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Manual - Magtrol

1. gt a Fg Power Absorption Curves HD ED 2 2 gt 2 HD 700 HD 710 gt 30000 30000 gt 25000 25000 2 20000 5 20000 150001 15000 10000 10000 5000 5000 0 7 i 0 0 88 176 264 352 440 ozin 0 88 176 264 352 440 0 062 124 1 86 248 3 10 N m 062 124 186 2 48 3 10 N m TORQUE TORQUE HD 705 HD 715 and ED 715 30000 30000 25000 25000 8 20000 8 20000 15000 15000 10000 10000 9 5000 5000 00 11 22 33 44 55 Ibin 00 11 22 33 44 55 Ibin O 1 24 248 372 496 6 20 0 124 248 372 496 6 20 TORQUE TORQUE HD 800 HD 810 15000 15000 12000 12000 a E 9000 9000 6000 6000 5 3000 9 3000 0 0 0 25 50 75 100 125 4 0 25 50 75 100 125 Ibin 0 28 56 84 112 14 0 N m 0 28 56 84 112 140 Nm TORQUE TORQUE HD 805 HD 815 and ED 815 15000 15000 12000 12000 E 9000 E 0000 d d H 6000 m 6000 3000 3000 0 0 0 50 100 150 200 250 Ibin 0 50 100 150 200 250 Ibin 0 56 113 168 224 28 Nm 0 56 113 168 224 28 TORQUE TORQUE 10000 8000 a
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3. 40 419 EDDY GURRENTS tees ei Oe tet n i bte bete ee 40 Magftrol Hysteresis Dynamometers Table of Contents 41 10 TEMPERATURE RISE esae te boten nid e i t ee herbae 41 5 OPERATING PRINCIP E S 2 co ead n eS a RP ERRAT MAN IER PNEU NE PUR 42 Det SPEED 42 9 2 ore i eo expe e e Di t et is a te qe eO ees 42 5 3 TORQUE SIGNAL AMPLIBICATION i itte Lak e Tee RC ae e EE eee Dee Weds 43 5 4 DECIMAL POINT CONTROL eit ete nr ER RE eer eter ed e ee e Red Ede dtes 43 3 5 DAMPER CYLINDER i ester e o ee USD Pa UR eie UR 44 2 6 BRAKE CONTROL POWER nO Re i HR HUI ERE RI br eR tr iens 44 3 61 HD 800 815 A ND ED 815 re e en teh p dat dd eere 44 362 HD 825 i iicaeeea Ge d eO ete a e re Lue tbe Ted is tha Ve eere de 44 6 CALIBRATION mE 45 6 1 INITIAL CALIBRATION eoe Eno REPE RP ERES ERIT QE Fe Pepe at Res 45 6 2 CALIBRATION BEAMS AND WEIGHTS 45 6 3 CALIBRATION PREPARATION tette enacted dae ER Ye tette ee oed Ie eset eoe Eid Deve ck eme Reeve 46 6 4 CATIBRATION PROCEDURE yiri rr ht e gu ee e ne rar no eh p e de 46 6 5 CAL
4. 30000 25000 20000 m 15000 10000 a 5000 0 0 24 48 72 96 120 oz in 0 170 340 510 680 850 mN m TORQUE Figure 4 6 HD 510 Power Absorption Curve HD 505 0 3745 in 0 3750 in Sha Diameter 9 512 mm 9 525 mm Shaft Height 4 00 in 101 6 mm 240 oz in Torque Range 17 00 kg cm 1700 mN m Input Inertia 1 61 x 104 Ib ft s gt Maximum Speed 25 000 rpm ro ssi continuous duty 160 W 2 aximum Input Power B minuies 800 W 30000 25000 2 20000 15000 10000 a 5000 0 i 1 0 48 96 144 192 240 oz in 0 340 680 1020 1360 1700 mN m TORQUE Figure 4 7 HD 505 Power Absorption Curve HD 515 0 3745 in 0 3750 in Shaft Diameter 9 512 mm 9 525 mm Shaft Height 4 00 in 101 6 mm 240 oz in Torque Range 17 00 kg cm 1700 mN m Input Inertia 1 61 x 10 Ib ft s Maximum Speed 25 000 rpm Maximum Input Power continuous duty 900 W 5 minutes 1500W 30 Magtrol Hysteresis Dynamometers Chapter 4 Testing 30000 25000 20000 15000 10000 5000 SPEED rpm 48 96 144 192 240 ozin O 340 680 1020 1360 1700 TORQUE Figure 4 8 HD 515 Power Absorption Curve HD 700 0 4995 in 0 5000 Sha Diameter 12 687 mm 12 700 mm Shaft Height 5 875 in
