EE PEE FUE Ye Ere Eee 67 4 3 CONNECTION TO NON MAGTROL ELECTRONIC CONTROL UNITS eere 68 4 3 1 POWBR AND THERMOSTAT CONNECTION pete t erre ud 68 432 TORQUE SIGNAL CONNECTION 70 4 3 3 SPEED SIGNAL CONNECTION 71 5 OPERATING PRINCIPLES sssssssssssssssssssssssssssssessssesssssesssnesssseessssessssesssstesssnesssscesssneessstassanesssneessass 72 5 1 EDDY CURRENT DYNAMOME TERS 00 2 0422 0 6 000000000000000000000000020 72 5 2 MAGNETIC POWDER DYNAMOMETERS BB 72 03 VS ca cade sua EMI 72 6 CALIBRATION cccssssssssssssssssssssssssessssssssssssssseessssesssseessstesssnesssstesssnesssstsssseesssneessseesssneessaeassauessaneessass 73 6 1 BASIC CALIBRATION 73 6 1 1 CALIBRATION ARMS
57. DG All models including tandems are equipped with a 30 bit optical speed sensor On PB Dynamometers a 600 bit or 6000 bit speed pickup encoder is available as an option for low speed applications A mechanical rotor blocking device which allows locked rotor testing is available for the WB Dynamometer DYNAMOMETER MODELS Eddy Current Powder Tandem 1 WB 43 1 PB 43 2 WB 43 EK 1 PB 43 2 WB 43 2 PB 43 2 WB 43 EK 2 PB 43 ORDERING INFORMATION If one of the listed options is desired please follow the dynamometer model see table above with a dash and then the appropriate suffix as noted in parenthesis For example a Model 1 PB 43 Powder Dynamometer with an optional 600 bit speed pickup is a 1 PB 43 DG 600 Example 1 PB 43 DG 600 Dynamometer Model Option SYSTEM OPTIONS AND ACCESSORIES DESCRIPTION MODEL PART Q High Speed Programmable Dynamometer Controller DSP7000 2 Torque Speed Conditioner includes necessary cables TSC 401 111 Power Supply includes necessary cables DES 410 111 High Speed Single Phase Power Analyzer 6510e High Speed Three Phase Power Analyzer 6530 M TEST 7 Motor Testing Software M TEST 7 9 5 Temperature Testing Hardware HW TTEST Dynamometer Table with grooved table top 005449 T Transformer 24 VDC for electromagnetic clutch of tandem dynamometers 234 31 1 920 01 1 Couplings Thermosta
58. ED BY MAGTROL MAGTROL MOTOR TESTING ELECTRONICS ARE FITTED WITH SAFETY DEVICES SUCH AS FUSES CURRENT LIMITERS THERMOSTATS ETC PREVENTING THE DYNAMOMETERS FROM OPERATING OUTSIDE OF THEIR LIMITS Magtrol WB PB Dynamometers are fitted with two types of connectors The WB PB 2 7 and 43 Series Dynamometers are fitted with LEMO type connectors and WB PB 65 115 and 15 Series Dynamometers use MS type connectors Additionally the available options vary from one dynamometer to the other Therefore two or three different pin configurations are shown for each connection AND THERMOSTAT CONNECTION The PB Series Dynamometer torque depends exclusively on the excitation current whereas the torque of a WB Series Dynamometer is determined by both the excitation current and its speed Therefore with WB Dynamometers the excitation current must be reduced when its speed is being increased to hold a constant torque To keep operating temperatures at acceptable levels it is important to run dynamometers within their power ratings The breaking power of the dynamometer must therefore be regularly checked by referring to the torque speed power rating curves shown in Section 2 10 of this manual or by using the following equation Breaking Torque N m x n rpm 9550 Breaking Power kW The thermostat is a normally closed contact which opens when a temperature limit of approximately 50 C 120 F is reached When this limit is reached the
59. ITIONER THE TSC UNIT MUST BE CONNECTED TO THE TSC2 INPUT OF THE DSP As THE INPUT CANNOT MEASURE A VALUE OF MORE THAN 130 OF THE NOMINAL TORQUE 6 4 1 WB PB 43 Series AB 9 D E Figure 6 2 WB PB 43 Overload Protection Calibration Mount the calibration arms See Section 6 1 1 Calibration Arms Place 100 of the calibration weight on the arm on the connector side Adjust the screw to decrease the torque slightly Place 200 of the calibration weight on the arm on the connector side Adjust the screw so that the display indicates 150 of the nominal torque Move the 100 calibration weight onto the opposite arm Adjust the screw Q to decrease the torque slightly Place 200 of the calibration weight on the arm Adjust the screw so that the display indicates 150 of the nominal torque 10 Remove the calibration weight and arms 76 Magtrol WB PB Dynamometers Chapter 6 Calibration 6 4 2 WB PB 65 Series Figure 6 3 WB PB 65 Overload Protection Calibration Mount the calibration arms See Section 6 1 1 Calibration Arms Place 100 of the calibration weight on the arm on the connector side Loosen the nut and adjust the screw to decrease the torque slightly
60. NG RANGE As with most transducers dynamometers should be operated in the upper part of their measuring range between 10 and 100 of their rating DRAG TORQUE Magtrol dynamometers are characterized by a low drag torque approximately 1 of the rated torque for WB Series Dynamometers and approximately 2 for PB Series Dynamometers Refer to the corresponding data sheets see Section 1 2 for the maximum drag torque values of each model Drag torque which is measured by the dynamometer is generated by friction originating from the bearings the contact between the powder and the rotor unit in magnetic powder brakes as well as all other mechanical contacts TOLERATED RADIAL AND AXIAL FORCES Note Any radial or axial force exercised on a dynamometer causes premature wear of the bearings as well as an increase of the drag torque The following table shows the maximum axial and radial forces the WB PB Series Dynamometer can support without being damaged Seas Standard version High speed version HS max N Fragia max max N max N WB PB 2 7 20 5 4 2 5 WB PB 43 40 30 8 15 WB PB 65 200 60 40 30 WB PB 115 300 200 60 100 WB PB 15 N A N A N A N A Only Eddy current WB Dynamometers have as an option a high speed version For WB HS Dynamometers the limit is lower in order to protect the high performance bearings Magtrol offers for the same reaso
61. ORDERING INFORMATION If one of the listed options is desired please follow the dynamometer model see table above with a dash and then the appropriate suffix as noted in parenthesis For example a Model 1 PB 65 Powder Dynamometer with an optional 6000 bit speed pickup is a 1 PB 65 DG 6000 1 PB 65 DG 6000 Example low speed applications Dynamometer Model Option SYSTEM OPTIONS AND ACCESSORIES DESCRIPTION MODEL PART High Speed Programmable Dynamometer Controller DSP7000 2 Torque Speed Conditioner includes necessary cables TSC 401 121 Power Supply includes necessary cables DES 411 111 High Speed Single Phase Power Analyzer 6510e M High Speed Three Phase Power Analyzer 6530 M TEST 7 Motor Testing Software M TEST 7 9 5 Temperature Testing Hardware HW TTEST Dynamometer Table with grooved table top 005450 Transformer 24 VDC for electromagnetic clutch of tandem dynamometers 234 31 1 920 011 2 Couplings Thermostatic Sluice Pressure Sensitive Switch On Request Water Cooling System for Brake On Request Calibration Weights On Request 24 Magtrol WB PB Dynamometers Chapter 1 Introduction 1 2 4 WB PB 115 Series WB PB 115 Series Eddy Current FEATURES e 4 Models with Maximum Torque from 50 N m to 200 N m 36 lb ft to 147 Ib ft e Braking Power 5 kW to 30 kW e Stable Braking Torque without Shock e Moment o
62. PB Dynamometers Chapter 1 Introduction Specifications WB PB 43 SINGLE DYNAMOMETER DIMENSIONS T removable calibration arm Use outer E groove to 255 mm for achieve X 250 mm for librati Center hole Tapping for calibration arm lon i DIN 232 D when using weight in kg EXCITATION TORQUE Reference surface Cooling water connection 10 mm 40 39 in NOTE Original dimensions are in Metric units Dimensions converted to English units have been rounded up to 2 decimal places Model units A B D E F G H J K L M N mm 240 186 10010 12h6 22 25 202 240 284 9 22 22 160 1 WB 43 1 PB 43 7 Q 0 4724 9 45 7 32 3 94 0 4721 mm 290 236 15010 12h6 22 25 252 290 334 2 WB 43 2 PB 43 0 4724 11 42 9 29 5 91 0 4721 9 22 22 160 0 0 87 0 98 7 95 9 45 11 18 0 0 35 0 87 0 87 6 30 0 87 0 98 9 92 11 42 18 15 0 35 0 87 0 87 6 30 Model units P Q R S T U V X Y 2 Weight mm 202 25 125 0 05 198 524 0 145 419 15 80 46 153 24 kg 1WB43 1PB43 4 923 0 1574 in 7 95 0 98 4919 7 80120 63 0 5 71 0 1563 0 59 3 15 1 81 6 02 52 91 Ib mm 202 25 125 0 05 198 524 0 145 419 15 80 46 167 31 kg 2WB43 2PB43 4 923 0