5. M 61 SERVICE INFORMATION cds cer nds qu D E dO e rap xl ER REO C FERRI OE RN EUR 63 RETURNING MAGTROL EQUIPMENT FOR REPAIR AND OR CALIBRATION eee 63 RETURNING EQUIPMENT TO MAGTROL INC UNITED STATES eese 63 RETURNING EQUIPMENT TO MAGTROL SA SWITZERLAND eene 63 Table of Contents Magftrol Hysteresis Dynamometers TABLE OF FIGURES 2 INPUTS OUTPUTS Figure 2 1 ee ve saved Ata a ee eee 16 Figure 2 2 Dynamometer Brake Input sccscccccsseesceseeseeseeseeseeseeseeseesecuceseseeseeseeseesecseeceaeeceeseeseesecaeeseeaeeeeeeaeeaeeaees 16 Figure 2 3 CONNECION aee terere etna neto e ESSERE te 16 Figure 2 4 Calibration Potentiometers eee 17 Kigure 2 5 Speed Encoder Switch eee dee ee o e a diee etie 17 Figure 2 6 Blower Input is Figure 2 7 Compressed Air Input s eto etu e eed OR bedient 17 3 INSTALLATION CONFIGURATION Figure 3 1 HD 100 500 Series Shipping Restraining Bolt Location eerte 18 Figure 3 2 HD 700 Series Shipping Restraining Bolt Location eee 19 Figure 3 3 ED 715 Shipping Restraining Bolt Location 19 Figure 3 4 HD 100 500 Series Top View
6. The maximum speed will depend on what type of keyway if any is used on the shaft Unless specified the dynamometer shaft will be made without a keyway 5 Volt Output NOTE Operating at the continuous power rating for periods of up to 4 hours is acceptable However operating for extended periods at high temperatures will result in premature component and bearing failure Limiting the length of the cycle and the component temperatures will guard against premature failure Where continuous duty is desired for longer time intervals component temperatures should be maintained less than 100 C monitoring the outside brake surface temperature is a sufficient reference Magftrol Hysteresis Dynamometers Chapter 1 Introduction Ratings HD ED J g m ELECTRICAL POWER AND FUSES zZ Model Voltage VA Style Rating HD 1XX XN 120 V 30 UL CSA 300 250V SB HD 1XX XNA 240 V 30 125mA 250V T HD 4XX XN 120 V 30 UL CSA 300 250V SB HD 4XX XNA 240 V 30 EC 125mA 250V T HD 5XX XN 120V 30 UL CSA 1300 250V SB HD 5XX XNA 240 V 30 125 250V HD 800 XN 120V 65 UL CSA 800 250V SB HD 800 XNA 240 V 65 315mA 250V T HD 810 XN 120V 65 UL CSA 800 250V SB HD 810 XNA 240 V 65 315mA 250V T HD 805 XN 120V 130 UL CSA 125 250V SB HD 805 XNA 240 V 130 630mA 250V T HD ED 815 XN
7. o BRAKE CONNECTION 9 O PAD10 MOUNT HOLES 57 gt 0 0 m 2 m B Schematics Magftrol Hysteresis Dynamometers B 3 LOAD CELL SCHEMATIC VOLTAGE LEVELS TEMP COMP 5 VDC 4 0 11 MILLIVOLT SIGNAL LEVEL BLUE TO GREEN BLUE S G 4 350 OHM 0 15 5 4 42K OHM GREEN 3 1 OHM 2 WHITE 5 VDC FINE re com 100 OHM 58 gt 0 0 2 m Schematics 800 815 BRAKE CONTROL SUPPLY Magftrol Hysteresis Dynamometers B 4 APPENDICES LLN O LIN JOA 104 uoneJqi eo JO 1e 2 SI 101615 M 099 099 SNVH L SH vH 37000 37000 20 10 ZSNVYL O LSNVYL VELdMS VELdMG VELdMG SZOSNL vOOPVNL O O3N NI edd o eM vOOVNI O SHOA 92 SOd NI O 3svao ed 401931109 0 SZ9SN L 59 Schematics Magftrol Hysteresis Dynamometers B 5 HD 825 BRAKE CONTROL SUPPLY 1 2 3 4 5 Ti MPI 300 28 35
8. 00 11 22 0 1 24 2 48 33 44 TORQUE Figure 4 11 HD 705 Power Absorption Curve 55 372 496 6 20 HD 715 Shaft Diameter 0 4995 0 5000 in 12 687 mm 12 700 mm Shaft Height 5 875 in 149 2 mm 55 0 Ibin Torque Range 62 0 kg cm 6 20 Input Inertia 1 101 x 10 Ib ft s Maximum Speed 25 000 rpm Maximum Input Power continuous duty 3000 W 5 minutes 3400 W 32 je P O 2 Magtrol Hysteresis Dynamometers Chapter 4 Testing 30000 25000 20000 15000 10000 5000 SPEED rpm 0 11 22 33 44 55 Ib in 0 124 2 48 3 72 4 96 6 20 TORQUE Figure 4 12 715 Power Absorption Curve HD 800 0 9995 1 0000 Shaft Diameter 25 387 mm 25 400 mm Shaft Height 9 00 in 228 6 mm 125 0 o Torque Range 140 0 kg cm 0 14 00 Input Inertia 4 43 x 10 Ib ft s gt Maximum Speed 12 000 rom e Maximum Input Power continuous duty 1800 W lt 5minutes 2800 W 15000 12000 9000 m 6000 3000 0 Li 25 50 75 100 125 Ib in 0 2 8 5 6 8 4 11 2 14 0 N m TORQUE Figure 4 13 HD 800 Power Absorption Curve HD 810 0 9995 1 0000 Shaft Diameter 25 387 mm 25 400 mm Shaft Height 9 00 in
9. ica NN 5 trei e RR te mete iei tette VI WHO SHOULD USE THIS MANUAL reote eret e eie e teet idee rae eet VI MANUATI ORGANIZATION tete ete nein mete mt EU PE VI CONVENTIONS USED diet Ie etse eese oec ee eee aepo en reos eae pee ene ete doas VII UN INTRODUCTION eR 1 1 1 UNPACKING YOUR HYSTERESIS 1 1 2 FEATURES OF THE HYSTERESIS DYNAMOMETER 2 1 2 1 HD SERIES criari eet Ree p i TI e t CE ed 2 12 2 SEDISERIES ue E Reo e HI RI MIN iS 2 1 3 DATA SHEE cene ned 3 2 INPUTSIOUTPUTS 16 2 inei cde d teen ee ee 16 2 2 INPUTS AND OUTPUTS t ttt ree dee dad eere etre sea 16 3 INSTALLATION CONFIGURATION ssssssssssssssssssssssssssssssssssssssscssssssscesssssseesssssucesssssseesssssucesseansceess 18 3 1 REMOVAL OF THE LOAD CELL SHIPPING RESTRAINING BOLT eese nennen 18 3 1 1 HD 100 400 AND 500 SERIES ertet e Fas tt Feed tete eua ceu t oe AUR bates 18 2252 HD 700 SERIES cre ete etate i ee en a teg tee Tre ped e roce es 19 3 1 3 HD 800 SERIES dieti tette et
10. 2 20 Figure 3 5 HD 800 Series Top View 2 20 Figure 3 6 Dynamometer with 6200 21 Figure 3 7 Dynamometer with DSP7001 Controller and M TEST 22 Figure 3 8 Dynamometer with 6510e Power Analyzer DSP7001 Controller and M TEST Software 22 Figure 3 9 Air Flow Sensor Schematic Figure 3 10 Dynamometer with Blower 2 24 Figure 3 11 Dynamometer with Compressed Air Connection eese 24 4 TESTING Figure 4 1 Power Absorption Curve Parameters eese teen 27 Figure 4 2 HD 106 Power Absorption Curve eese eene eterne treten nenne tetne teens te enennne Figure 4 3 HD 100 Power Absorption Curve Figure 4 4 HD 400 Power Absorption Figure 4 5 HD 500 Power Absorption Curve Figure 4 6 HD 510 Power Absorption Curve eese eene tette tne eene nenne tee nenne netten Figure 4 7 HD 505 Power Absorption Curve essent eene enne nete tnetne nenne tenete nenne trennen Figure 4 8 HD 515 Power Absorption Curve Figure 4 9 HD 700 Power Absorption Curve Figure 4 10 HD 710 Power Absorption Curve Figure 4 11 HD 705 Power Absorption Curve Figure 4 12 HD 715 Power Absorption Curve Figure 4 13 HD 800 Power Abs