63. RINCIPLES The WB Eddy Current Dynamometers develop their full power for motors which rotate at high speeds up to 30 000 rpm The at high rotation speeds The 65 Series is particularly intended braking torque depends on the rotation speed WB DYNAMOMETER RATINGS Max Speed Model Rated Torque Siy Nominal Input Inertia 27 2 standard version version HS Ib in kg m Ib ft s kW rpm rpm rpm A 1WB 65 10 0 1 0 88 0 82 x 1031 6 04 x 104 6 5730 30 000 50 000 2 5 2 WB 65 20 1471 0 2 1 77 1 55 10 1 14x 103 12 5730 30 000 50 000 5 Voltage at 20 C is 30 volts Optical Speed Sensor Cooling Water Consumption Each 65 Series WB Dynamometer has an optical speed sensor For all WB models 30 1 kWh at At 30 C Metric with a 60 bit pulse wheel delivered as standard 8 gal kWh at A 86 F US WB TORQUE SPEED POWER CURVES The diagram below shows the characteristic curves for the 65 Series Eddy Current Dynamometers 5730 rpm 30 000 rpm 100 100 of Ree eee 1 52 c JS Q gt D 5 o o lt 24 o 62 o n id Se
64. S 2 INSTALLATION MOUNTING Figure 2 1 WB PB 2 7 Load Cell Locking System ette notion o aai e n LM ERE Me E SE HO EENS CX RAE deste Ligure 2 2 WB PB A3 Load Cell Locking Systems ees tre tr peto Figure 2 3 WB PB 65 Load Cell Locking System eee tne ede aa ee a eld need n e ev de a Figure 2 4 WB PB 115 Load Cell Locking System e Figure 2 5 WB PB 15 Load Cell Locking System cteo idi etam te dee Fei re ep 2 6 Couplings Using Key Clampllg sso around nera SE PERO Te KERN Figure 2 7 Example of Protective System ettet te IHE e e EROR EV sivas ERE NR EY EYE Figure2 5 WB2 7 Ratings CUrVe accio rtm a astantes Figure 2 9 PB 2 7 Ratings Curve IU APIBUS En PAESI Figure 2 11 PB 43 Ratings CUEtVe esent E IR EVERY REO MORET XE Ee ERROR Figure 2 12 WB 65 Ratings CUrve easet etre RELIER ONGEDER EI YI EE CES rest ER DONIS NN EY RN YR HERE URGE ORE Figure 2 13 PB 65 Ratings CUEVe cei iei ER P He E EE ee A Pes lee heo ir Figure 2 14 WB 115 Ratings Figure 2 15 PB 115 Ratings Curve Figure 2 16 WB 15 Ratings Curve s Figure 2 17 15 Ratings
65. Speed Conditioner and DSP7000 High Speed Programmable Dynamometer Controller Eddy Current WB OR Powder Brake PB Dynamometer TSC 401 Torque Speed Conditioner Magtrol also offers In Line Torque Transducers for extremely accurate torque and speed measurement with high noise immunity The transducers employ a unique non contact differential transformer torque measuring technology which prevents the rotation of electronic components during operation without the usage of sliprings For a dynamic high precision system the torque transducer can be mounted in line between the unit under test and the dynamometer Eddy Current WB OR Powder Brake PB Dynamometer TM Torque TSC 401 Transducer Torque Speed Conditioner Chapter 1 Introduction Magtrol WB PB Dynamometers Specifications WB 2 7 EDDY CURRENT DYNAMOMETER OPERATING PRINCIPLES The WB Eddy Current Dynamometers develop their full power for motors which rotate at high speeds up to 50 000 rpm The at high rotation speeds The 2 7 Series is particularly intended braking torque depends on the rotation speed WB DYNAMOMETER RATINGS Model Rated Torque x bie Nominal Input Inertia d EE ozin kg m Ib ft s Ww rpm rpm A 2WB 2 7 8 0 30 42 4 9 1 27 2 33 10 1 71 105 500 15 915 50 000 1 0 2 7 8 0 45 63 7 9 1
66. WER HEAT DISSIPATION All Magtrol WB PB Series Dynamometers are instruments which absorb energy They convert the kinetic energy of the coupled rotating systems into heat The quantity of heat which can be dissipated by the dynamometers is not infinite Additionally the dynamometers cannot resist excessive temperatures without damage The most frequent consequence of a too important energy supply is a premature deterioration of the excitation coils of the stator possibly inducing serious damages to the dynamometer and even to its immediate environment An excessive supply of energy over a long period can induce damages which may remain undetected if no detailed examination is performed This can lead to a premature degradation of the bearing lubricant or to defects of the insulation of coils generating the magnetic field Converesely dynamometers should never be loaded at full speed when cold If a motor must be tested cold warm up the dynamometer with a different motor first CAUTION IT 15 IMPORTANT TO FAMILIARIZE YOURSELF WITH THE DYNAMOMETER S RATINGS RUNNING THE SYSTEM OUTSIDE OF THE LIMITS SPECIFIED IN THE DATA SHEETS SEE SECTION 1 2 CAN CAUSE IRREVERSIBLE DAMAGE TORQUE SPEED POWER CURVES The diagrams on the following pages illustrate the characteristic curves for the WB PB Series Dynamometers 15 915 rpm 50 000 rpm
67. anges the property of the powder thus producing a smooth braking PB DYNAMOMETER RATINGS PB 2 7 torque through friction between rotor and stator The Powder Dynamometers PB produce their rated torque at zero speed The element to be tested can be loaded at standstill to determine the starting torque Modei PatedTorque pag 708908 Nominal input inertia Current N m ozin mN m kg m Ib ft s W rpm rpm A 1 PB 2 7 8 0 6 84 18 2 54 1 49x 10 1 09 x 10 20 320 3000 0 5 2 PB 2 7 8 1 2 169 30 424 2 33 105 1 74 x 105 40 320 3000 1 4 PB 2 7 8 2 4 339 48 6 79 4 03 105 2 97 x 10 80 320 3000 2 1 PB 2 7 8K 0 6 84 18 2 54 1 49x 10 1 09 x 10 150 2390 10 000 0 5 2 PB 2 7 8K 1 2 169 30 424 2 33x10 1 71x 10 300 2390 10 000 1 4 PB 2 7 8K 2 4 339 48 6 79 4 03x 105 2 97 x 105 600 2390 10 000 2 Voltage at 20 C is 24 volts Optical Speed Sensor Cooling Circuit Each 2 7 Series PB Dynamometer has an optical speed sensor with a 30 bit pulse wheel delivered as standard The 2 7 Series PB Dynamometers are available with K or without a cooling circuit The cooling water consumption for all PB 8K models is 30 I kWh at At 30 C Metric 8 gal kWh at 86 F US PB TORQUE SPEED POWER CURVES The diagrams below shows the characteristic curves for the 2 7 Series Powder Dy
68. chanical rotor blocking device which allows locked rotor testing is available for the WB Dynamometer SYSTEM OPTIONS AND ACCESSORIES DESCRIPTION MODEL PART 9 High Speed Programmable Dynamometer Controller DSP7000 2 Torque Speed Conditioner includes necessary cables TSC 401 121 Power Supply includes necessary cables DES 411 111 High Speed Single Phase Power Analyzer 6510e High Speed Three Phase Power Analyzer 6530 M TEST 7 Motor Testing Software M TEST 7 5 Temperature Testing Hardware HW TTEST Dynamometer Table with grooved table top 005034 o Transformer 24 VDC for electromagnetic clutch of tandem dynamometers 234 311 920 01 1 Couplings Thermostatic Sluice Pressure Sensitive Switch On Request Water Cooling System for Brake On Request Calibration Weights On Request 32 Magtrol WB PB Dynamometers Chapter 1 Introduction 1 2 5 WB PB 15 Series WB PB 15 Series Eddy Current and Powder Dynamometers FEATURES e 7 Models with Maximum Torque from 140 N m to 1200 N m 103 Ib ft to 885 Ib ft e Braking Power 12 kW to 140 kW e Stable Braking Torque without Shock Low Moment of Inertia e Low Residual Torque e Operation in Either Rotational Direction e Braking Torque Measurement Included e High Rotational Speed e Rated Torque Available From Zero Speed Powder Dynamometers Integrated Optical Speed Sensor DESCRIPTION Eddy Current Brake Dynamometers WB
69. ct aluminum Furthermore they are acid based dangerous and toxic e Borates should not be used as they cannot prevent deposits from forming e Phosphates should not be used as they will cause algae growth Chlorides nitrates and sulfates should not be used as they will cause corrosion Ifthe available water proves to be of questionable quality the user should contact the local authorities to be informed about an adequate form of water treatment Special attention should be paid to water found in industrial areas where contained polluting substances may represent a source of potential dangers for the dynamometer cooling system Furthermore water inhibitors improperly used can have a negative impact on the environment 62 Magtrol WB PB Dynamometers Chapter 3 Cooling 3 4 6 3 5 CONDENSATION CAUTION WHEN THE DYNAMOMETER IS AT A STANDSTILL THE COOLING WATER MUST BE TURNED OFF THIS REDUCES THE LEVEL OF SCALE DEPOSITS AND EVEN MORE IMPORTANT AVOIDS CONDENSATION As a general rule condensation occurs in the dynamometer when the outlet temperature of the cooling water is lower than the ambient temperature in the room When using a PB Series Magnetic Powder Dynamometer the condensation oxidizes the powder which leads to a decrease of the braking torque This happens very quickly and forces the user to send the dynamometer back to Magtrol for replacement of the magnetic powder On WB Series Eddy current Dynamometers the
70. ded holes found on each side of the stator See Figure 6 1 Calibration Arm Mounting Each calibration arm has two grooves the outer groove allows for calibration in N m the inner in mkp 987 Note Mkpis an obsolete unit of torque measurement Magtrol recommends calibration in N m by using the outer groove and calibration weight in kg Refer to Section 6 1 2 Calibration Weight R ble calibrati Threaded hole for attaching ye the calibration arm mkp gt Calibration weight B nn ay AN ULL AN 100 H Figure 6 1 Calibration Arm Mounting CAUTION AFTER CALIBRATION DO NOT FORGET TO REMOVE THE CALIBRATION ARMS FROM THE DYNAMOMETER 73 Chapter 6 Calibration Magtrol WB PB Dynamometers 6 1 2 CALIBRATION WEIGHT The calibration weight is determined by dynamometer model according to the table below IS Note Use outer groove to achieve calibration in N m when using weight in kg Model Weight Nominal deg Torque
71. emoved by boiling the water which only takes the calcium and magnesium carbonates and bicarbonates into account The permanent hardness is caused by the presence of calcium and magnesium sulfates in the water and cannot be removed by boiling Soft water has a hardness between 3 and 6 dH whereas hard water may have a hardness of more than 16 dH Open circuit Closed circuit Cooling Cooling pH value 6 8 6 8 Total hardness lt 20 dH lt 15 dH Temporary hardness lt 10 dH lt 6 Permanent hardness lt 10 lt 9 dH Free carbon dioxide CO lt 10 mg l 3 mg l Organic substances 10 mg l 10 mg l Algae and fungal attacks not acceptable Sand and mud 0 0 mg l Sulfates 50 2 50 mg l lt 50 mg l Chlorides lt 30 mg l lt 30 mg l Solute iron Fe and Fe lt 1 mg l 1 mg l Phosphates 0 mg l 0 mg l Total salt content NaCl lt 3000 mg l 3000 mg l Manganese Mn 0 1 mg l 0 1 mg l 61 Chapter 3 Cooling Magtrol WB PB Dynamometers 3 4 3 3 4 4 3 4 5 dH German hardness degree 10 mg CaO liter THfr French hardness degree 10 mg CaCO liter eH English hardness degree 1 grain CaCO gallon THus American hardness degree 1 mg CaCO liter ppm 1 dH 1 79 THfr 1 25 eH 17 9 THus CAUTION NEVER USE DEMINERALIZED WATER FOR THE COOLING OF DYNAMOMETERS AS THIS WATER IS
72. ersonal safety and proper operation Check line voltage before operating electronic equipment Make sure that dynamometers and motors under test are equipped with appropriate safety Note Detailed information regarding Motor Test Protective Systems can be found in Section 2 8 Protective Systems Always select a coupling that matches the speed and braking torque of the tested system Wear protective glasses when working on a test bench Never wear a necktie or baggy clothes when standing close to the test bench Never stand too close to the running test bench or bend over a rotating shaft Electrically insulate the motor terminal block Always connect the motor envelope to earth ground Make sure that the safety circuitry of the motor control cannot be deactivated by accident WARNING A DEFECT ON THE ELECTRICAL TRANSMISSION LINE CAN CAUSE A SHORT CIRCUIT WHICH CAN PROPAGATE TO ALL CONNECTED INSTRUMENTS OR PERSONS IN CONTACT WITH THE APPARATUS Revisions This Manual The contents of this manual is subject to change without prior notice Should revisions be necessary updates to all Magtrol User s Manuals can be found at Magtrol s website 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 Ist edition
73. f Inertia e Low Residual Torque e Operation in Either Rotational Direction e Braking Torque Measurement Included e High Rotational Speed e Rated Torque Available From Zero Speed Powder Dynamometers Integrated Optical Speed Sensor DESCRIPTION Eddy current Brake Dynamometers WB series are ideal for applications requiring high speeds and also when operating in the middle to high power range Eddy Current Brakes provide increasing torque as the speed increases reaching peak torque at rated speed The dynamometers have low inertia as a result of small rotor diameter Brake cooling is provided by a water circulation system which passes inside the stator to dissipate heat generated by the braking power The water cooling in the WB provides high continuous power ratings max 30 kW Powder Brake Dynamometers PB series are ideal for applications operating in the low to middle speed range or when operating in the middle to high torque range Powder Brakes provide full torque at zero speed and are water cooled allowing for power ratings up to 10 kW Both WB and PB Dynamometers have accuracy ratings of 0 3 to 0 5 full scale depending on size and system configuration APPLICATIONS Mounted on test benches WB PB 115 Series Dynamometers allow performance and reliability testing on driving elements such as electric motors combustion engines hand held drills servomotors fans geared motors reduction gears pneumatic equi
74. g data from other sources e g thermocouples controlling motor power and providing audio visual indicators is relatively easy Magtrol s M TEST 7 Software is ideal for simulating loads cycling the unit under test and motor ramping Because it is easy to gather data and duplicate tests the software is ideal for use in engineering labs Tests can be programmed to run on their own and saved for future use allowing for valuable time savings in production testing and incoming outgoing inspection Chapter 1 Introduction Magtrol WB PB Dynamometers System Configurations WB PB 43 SINGLE DYNAMOMETER CONFIGURATIONS The Dynamometers can be complemented by various electronic modules such as the DES 410 Power Supply TSC 401 Torque Speed Conditioner and DSP7000 High Speed Programmable Dynamometer Controller Eddy Current WB OR Powder Brake PB Dynamometer 5 401 Torque Speed Conditioner DES Power Supply Magtrol also offers In Line Torque Transducers which employ a unique non contact differential transformer torque measuring technology providing extremely accurate torque and speed measurement with superior electrical noise immunity For a dynamic high precision system the torque transducer can be mounted in line between the unit under test and the dynamometer Eddy Current WB OR Powder B
75. h quality couplings should be used Couplings with insufficient torsion stiffness will generate unwanted sinusoidal signals on the original measuring signal The coupling must be dynamically balanced Q1 for WB Series Dynamometers and Q2 5 for PB Series Dynamometers This balancing must compensate for maximum tolerated misalignment between the motor under test and the dynamometer For all Magtrol WB PB Series Dynamometers it is advisable to employ a twin dual disc coupling clamped onto the shaft keys as shown in the figure below Figure 2 6 Couplings Using Key Clamping By using this method no slipping will damage the coupling or the dynamometer shaft With small dynamometers such as the WB PB 2 7 and 43 Series Dynamometers mounting takes place by tightening onto a smooth shaft or using a self centering coupling with two tightening screws Couplings must dampen axial and radial vibration and isolate the dynamometer from vibrations generated by the tested unit particularly in case of gas engines With high speed Eddy current WB HS Dynamometers consult your Magtrol representative for the best suited coupling for your specific application Note With more than 50 years of experience in the field of motor testing Magtrol is your best partner to determine the best suited dynamometer for any given application 48 Magtrol WB PB Dynamometers Chapter 2 Installation Mounting 2 4 2 5 2 6 ee MEASURI
76. hielding to the connector housing 70 Magtrol WB PB Dynamometers Chapter 4 Connections Configuration 4 3 3 SPEED SIGNAL CONNECTION Speed measuring requires a5 V supply The square TTL type output signal frequency is proportional to the speed According to the polar wheel mounted on the system the pulse number per revolution will be 30 60 600 or 6000 For additional information on this item refer to the dynamometer s corresponding data sheet in Section 1 2 eS Note The use of a 600 bit encoder limits the speed of the system to 10 000 rpm If the testing application requires Magtrol can offer a speed sensor providing 6 000 impulses per revolution This provides a higher resolution but limits the speed to 1000 rpm e 1 Supply 5 V 2 SupplyOV 3 Signal TTL Figure 4 12 Connector Pin Configuration for WB PB 2 7 and 43 Dynamometer Speed Signals 857 Note The use of shielded cable is mandatory Connect cable shielding to the connector housing Supply 0 V B Signal TTL C Shield Grounding D Supply 5 V Figure 4 13 Connector Pin Configuration for WB PB 65 115 and 15 Dynamometer Speed Signals IESE Note The use of shielded cable is mandatory Connect cable shielding to the connector housing 71 5 Operating Principles 5 1 5 2 5 3 EDDY CURRENT DYNAMOMETERS WB Magtrol Eddy current Dynamometers carry the designation of WB which stands for Wirbelstrom