11. 6N 500 3 5 Ib in Blower 2 2 HD 825 EN UE 1 85 102 2 51 x 10 14 000 12 000 8 000 included 8N 56 5 0 40 N m Requires air cooling provided by user Regulator and filter package is provided as standard equipment on these units 5 Volt output NOTE Operating at the continuous power rating for periods of up to 4 hours is acceptable However operating for extended periods at high temperatures will result in premature component and bearing failure Limiting the length of the cycle and the component temperatures will guard against premature failure Where continuous duty is desired for longer time intervals component temperatures should be maintained less than 100 C monitoring the outside brake surface temperature is a sufficient reference Torque Maximum Drag Torque Nominal Max Power Ratings Maximum Brake Model Measure Torque De Energized Input Inertia 5 minute continuous Speed Cooling Unit Code Range at 1000 rpm Ib ft s kg m hp W hp wW rpm Method 5N 6 20 0 035 N m 6N 55 0 Ib in 0 3 Ib in Blower d 3 3 ED 715 7N 62 0 kg om 0 36 kg om 1 27 x 10 1 72 x 10 5 3400 4 3000 25 000 included 8N 6 20 0 035 5N 28 0 0 14 6N 250 Ib in 1 2 Ib in Blower 61 x 1034 1 102 1017 12 0 815 7N 280 14 9 61 x 10 30 x 10 0 7000 8 6000 000 includea 8N 28 0 0 14
12. Friction of shaft bearings is a measurable load but some friction can exist in carrier bearing When correctly loaded and lubricated the friction is insignificant The value may be quantitatively established by the following procedure 1 Remove all attachments to the dynamometer shaft Advance the torque control slightly to obtain a small torque load Apply a small amount of torque by hand in one direction of rotation Carefully release the shaft allow several seconds and record the torque reading if any Then carefully re apply torque in the opposite direction tA 2 Slowly release the shaft as above and compare the two readings The difference should be less than 190 of full scale During actual motor testing there is usually enough system vibration to settle negating frictional effects If excessive drag is present mechanical realignment may be required dependent upon dynamometer size Certain mechanical factors need to be determined before corrective action proceeds Please contact Magtrol Technical Assistance 4 1 7 VIBRATION rotating dynamometer assemblies are precision balanced however the dynamometer shaft is cantilevered This may cause vulnerability to radial forces v m gt O 2 At high speeds some vibration noise are inevitable but not necessarily harmful However excessive resonant vibrations caused by bent shafts poor alignment and out of balance coupling