77. ings in production testing and incoming outgoing inspection 33 Chapter 1 Introduction Magtrol WB PB Dynamometers System Configurations WB PB 15 SINGLE DYNAMOMETER CONFIGURATIONS The Dynamometers can be complemented by various electronic modules such as the DES 411 Power Supply TSC 401 Torque Speed Conditioner and DSP7000 High Speed Programmable Dynamometer Controller Eddy Current WB g OR Powder Brake PB Dynamometer TSC 401 Torque Speed Conditioner DES Power Supply 5m PC Magtrol also offers In Line Torque Transducers which employ a unique non contact differential transformer torque measuring technology providing extremely accurate torque and speed measurement with superior electrical noise immunity For a dynamic high precision system the torque transducer can be mounted in line between the unit under test and the dynamometer Eddy Current WB OR Powder Brake PB g mj Dynamometer TSC 401 Torque Speed Speed Conditioner Torque TM Torque Transducer Excitation DES Power Supply DSP7002 Dynamometer Controller TANDEM CONFIGURATION Magtrol offers Eddy Current and Powder Dynamometers mounted in tandem In tandem the unique features of each type
78. is clean EXAMPLE The simplest example of an open circuit cooling system is a clean water supply and flow rate regulation by means of a tap The dynamometer water outlet should be equipped with a thermometer and the flow rate must be adjusted in order to maintain the outlet water temperature between 40 C and 50 C resp 100 F to 120 CAUTION THE TAP SHOULD ALWAYS REMAIN OPEN AND RUNNING WHEN THE DYNAMOMETER IS IN USE B Cooling Water Outlet Cooling Water Inlet 1 3 Figure 3 1 Open circuit Cooling Example 59 Chapter 3 Cooling Magtrol WB PB Dynamometers 3 3 CLOSED CIRCUIT COOLING SYSTEMS The closed circuit cooling system uses water to air or water to water heat exchangers or a chiller This system is used when the water supply is restricted or when the water cannot be used for cooling without prior treatment filtering IESE Note It is recommended to use water specific additives to avoid proliferation of living organisms and to protect against corrosion and mineral deposits 3 3 1 EXAMPLE A closed circuit cooling system simply requires a water tank in which the heat exchange will take place The ideal operating temperature of the dynamometer is maintained by a temperature regulated valve on the dynamometer cooling water outlet Valve regulated by the dynamometer outlet water temperature
79. l depend largely on the type of testing to be performed With over 50 models to choose from Magftrol Sales professionals are readily available to assist in selecting the proper Dynamometer to meet your testing needs Model 2WB 15 Eddy Current Dynamometer MOTOR TESTING SYSTEMS Magtrol s M TEST 7 Software is a state of the art motor testing program for Windows based data acquisition Used with a Magtrol DSP7000 Programmable Dynamometer Controller Magtrol M TEST 7 Software provides the control of any Magtrol Eddy Current or Powder Brake Dynamometer and runs test sequences in a manner best suited to the overall accuracy and efficiency of the Magtrol Motor Test System The data that is generated by Magtrol s Motor Testing Software can be stored displayed and printed in tabular or graphic formats and can be easily imported into a spreadsheet Written in LabVIEW M TEST 7 has the flexibility to test a majority of motor types in a variety of ways Because of LabVIEW s versatility obtaining data from other sources e g thermocouples controlling motor power and providing audio visual indicators is relatively easy Magtrol s M TEST 7 Software is ideal for simulating loads cycling the unit under test and motor ramping Because it is easy to gather data and duplicate tests the software is ideal for use in engineering labs Tests can be programmed to run on their own and saved for future use allowing for valuable time sav
80. l to determine the starting torque Moder PatedToraue peenergized Nominalinputinertia power Speed Speed Current N m Ib ft N m Ib in kg m Ib ft s kW rpm rpm A 1 PB 115 100 737 2 17 7 1 24x 10 9 14 x 103 5 480 3000 2 5 2 PB 115 200 147 5 4 35 4 2 50x 10 1 84 x 10 10 480 3000 5 Voltage at 20 C is 30 volts Optical Speed Sensor Cooling Water Consumption Each 115 Series PB Dynamometer has an optical speed sensor For all PB models 30 1 kWh at A 2 30 Metric with a 60 bit pulse wheel delivered as standard For better speed resolution in low speed applications Magtrol offers a 600 bit or 6000 bit speed pickup encoder as an option 8 gal kWh at At 86 F US PB TORQUE SPEED POWER CURVES The diagram below shows the characteristic curves for the 115 Series Powder Dynamometers 480 rpm 3000 rpm 1000 AERIS 10 H or 2 PB 115 TORQUE SUL 1 PB 115 TORQUE 100 1 4 4 Sud E 9 2 ze 2 5 4 5 XN in 45 0 1 ott Or 9 Ye ot a m x 2 4 E E 1 0 01 1 10
81. ll WB models 30 1 kWh 30 C Metric with a 60 bit pulse wheel delivered as standard 8 gal kWh at A 86 F US WB TORQUE SPEED POWER CURVES The diagram below shows the characteristic curves for the 115 Series Eddy Current Dynamometers 2865 rpm 18 000 rpm 100 100 Jo oF AS Q9 N Q gla ale mle ee TER gt 41 10 X S E 10 Ki 4 i c z 41 5 a gt 5 amp 52 A 1 Qr 4 1 S Nie e Nit gt 2 41 o 1 D M 0 1 100 1000 10 000 100 000 Rotation Speed rpm 27 Chapter 1 Introduction Magtrol WB PB Dynamometers Specifications PB 115 POWDER DYNAMOMETER OPERATING PRINCIPLES The PB Powder Dynamometers contain as their name suggests a magnetic powder The electrical current passing through the coil generates a magnetic field which changes the property of the powder thus producing a smooth braking PB DYNAMOMETER RATINGS torque through friction between rotor and stator The Powder Dynamometers PB produce their rated torque at zero speed The element to be tested can be loaded at standstil
82. m 0 59 NOTE Original dimensions are in Metric units Dimensions converted to English units have been rounded up to 2 decimal places Model units A D E F G H J K L M N P Q R mm 500 0 32h6 4 54 388 6854 91510 13 115 35 250 310 135 260 0 2 2 115 1 PB 1151 Q 1 2598 10 244 19 69 1 2593 0 16 2 13 15 28 26 97 36 02 0 51 4 53 1 38 9 84 12 20 5 31 10 228 mm 50010 32 6 4 54 388 795 1025 O 13 115 35 250 310 135 260 0 2 2WB 115 EK 2PB 1151 1 2598 10 244 in 19 69 1 2593 0 16 2 13 15 28 31 30 40 35 0 51 4 53 1 38 9 84 12 20 5 31 10 228 mm 500 0 32h6 4 5 53 388 795 1025 0 13 115 35 250 310 135 260302 2WB 115 2WB 11 5 im 19 69 2 12598 0 18 20915 28 31 30 40 35 0 51 4 53 1 38 9 84 12 20 5 31 10244 1 2593 10 228 Model units S T V X Y AA BB CC DD EE GG Weight mm 385 1038 10 38 125 50 390 15 127 60 160 01 2801 214 2WB 115 1 PB 1151 6 303 in 15 15 40 87 0 39 1 50 4 92 1 97 15 35 0 59 5 00 2 36 6 295 11 02 471 79 Ib mm 385 1038 10 38 125 50 500 15 127 60 160 0 1 390 264 2WB 115 EK 2 PB 1151 6 303 15 15 40 87 0 39 1 50 492 1 97 19 69 0 59 5 00 2 36 6 295 15 35 582 02 Ib mm 385 1038 10 381 125 50 500 15 127 60 160 011 390 264 kg 2WB 115 MK 2WB 115 4 6 303 15 15 40 87 0 39 1 50 4 92 1 97 19 69
83. magnetic clutch The connecting cable between the DES Power Supply and the transformer is already connected to the transformer terminals 1 brown lead and 2 blue lead The yellow green lead is to be connected to the GND Refer to the corresponding section of the DES Power Supply User s Manual for more information brown Y Y brown blue blue yellow green 7 lt 7 yellow green Figure 4 4 Supply Cable Between 24 V DC Transformer and DES Power Supply Connect the electrical cable to terminal 3 brown lead and 4 blue lead of the transformer to link the electromagnetic clutch to the transformer The polarity is unimportant as the clutch can run either with 24 V DC or 24 V DC m E brown Supply 24 V AU aE cj blue Supply OV Figure 4 5 Control Signal Cable for WB PB 2 7 and 43 Tandem Dynamometer Clutches O X brown Supply 24 V 1 blue Supply OV L 7 yellow green Figure 4 6 Control Signal Cable for WB PB 65 115 15 Tandem Dynamometer Clutches Note The electromagnetic clutch has no common ground connection with the transformer 67 Chapter 4 Connections Configuration Magtrol WB PB Dynamometers 4 3 4 3 1 CONNECTION TO NON MAGTROL ELECTRONIC CONTROL UNITS CAUTION USE EXTREME CAUTION WHEN USING ELECTRONIC CONTROL UNITS NOT PROVID
84. ms below show the characteristic curves for the 15 Series Tandem Dynamometers 382 rpm 2390 rpm 7500 rpm 382 rpm 2390 rpm 7500 rpm 10000 1 1000 10 000 1 1000 2 WB 15 4 PB 15 TORQUE 4 WB 15 EK 4 PB 15 TORQUE 1 je j afm f 1000 100 1000 ettet 100 Li t I 2 WB 15 EK 2 PB 15 TORQUE batt RAE aii E L 4 WB 15 EK 2 PB 15 TORQUE 1 s 7 15 TORQUE 2 15 1 15 TORQUE 9 t 4 wp 15 EK 1 PB 3 nac E 5 7 n 5 6 d a 1 Oe e st 1 ac A 1 er NM 100 ert 9 110 100 ts tne 10 4 lt 6 5 x tet TT ho See SET E SATA OS E eU Le e 2 8 Vet t ef aba I 1 Wee xe al att utet E 5 Det E n d Md o of wot 2 st id g gt bet 10 il Ali 10 Pd 1 10 100 1000 10 000 10 100 1000 10 000 Rotation Speed rpm
85. n a specially adapted high speed coupling By applying a radial or axial force on the dynamometer the bearings are subjected to different stresses This hinders them from rotating freely and generates torque on the measuring line The side load of the measuring line is detected by the dynamometer cell This is not an offset but a real torque normally measured Thus the zero on the electronics must not be set when the dynamometer is mechanically coupled 49 Chapter 2 Installation Mounting Magtrol WB PB Dynamometers By slightly moving the dynamometer stator backwards and forwards when the motor is stopped the side load disappears If uncoupling the dynamometer makes the drag torque disappear either the coupling will have to be changed or it will have to be realigned with the motor CAUTION THE DYNAMOMETER MUST BE UNCOUPLED PRIOR TO CALIBRATION REFER TO CHAPTER 6 CALIBRATION FOR MORE DETAILS 2 7 CONNECTING THE COOLING SYSTEM Proper cooling of the dynamometer is essential to ensure a long operating life and accurate measuring results All Magtrol WB PB Series Dynamometers are water cooled to guaranty the best possible heat dissipation PB 2 7 Series Dynamometers are available with K or without a cooling circuit Note The cooling tubes must have an inside diameter in accordance with the indications on the corresponding dynamometer data sheets see Section 1 2 They must be fitted to the dynamometer u
86. namometers 320 rpm 3000 rpm 4 PB 2 7 8 TORQUE 2PB 2 7 8 TORQUE 1000 1 PB 2 7 8 TORQUE Torque mN m Aog 15 Ss S 100 TR Speed Limit for PB 10 100 1000 Rotation Speed rpm 10 000 1000 Power W 100 10 100 000 2390 rpm 10 000 rpm 4 PB 2 7 8 K TORQUE 2 PB 2 7 8 K TORQUE 1000 1 PB 2 7 8 K TORQUE Torque mN m 100 Speed Limit for PB 10 100 1000 Rotation Speed rpm 1000 Power W 100 10 100 000 Chapter 1 Introduction Magtrol WB PB Dynamometers Dimensions 2 7 DYNAMOMETERS WITH COOLING CIRCUIT T removable calibration Calibration 102 mm for N m FF with weight in kg Tapping for calibration arm EXCITATION TORQUE Cooling water connection 6 mm 0 24 in dimensions are in Metric units Dimensions converted to English units been rounded to 2 decimal places Model units A D K 138 98 56 O 815 366 20 190 21010 641 10 TPB 2 cek in 5 43 386 222 03148 1421 0 79 748 8270 0 252 0 39 0 39 162 1
87. nector Pin Configuration for WB PB 2 7 and 43 Dynamometer Speed Signals ss Figure 4 13 Connector Pin Configuration for WB PB 65 115 and 15 Dynamometer Speed Signals sese 6 CALIBRATION Pieute 6 1 Calibration Arni resto RD EDU E der Figure 6 2 WB PB 43 Overload Protection Calibration Figure 6 3 WB PB 65 Overload Protection Calibration Figure 6 4 WB PB 115 Overload Protection Calibration tnde mni et o en iion ere reside 78 Preface PURPOSE OF THIS MANUAL This manual contains information required for the installation and general use of Magtrol s WB Series and PB Series Dynamometers To achieve maximum capability and ensure proper use 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 a WB Eddy current or PB Magnetic Powder Dynamometer in order to determine the torque and power of a 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 these WB PB Dynamometers without risk MANUAL ORGANIZATION This section gives an overview of the structure of the manual and the information contained therein Some information has been deliberately repeated in different sections of
88. nerates a magnetic field which changes the property of the powder thus producing a smooth braking PB DYNAMOMETER RATINGS PB 15 torque through friction between rotor and stator The Powder Dynamometers PB produce their rated torque at zero speed The element to be tested can be loaded at standstill to determine the starting torque Drag Torque Rated Rated Max Excitation Model Rated Torque De energized Nominal input inertia Power Speed Speed Current Ib ft N m kg m Ib ft s kW rpm rpm A 1PB 15 300 221 6 53 5 40 x 102 3 98 102 12 382 2000 4 2 PB 15 600 442 12 106 1 08 x 10 7 96 x 10 24 382 2000 7 5 4 PB 15 1200 885 24 212 2 16 x 101 1 59 x 107 48 382 2000 12 Voltage at 20 C is 45 volts Optical Speed Sensor Cooling Water Consumption Each 15 Series PB Dynamometer has an optical speed sensor For all PB models 30 1 kWh at At 30 C Metric with a 60 bit pulse wheel delivered as standard For better speed resolution in low speed applications Magtrol offers a 600 bit or 6000 bit speed pickup encoder as an option PB TORQUE SPEED POWER CURVES The diagram below shows the characteristic curves for the 15 Series Powder Dynamometers 10 000 Torque 382 rpm 8 gal KWh at At 86 F US 2000 rpm 100 I 1000 441 4 10
89. nstructions 1 Ship your equipment to MAGTROL SA After Sales Service Route de Montena 77 1728 Rossens Fribourg Switzerland VAT No 485 572 2 Please use our forwarder TNT 1 800 558 5555 Account No 154033 Only ship ECONOMIC way 3 days max within Europe 3 Include the following documents with your equipment e Delivery note with Magtrol SA s address as listed above e Three pro forma invoices with e Your VAT number e Value for customs purposes only e Description of returned goods e Origin of the goods in general Switzerland e Noticed failures 4 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 This page was intentionally left blank Testing Measurement and Control of Torque Speed Power Load Force Weight Tension Displacement mere aa MAGTROL INC MAGTROL SA Subsidiaries in 70 Gardenville Parkway Route de Montena 77 Germany France Buffalo New York 14224 USA 1728 Rossens Fribourg Switzerland China India Phone 1 716 668 5555 Phone 41 0 26 407 3000 Worldwide Network ae Fax 1 716 668 8705 Fax 41 0 26 407 3001 of Sales Agents BUREAU VERITAS Certification E mail magtrol 9 magtrol com E mail magtrol magtrol ch WB PB US 09 15
90. ocking System WARNING WHEN THE DYNAMOMETER IS LOCKED DURING TRANSPORT THE LOAD CELL SHOULD NOT BE UNDER MECHANICAL STRESS COMPRESSION OR TRACTION 46 Magtrol WB PB Dynamometers Chapter 2 Installation Mounting 2 2 2 2 1 2 2 2 MOUNTING THE TEST BENCH The dynamometer should be placed on a stable horizontal base plate preferably constructed of cast iron steel or aluminum in order to eliminate vibrations to the greatest extend possible Flatness defects should not exceed 0 05 mm In addition the dynamometer frame must withstand the torque transmitted by the dynamometer without deformation Note Magtrol offers standard and custom dynamometer tables specially designed to support the entire range of Magtrol dynamometers The dynamometer is mounted onto the bench by means of four screws The size of these screws depends on the dynamometer model Tandem dynamometers require stronger screws than single dynamometers Refer to the data sheet of the corresponding dynamometer see Section 1 2 for additional information on the screw type and size ALIGNING THE DYNAMOMETERS ON THE TEST BENCH The proper alignment of the dynamometer with the motor under test is very important The higher the speed of the test the more care must be taken when performing the alignment The maximum tolerated misalignment depends on the selected coupling With high speed Eddy current dynamometers WB HS