13. z i m 2 gt Z Ie m Figure 8 1 Damper Connection The above diagram shows the location of these elements however you will only be able to view them from the top 8 While pressing down on the damper arm thus positioning the entire assembly tighten the load cell clamping screw Be sure the load cell assembly has not moved axially and is seated against the sleeve resting up against the inner race of the carrier bearing 9 Remove the shim 10 Reinstall the pulse disk reassemble the enclosure and then recalibrate 53 Chapter 8 Troubleshooting Magftrol Hysteresis Dynamometers 8 2 SPEED READOUT PROBLEMS If there is an erratic speed reading or no speed reading at all remove the rear panel of the dynamometer and inspect the pulse disk It must be tight on the rotor shaft and the shaft must rotate freely Also make sure that the disk is not bent or distorted If the disk is damaged contact Magtrol Technical Assistance for a replacement disk If the pulse disk appears normal then connect an oscilloscope with the probes across pins 8 and 10 of the dynamometer 14 pin D connector pin 8 is common or ground As the disk rotates the pulse voltage should switch between a low of about 0 4 VDC or less and a high of about 5 VDC If this signal is incorrect the problem is on the encoder optical pickup board The encoder optical pickup is replaceable as an assembly from the Magtrol Technical Assistance Departme
14. 0 4995 0 4999 5 875 28 13 62 11 0 625 951 10 26 5 9 5 0375 0 061 0 63 52 Ib 31 8 12 687 12 692 149 2 711 2 346 0 279 4 15 9 241 3 254 673 1 241 3 951 1 6 15 9 23 50 kg HD 715 1 25 0 4995 0 4999 5 875 30 14 29 11 0 625 9 5 10 285 9 5 0 375 N A 59 Ib 31 8 12 687 12 697 149 2 762 0 363 0 279 4 15 91241 3 254 723 9 241 3 9 5 26 60 kg HD 700 SERIES WITH SHORT BASE PLATE 1 4 ep SI Ed pce p d SHAFT END DETAIL 2 1 FLAT Model M ON P Weight HD 700 1 25 0 4995 0 4999 5 875 11 84 0 09 1110 625 951 10 9 841 9 84 0 35 0 061 0 63 30 Ib 31 8 12 687 12 692 149 2 288 0 2 2 279 4 15 9 241 3 2541250 0 250 9 1 6 15 9 13 6 kg HD 710 1 25 0 4995 0 4999 5 875 12 50 0 09 11 0 625 951 10 11 00 9 84 0 35 36 31 8 12 687 12 697 149 2 317 5 2 3 279 4 15 9 241 3 254 279 5 250 9 16 3 HD 705 1 25 0 4995 0 4999 5 875 14 45 0 07 11 0 625 9 5 10 12 95 9 84 0 35 0 061 0 63 43 Ib mm 31 8 12 687 12 692 149 2 367 0 1 8 279 4 15 9 241 3 254 329 0 250 9 1 6 15 9 19 5 kg HD 715 in 1 25 0 4995 0 4999 5 875 15 75 0 04 11 0 625 9 5 10 14 25 9 84 0 35 50 Ib 31 8 12 687 12 697 149 2 400 0 1 1 279 4 15 91241 3 2541362 0 250 9 22 7
15. OPERATING PRINCIPLES Information pertaining to theory of operation including speed torque torque signal amplification decimal point control damper cylinder and brake control power CALIBRATION Provides recommended calibration schedules along with step by step instructions for the calibration procedure OPTIONAL FEATURES Provides information regarding various optional features available to enhance the capability of Magtrol s Hysteresis Dynamometers including speed encoders and analog outputs TROUBLESHOOTING Solutions to common problems encountered during setup and testing CALIBRATION RECORD Data sheet for tracking calibration results SCHEMATICS For the torque amplification board speed sensor board load cell and brake control power supplies vi Magftrol Hysteresis 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 text