91. pment hydraulic transmission systems starter motors gas turbines and turbocompressors Magtrol offers three types of dynamometer brakes to absorb load Hysteresis Eddy current and Magnetic Powder Each type of Dynamometer has advantages and limitations and choosing the correct one will depend largely on the type of testing to be performed With over 50 models to choose from Magtrol Sales professionals are readily available to assist in selecting the proper Dynamometer to meet your testing needs Model 1 PB 115 Powder Dynamometer MOTOR TESTING SYSTEMS Magtrol s M TEST 7 Software is a state of the art motor testing program for Windows based data acquisition Used with a Magtrol DSP7000 Programmable Dynamometer Controller Magtrol M TEST 7 Software provides the control of any Magtrol Eddy Current or Powder Brake Dynamometer and runs test sequences in a manner best suited to the overall accuracy and efficiency of the Magtrol Motor Test System The data that is generated by Magtrol s Motor Testing Software can be stored displayed and printed in tabular or graphic formats and can be easily imported into a spreadsheet Written in LabVIEW M TEST 7 has the flexibility to test a majority of motor types in a variety of ways Because of LabVIEW s versatility obtaining data from other sources e g thermocouples controlling motor power and providing audio visual indicators is relatively easy Magtrol s M TEST 7 Soft
92. que Transducers which employ a unique non contact differential transformer torque measuring technology providing extremely accurate torque and speed measurement with superior electrical noise immunity For a dynamic high precision system the torque transducer can be mounted in line between the unit under test and the dynamometer b OR Powder Brake PB Dynamometer Eddy Current WB TM Torque Transducer TSC 401 Torque Speed Conditioner Excitation DES Power Supply TANDEM CONFIGURATION Magtrol offers Eddy Current and Powder Dynamometers mounted in tandem In tandem the unique features of each type of dynamometer brake are utilized allowing the unit under test to be applied with nominal braking torque from zero speed to maximum rotation The Tandem Dynamometers are available on a number of WB PB combinations Clutch i 1 1 Powder Brake Dynamometer PB Dynamometer WB q n Eddy Current Brake TSC 401 TSC 401 Torque Speed Torque Speed Conditioner Speed Conditioner Excitation dengue DES Power Supply Excitation DSP7002 Dynamometer Controller 9 o Magtrol WB PB Dynamometers Chapter 1 Introduction Specifications WB 65 EDDY CURRENT DYNAMOMETER OPERATING P
93. rake PB mi H q Dynamometer TM Torque TSC 401 Torque Speed Conditioner Transducer Excitation DES Power Supply DSP7002 Dynamomet TANDEM CONFIGURATION Magtrol offers Eddy Current and Powder Dynamometers mounted in tandem In tandem the unique features of each type of dynamometer brake are utilized allowing the unit under test to be applied with nominal braking torque from zero speed to maximum rotation The Tandem Dynamometers are available on a number of WB PB combinations Powder Brake Dynamometer PB q Eddy Current Brake Dynamometer WB m TSC 401 TSC 401 Torque Speed Torque Speed Conditioner Conditioner Speed DES Power Supply PC DSP7002 Dynamometer Controller 10 Magtrol WB PB Dynamometers Chapter 1 Introduction Specifications WB 43 EDDY CURRENT DYNAMOMETER OPERATING PRINCIPLES The WB Eddy Current Dynamometers develop their full power for motors which rotate at high speeds up to 50 000 rpm The at high rotation speeds The 43 Series is particularly intended braking torque depends on the rotation speed WB DYNAMOMETER RATINGS Max Speed Drag Torque Rated Rated Excitation Model Rated Torque De energized Nominal Input Inertia Power Speed Standard high speed Current version version HS
94. riving elements such as electric motors combustion engines hand held drills windshield wiper motors servomotors fans geared motors reduction gears pneumatic equipment hydraulic transmission systems and motors for domestic appliances Magtrol offers three types of dynamometer brakes to absorb load Hysteresis Eddy Current and Magnetic Powder Each type of Dynamometer has advantages and limitations and choosing the correct one will depend largely on the type of testing to be performed With over 50 models to choose from Magtrol Sales professionals are readily available to assist in selecting the proper Dynamometer to meet your testing needs Model 2 WB 43 Eddy Current Dynamometer MOTOR TESTING SYSTEMS Magtrol s M TEST 7 Software is a state of the art motor testing program for Windows based data acquisition Used with a Magtrol DSP7000 Programmable Dynamometer Controller Magtrol M TEST 7 Software provides the control of any Magtrol Eddy Current or Powder Brake Dynamometer and runs test sequences in a manner best suited to the overall accuracy and efficiency of the Magtrol Motor Test System data that is generated by Magtrol s Motor Testing Software can be stored displayed and printed in tabular or graphic formats and can be easily imported into a spreadsheet Written in LabVIEW M TEST 7 has the flexibility to test a majority of motor types in a variety of ways Because of LabVIEW s versatility obtainin
95. rque at zero through the coil generates a magnetic field which changes speed The element to be tested can be loaded at standstill to the property of the powder thus producing a smooth braking determine the starting torque PB DYNAMOMETER RATINGS PatedTorque 0799798908 Nominal input inertia Power Cument N m Ib ft N m oz in kg m Ib ft s kW rpm rpm A 1 PB 43 5 3 6 0 1 14 1 1 41x 1041 1 03 x 104 0 5 955 4000 1 2 PB 43 10 7 8 0 2 28 3 2 40 x 104 1 77 x 104 1 955 4000 2 Voltage at 20 C is 24 volts Optical Speed Sensor Cooling Water Consumption Each 43 Series PB Dynamometer has an optical speed sensor For all PB models 30 1 kWh at A 2 30 Metric with a 30 bit pulse wheel delivered as standard For better 8 gal kWh at Ar 86 F US speed resolution in low speed applications Magtrol offers a 600 bit or 6000 bit speed pickup encoder as an option PB TORQUE SPEED POWER CURVES The diagram below shows the characteristic curves for the 43 Series Powder Dynamometers 955 rpm 4000 rpm 100 10 10 1 3 5 5 5 e 1 0 1 5 l 0 1 0 01 10 100 1000 10 000 Rotation Speed rpm 12 Magtrol WB
96. s of the WB and PB dynamometers An electromagnetic clutch is needed for this application are complementary Magtrol is able to offer them mounted which automatically switches off at the maximum speed of in a tandem setup Each dynamometer WB and PB can the PB Powder Dynamometer and automatically switches on autonomously operate according to its own characteristics at zero speed TANDEM DYNAMOMETER RATINGS ico RatedTorque pe energized Nominal Input Inertia Bower Speed Speed Current N m Ib in kg m Ib ft s kW rpm rpm A 2WB15 EK 1PB15 300 221 8 8 77 1 77 1011 1 31 x 107 70 2390 7500 7 5 2 15 EK 2 15 6001 442 14 8 130 2 31 x 107 1 70 x 1071 70 2390 7500 7 5 2 WB 15 4 PB 15 1200 885 26 8 237 3 39 x 10 2 50 x 1071 70 2390 7500 12 4 15 1 15 300 221 11 6 102 2 77 x 101 2 04 107 140 2390 7500 12 4 15 EK 2 15 6001 442 17 6 155 3 31 x 101 2 44 1011 140 2390 7500 12 4 15 4 15 1200 885 29 6 261 4 39 101 3 23x 101 140 2390 7500 12 Voltage at 20 C is 45 volts Optical Speed Sensor Cooling Water Consumption Each 15 Series Tandem Dynamometer has an optical speed For all Tandem models 30 I kWh at 30 Metric sensor with a 60 bit pulse wheel delivered as standard 8 gal kWh at At 86 F US TANDEM TORQUE SPEED POWER CURVES The diagra
97. sing a metal ring Also check for correct water flow direction The cooling water input is marked COOLING WATER INLET on the dynamometer housing The other nipple is used for the water outlet Check for correct connections For more information on dynamometer s cooling system refer to Chapter 3 Cooling 2 8 PROTECTIVE SYSTEMS PROTECTIVE SYSTEM TO ENSURE THAT THE USER AS WELL AS ALL OTHER SURROUNDING PEOPLE AND OBJECTS WILL NOT BE INJURED OR DAMAGED AS A RESULT OF THE MOTOR UNDER TEST BECOMING BLOCKED A TORQUE OVERLOAD OR ANY OTHER POTENTIAL PROBLEM STOP WARNING ALL ROTATING PARTS MUST BE FITTED WITH A The following precautions concerning protective equipment of the drive train must be observed e Protective elements must prevent access to moving parts during test e Protective elements must cover all parts which can cause crushing or cutting and protect against projections of parts having become loose e Avoid attaching protective elements to rotating parts e Keep protective elements at a sufficient distance away from rotating parts 50 Magtrol WB PB Dynamometers Chapter 2 Installation Mounting Figure 2 7 shows a good example of a protective system All parts of the bench are accessible but the covers prevent any risk to the user when closed Figure 2 7 Example of Protective System 51 Chapter 2 Installation Mounting Magtrol WB PB Dynamometers 2 9 2 10 PO
98. t re A 2 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 PARTIES MAY BE PUT AT RISK THE READER MUST ABSOLUTELY TAKE NOTE OF THE ACCOMPANYING TEXT AND ACT UPON IT BEFORE PROCEEDING FURTHER vii Preface Magtrol WB PB Dynamometers This page was intentionally left blank viii 1 Introduction 1 1 GENERAL DESCRIPTION The WB and PB Dynamometers manufactured by Magtrol are used for testing all types of motors and rotational systems and measuring their torque and power according to their speed They have been specially designed for integration in a complete motor testing system The WB Series Dynamometers feature Eddy current braking systems and are able to be operated at high speeds However
99. t the display indicates 150 of the nominal torque 11 Tighten the nut 12 Remove the calibration weight and arms 78 7 Maintenance and Repair 7 1 7 2 7 3 MAINTENANCE Just like any rotating equipment Magtrol dynamometers require periodic maintenance It is recommended that maintenance be performed every 5000 hours of normal operation This corresponds to the theoretical life of the bearings and the time after which Magtrol recommends their replacement Bearings should be replaced as soon as they start showing signs of wear Higher wear occurs when the dynamometer is operated outside its optimal working conditions This is especially true when the dynamometer is operated at excessive rotational speeds which results in the generation of axial and radial forces on the bearings Various indicators alert the user as to when maintenance is required The dynamometer can no longer reach its nominal torque particularly true with magnetic powder dynamometers water tubing is clogged causing a temperature rise e residual torque is out of specification When the bearings generate noises it indicates that maintenance is overdue At this stage measurements have already been distorted and the entire dynamometer unit is subject to vibrations reducing its operating life REPAIR In case of a defect please refer to both the Warranty and Service Information located at the back of this manual Whether yo
100. ter Brake cooling is provided by a water circulation system which passes inside the stator to dissipate heat generated by the braking power The water cooling in the WB provides high continuous power ratings max 1 kW Powder Brake Dynamometers PB series are ideal for applications operating in the low to middle speed range or when operating in the middle to high torque range Powder Brakes provide full torque at zero speed and are water cooled allowing for power ratings up to 600 W Both WB and PB Dynamometers have accuracy ratings of 2 full scale depending on size and system configuration APPLICATIONS Mounted on test benches the WB PB 2 7 Series Dynamometers allow performance and reliability testing on driving elements such as servomotors micromotors for cameras small fans dental drills geared motors small reduction gears pneumatic equipment hydraulic transmission systems and motors for small domestic appliances Magtrol offers three types of dynamometer brakes to absorb load Hysteresis Eddy Current and Magnetic Powder Each type of Dynamometer has advantages and limitations and choosing the correct one will depend largely on the type of testing to be performed With over 50 models to choose from Magftrol Sales professionals are readily available to assist in selecting the proper Dynamometer to meet your testing needs Model 4 WB 2 7 8K Eddy Current Dynamometer MOTOR TESTING SYSTEMS Magtrol s M TEST 7
101. the document to minimize cross referencing and to facilitate understanding through reiteration The structure of the manual is as follows Chapter 1 INTRODUCTION Contains technical data sheets of all Magtrol WB PB Series Dynamometers which describe their technical characteristics and give a brief overview of their application fields Chapter 2 INSTALLATION MOUNTING Provides information needed for the mounting of the dynamometers as well as limits and precautions to observe during operation Chapter 3 COOLING Describes the necessary measures to take in order to guaranty an optimal dynamometer operating temperature Chapter 4 CONNECTION CONFIGURATION Provides information about the wiring between the dynamometers and the electronic control units as well as tandem setups of dynamometers Chapter 5 OPERATING PRINCIPLES Describes the physical phenomena on which the Eddy current WB and magnetic powder PB dynamometer technology is based Chapter 6 CALIBRATION Provides recommended calibration schedules along with step by step instructions for the calibration procedure Chapter 7 MAINTENANCE AND REPAIR Provides information on how to return a WB PB series dynamometer to Magtrol for servicing preventative maintenance or repair vi Magtrol WB PB Dynamometers Preface CONVENTIONS USED IN THIS MANUAL The following symbols and type styles may be used in this manual to highlight certain parts of the tex
102. the load cell must first be unlocked The shipping restraining pin of the locking system is found on the lower part of the brake Proceed as follows and refer to figure 2 1 to unlock the dynamometer 1 Loosen the fixing screw 2 Remove the shipping restraining pin 2 and re insert it with the thinner part inside 3 Tighten the screw Figure 2 1 WB PB 2 7 Load Cell Locking System 42 Magtrol WB PB Dynamometers Chapter 2 Installation Mounting 2 1 2 WB PB 43 Series WB PB 43 Series Dynamometers are fitted with a connecting screw between the stator assembly and the load cell After installing the dynamometer on a test bench fasten the connecting screw to get the load cell operational Proceed as follows and refer to figure 2 2 CAUTION WHILE TIGHTENING THE SCREW KEEP THE WRENCH PARALLEL THE VERTICAL CONNECTING ROD TO AVOID LOAD CELL OVERLOAD 1 Insert the hexagon cap screw supplied with the dynamometer into the rod end 2 Fasten the screw IESE Note The overload protection screws and nuts and are adjusted at the factory refer to Chapter 6 Calibration for possible adjustments B
103. the stator of the brake Due to the action of the magnetic field some columns build up which generate friction between the rotor teeth and the stator surface By varying the coil current the braking torque can be varied continuously WB VS PB Mechanically PB and WB dynamometers are quite similar and only differ by their size and the shape of the rotor teeth Fundamentally the difference between an Eddy current and a magnetic powder dynamometer lies in the fact that the maximum braking torque of the later is already available at standstill On the other hand the friction generated in magnetic powder brakes limits the speed of the dynamometer at lower levels to prevent premature wear and powder dispersion into the bearings due to centrifugal forces 72 6 Calibration Every new Magtrol WB PB Series Dynamometer is factory calibrated Static calibration of the zero and torque is recommended from time to time especially after having maintenance performed IESE Note Do not forget to unlock the dynamometer following transport after it returns from overhaul in accordance with Section 2 1 Locking the Dynamometer for Transport 6 1 BASIC CALIBRATION INFORMATION Prior to calibration the motor must be separated from the dynamometer so that the dynamometer shaft can rotate freely 6 1 1 CALIBRATION ARMS Two calibration arms are delivered with each Magtrol WB PB Series Dynamometer These arms are inserted into the threa
104. ther nipple is used for the water outlet Check for correct connections Water FLow AND PRESSURE The required cooling water flow rate can be worked out by means of the following formula Braking Power kW 860 1 C kWh Flow rate l h Outlet Water Temperature C Inlet Water Temperature C Note 1 kWh 860 kcal 3600 kJ The dynamometer cooling system has been designed for an open outflow and freely flowing water without back pressure The maximum input pressure must not exceed 2 bars for models WB PB 15 WB PB 115 and WB PB 65 The maximum input pressure must not exceed 0 5 0 8 bars for models WB PB 2 7 and WB PB 43 A pressure valve can be added to the cooling system of the brake upon request CooLiNG WATER CONSUMPTION 30 1 kWh at At 30 C Metric 8 gal kWh at At 86 F US 58 Magtrol WB PB Dynamometers Chapter 3 Cooling 3 1 4 3 2 3 2 1 TEMPERATURE SENSOR The dynamometer is fitted with a sensor measuring the outlet water temperature This sensor generates an alarm in case of overheating OPEN CIRCUIT COOLING SYSTEMS In an open circuit cooling system the necessary water comes directly from the main water distribution system faucet passes through the dynamometer and is then disposed of down a drain The advantage of this type of system is its low installation cost This solution is acceptable if there are no restrictions on water supply and if the available water