Note This is intended to draw the operator s attention to complementary information or advice relating to the subject being treated It introduces information enabling the correct and optimal function of the product CAUTION THIS IS USED TO DRAW THE OPERATOR S ATTENTION TO INFORMATION DIRECTIVES PROCEDURES ETC WHICH IF IGNORED MAY RESULT IN DAMAGE TO THE MATERIAL BEING USED THE ASSOCIATED TEXT DESCRIBES THE NECESSARY PRECAUTIONS TO TAKE AND THE CONSEQU
16. 22 2 9 512 9 525 101 6 203 2 3 2 279 4 12 7 159 216 177 8 250 9 5 7 kg HD 505 in 0 88 0 3745 0 3750 4 0 9 5 0 10 11 0 5 63 8 5 8 5 9 84 0 35 0 05 0 375 13 0 Ib mm 22 2 9 512 9 525 101 6 241 3 2 6 279 4 12 7 159 216 215 9 250 91 1 27 9 53 5 9kg HD 515 0 88 0 3745 0 3750 4 0 10 25 0 10 11 05 63 8 5 9 25 9 84 0 35 N A 13 0 Ib mm 22 2 9 512 9 525 101 6 260 4 2 6 279 4 12 7 159 216 234 9 250 9 5 9 kg These dimensions represent the distance between mounting holes There are four 4 mounting holes on each base plate 8 Magftrol Hysteresis Dynamometers Chapter 1 Introduction Dimensions 2 7 SERIES WITH LONG BASE PLATE es m 2 m 2 gt T O 2 SHAFT END DETAIL 2 1 FLAT Model units OB D E P Q Weight HD 700 1 25 0 4995 0 4999 5 875 24 12 75 11 0 625 95 10 225 9 5 0 375 0 06 0 63 39 Ib mm 31 8 12 687 12 692 149 2 609 6 323 9 279 4 15 9 241 3 254 571 5 241 3 9 5 1 6 15 9 17 63 710 1 25 0 4995 0 4999 5 875 26 13 59 1110 625 951 10 24 5 9 510 375 N A 45 Ib mm 31 8 12 687 12 697 149 2 660 4 345 2 279 4 15 9 241 3 254 622 3 241 3 9 5 20 30 HD 705 1 25
17. ED SERIES ENGINE DYNAMOMETERS eq SHAFT END DETAIL 2 1 SQUARE KEY units M ON P Q R Weight ED 715 in 1 72 0 7490 0 7495 6 87 16 00 18 13 11 00 1 00 10 50 14 50 9 50 0 37 0 64 1 00 0 187 75 Ib 43 7 19 025 19 037 174 5 406 4 460 5 279 4 25 4 266 7 368 3 241 3 9 4 16 35 25 4 4 83 34 ED 815 3 02 1 4995 1 5000 11 00 23 00 23 27 17 00 2 00 16 63 20 80 15 00 5 8 11 1 287 2 00 0 375 285 Ib mm 76 7 38 087 38 100 279 4 584 2 591 1 431 8 50 8 422 4 528 3 381 0 THD 32 7 50 8 9 53 129 3kg Chapter 1 Introduction Magftrol Hysteresis Dynamometers Dimensions ED m 800 SERIES WITH LONG BASE PLATE 5 T O 2 NOTE For detailed dimension drawings of dynamometers with the T slot base plate option visit Magtrol s Web site Model units A OB D E F G H J K L M ON Weight HD 800 in 2 13 0 9995 1 0000 9 38 5 23 81 17 2 14 6 14 21 41 36 5 15 0 53 237 010 541 25 387 25 400 228 6 978 605 4321 50 81 3711 356 5441 9271 381 1351 107 2 HD 810 in 2 05 0 9995 1 0000 9 38 5 23 09 17 21 14 6 14 2071 36 5 151 0 53 233 01 52 2
18. It is important to consider all torque points that are to be tested not only rated torque but also locked rotor and breakdown torque Dynamometer selection should initially be based on the maximum torque requirement subject to determining the maximum power requirements Maximum Speed This rating is to be considered independent of torque and power requirements and is the maximum speed at which the Dynamometer can be safely run under free run or lightly loaded conditions It 15 not to be considered as the maximum