105. tic Sluice Pressure Sensitive Switch On Request Water Cooling System for Brake On Request Calibration Weights On Request 16 Magtrol WB PB Dynamometers Chapter 1 Introduction 1 2 3 WB PB 65 Series WB PB 65 Series Eddy Current FEATURES e 4 Models with Maximum Torque from 10 N m to 50 N m 7 3 lb ft to 36 lb ft e Braking Power 1 5 kW to 12 kW e Stable Braking Torque without Shock e Low Moment of Inertia e Low Residual Torque e Operation in Either Rotational Direction Braking Torque Measurement Included e High Rotational Speed e Rated Torque Available From Zero Speed Powder Dynamometers Integrated Optical Speed Sensor DESCRIPTION Eddy Current Brake Dynamometers WB series are ideal for applications requiring high speeds and also when operating in the middle to high power range Eddy Current Brakes provide increasing torque as the speed increases reaching peak torque at rated speed The dynamometers have low inertia as a result of small rotor diameter Brake cooling is provided by a water circulation system which passes inside the stator to dissipate heat generated by the braking power The water cooling in the WB provides high continuous power ratings max 12 kW Powder Brake Dynamometers PB series are ideal for applications operating in the low to middle speed range or when operating in the middle to high torque range Powder Brakes provide full torque at zero speed and are
106. tor Test System The data that is generated by Magtrol s Motor Testing Software can be stored displayed and printed in tabular or graphic formats and can be easily imported into a spreadsheet Written in LabVIEW M TEST 7 has the flexibility to test a majority of motor types in a variety of ways Because of LabVIEW s versatility obtaining data from other sources e g thermocouples controlling motor power and providing audio visual indicators is relatively easy Magtrol s M TEST 7 Software is ideal for simulating loads cycling the unit under test and motor ramping Because it is easy to gather data and duplicate tests the software is ideal for use in engineering labs Tests can be programmed to run on their own and saved for future use allowing for valuable time savings in production testing and incoming outgoing inspection 17 Chapter 1 Introduction Magtrol WB PB Dynamometers System Configurations WB PB 65 SINGLE DYNAMOMETER CONFIGURATIONS The Dynamometers can be complemented by various electronic modules such as the DES 411 Power Supply TSC 401 Torque Speed Conditioner and DSP7000 High Speed Programmable Dynamometer Controller Eddy Current WB OR Powder Brake PB Dynamometer 5 401 Torque Speed Conditioner Speed Excitation DES Power Supply also offers In Line Tor
107. trol offers Eddy Current and Powder Dynamometers mounted in tandem In tandem the unique features of each type of dynamometer brake are utilized allowing the unit under test to be applied with nominal braking torque from zero speed to maximum rotation The Tandem Dynamometers are available on a number of WB PB combinations Eddy Current Brake Dynamometer WB m Powder Brake Dynamometer PB TSC 401 TSC 401 Torque Speed Torque Speed Conditioner Conditioner DSP7002 Dynamometer Controller 26 Magtrol WB PB Dynamometers Chapter 1 Introduction Specifications WB 115 EDDY CURRENT DYNAMOMETER OPERATING PRINCIPLES The WB Eddy Current Dynamometers develop their full power for motors which rotate at high speeds up to 22 000 rpm The at high rotation speeds The 115 Series is particularly intended braking torque depends on the rotation speed WB DYNAMOMETER RATINGS Max Speed Model Rated Torque Be chee Nominal Input Inertia 5 Speed standard version version HS lb ft Ib in kg m Ib ft s kW rpm rpm rpm A 1WB 115 501 36 8 0 5 4 43 1 27x10 9 36x103 15 2865 18 000 22 000 2 5 2 WB 115 100 73 7 1 0 8 85 2 57 x 102 1 89 102 30 2865 18 000 22 000 5 Voltage at 20 C is 30 volts Optical Speed Sensor Cooling Water Consumption Each 115 Series WB Dynamometer has an optical speed sensor For a
108. u are directed to ship your equipment back to Magtrol Inc in the United States or Magtrol SA in Switzerland it is very important to include the following information with your return shipment Model number part number serial number order number and date of purchase e Description of the defect and the conditions in which it appeared e Description of the test bench drawing photographs sketches etc e Description of the tested object drawing photographs sketches etc e Description of the test cycle SENDING EQUIPMENT TO MAGTROL FOR MAINTENANCE REPAIR CAUTION MAINTENANCE MUST BE PERFORMED BY MAGTROL IN ORDER TO GUARANTY FUTURE MEASURING ACCURACY TO ALLOW MAGTROL TO COMPLETE THE WORK IN THE BEST POSSIBLE TIME FOLLOW THE PROCEDURE OUTLINED BELOW AS WELL AS THE PROCEDURE OUTLINED IN THE REAR OF THIS MANUAL UNDER SERVICE INFORMATION 1 Do not dismantle the dynamometer so that Magtrol can test it prior to performing maintenance 2 Lock the dynamometer for transport see Section 2 1 Locking the Dynamometer for Transport 3 Carefully pack the dynamometer 4 The Magtrol DES Power Supply and TSC Torque Speed Conditioner that is used with the dynamometer should also be returned at this time for calibration 79 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
109. ulse wheel delivered as standard 8 gal kWh at At 86 F US TANDEM TORQUE SPEED POWER CURVES The diagram below shows the characteristic curves for the 115 Series Tandem Dynamometers 4 2 1 1000 80 1pm 865 rpm 5 000 rpm 4000 i Torque i Power 2WB 115 EK P PB 115 2 115 1 115 100 100 3 1 1 4 PR oY 7 A 5 4 7 9 9 27 7 1 L 1 te 4 ly 1 10 Z 10 t SK eae 5 L g 47 4 NI ALS AY P xv 2 F i Vv 7 I 1 Us e 0 1 10 100 1000 10 000 100 000 Rotation Speed rom 30 Magtrol WB PB Dynamometers Chapter 1 Introduction Tandem Specifications TANDEM DIMENSIONS DRIVE SIDE Electromagnetic tooth clutch EK gt AA WB 115 aB H PB 115 or WB 115 Inlet T removable calibration arm WB PB 115 4510 mm for N m 500 mm for mkp Use outer groove to achieve calibration in N m when using weight in kg 4 Cooling water connection 15 m
110. ware is ideal for simulating loads cycling the unit under test and motor ramping Because it is easy to gather data and duplicate tests the software is ideal for use in engineering labs Tests can be programmed to run on their own and saved for future use allowing for valuable time savings in production testing and incoming outgoing inspection 25 Chapter 1 Introduction Magtrol WB PB Dynamometers System Configurations WB PB 115 SINGLE DYNAMOMETER CONFIGURATIONS The Dynamometers can be complemented by various electronic modules such as the DES 411 Power Supply TSC 401 Torque Speed Conditioner and DSP7001 High Speed Programmable Dynamometer Controller Eddy Current WB OR Powder Brake PB Dynamometer TSC 401 Torque Speed Conditioner Excitation DES Power Supply Magtrol also offers In Line Torque Transducers which employ a unique non contact differential transformer torque measuring technology providing extremely accurate torque and speed measurement with superior electrical noise immunity For a dynamic high precision system the torque transducer can be mounted in line between the unit under test and the dynamometer Eddy Current WB OR Powder Brake PB Dynamometer TM Torque Transducer TSC 401 Torque Speed Conditioner TANDEM CONFIGURATION Mag
111. wheel delivered as standard 8 gal kWh at At 86 F US TANDEM TORQUE SPEED POWER CURVES The diagrams below shows the characteristic curves for the 43 Series Tandem Dynamometers 955 rpm 9550 rpm 25 000 rpm 100 100 10 10 c gt o 9 1 1 o S He 5 zl 15 2 0 1 4 Ad 0 1 10 100 1000 10 000 100 000 Rotation Speed rpm 14 Magtrol WB PB Dynamometers Chapter 1 Introduction TANDEM DIMENSIONS DRIVE SIDE Electromagnetic tooth clutch EK T removable calibration arm 255 mm for gt Use outer groove to achieve calibration 250 mm for in N m when using weight in kg EXCITATION TORQUE CLUTCH EXCITATION TORQUE SPEED L Cooling water connection 10 mm 0 39 in du dimensions are in Metric units Dimensions converted to English units have been rounded up to 2 decimal places Model units D E F G H J K L M N P Q mm 29010 12h6 23 25 2501 5601 60010 11 20 35 180 250 30

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