speed at which full braking torque can be applied Maximum Power Ratings These ratings represent the maximum capability of the Dynamometer Braking System to absorb and dissipate heat generated when applying a braking load to the motor under test The power absorbed and the heat generated by the Dynamometer is a function of the Torque T applied to the motor under test and the resulting Speed n of the motor This is expressed in these power P formulas 7 SI P watts T N m x n rpm x 1 047 x 10 English P watts T Ib in x n rpm x 1 183 x 102 Metric P watts T kg cm x n rpm x 1 027 x 102 All of Magtrol s controllers readouts and software calculate horsepower as defined by 1 hp 550 lb ft s Using this definition hp P watts 745 7 we The Dynamometer s ability to dissipate heat is a function of how long a load will be applied For this reason the
19. 149 2 mm 440 oz in Torque Range 31 0 0 3 10 u Input Inertia 5 51 x 104 Ib ft s2 gt Maximum Speed 25 000 rpm ro Maximum Input Power 20114045 duty 150 W lt 5 minutes 700 W 30000 25000 20000 Q 15000 10000 5000 0 t t t f i i T 0 88 176 264 352 440 oz in 0 0 62 1 24 1 86 2 48 3 10 TORQUE Figure 4 9 HD 700 Power Absorption Curve HD 710 0 4995 in 0 5000 in Shaft Diameter 12 687 mm 12 700 mm Shaft Height 5 875 in 149 2 mm 440 oz in Torque Range 31 0 3 10 Input Inertia 5 51 x 104 Ib ft s Maximum Speed 25 000 rpm Maximum Ingut Power continuous duty 935 W lt 5 minutes 1400 W 31 Chapter 4 Testing Magftrol Hysteresis Dynamometers 30000 25000 20000 15000 10000 5000 88 176 0 0 62 1 24 264 352 440 ozin 1 86 2 48 3 10 N m TORQUE Figure 4 10 HD 710 Power Absorption Curve HD 705 SPEED rpm Shaft Diameter 0 4995 0 5000 in 12 687 mm 12 700 mm Shaft Height 5 875 in 149 2 mm 55 0 Ibin Torque Range 62 0 kg cm 6 20 Input Inertia 1 101 x 10 Ib ft s Maximum Speed 25 000 rpm Maximum Input Power continuous duty 300 W 5 minutes 1400 W 30000 25000 20000 15000 10000 5000
20. 228 6 mm 125 0 Torque Range 140 0 kg cm 14 00 N m Input Inertia 4 43 x 10 Ib ft s Maximum Speed 12 000 rpm Maximum Input Power continuous duty 3000 W lt 5 minutes 3500 W 33 Chapter 4 Testing Magftrol Hysteresis Dynamometers 15000 12000 9000 6000 3000 SPEED rpm 25 50 75 100 125 0 28 56 84 112 14 0 TORQUE o Figure 4 14 HD 810 Power Absorption Curve HD 805 0 9995 1 0000 in Shaft Diameter 25 387 mm 25 400 mm Shaft Height 9 00 in 228 6 mm 250 Ib in Torque Range 280 kg cm D 28 0 m Input Inertia 8 81 x 10 Ib ft s2 gt Maximum Speed 12 000 rpm ro Input Power continuous duty 3000 2 p lt 5 minutes 5300 W 15000 12000 9000 m 6000 3000 0 0 50 100 150 200 250 Ib in 0 5 6 113 168 22 4 28 N m TORQUE Figure 4 15 HD 805 Power Absorption Curve HD 815 F 0 9995 1 0000 shalt Diameter 25 387 mm 25 400 mm Shaft Height 9 00 in 228 6 mm 250 Ib in Torque Range 280 kg cm 28 0 Input Inertia 8 81 x 10 Ib ft s2 Maximum Speed 12 000 rpm laximurm input Power continuous duty 6000 W P lt 5 minutes 7000 W 34 Magtrol Hysteresis Dynamometers Chapter 4 Testing 15000 12000 9000 6000 3000
21. 4 1 4 Fixtures and Couplings e Windage Negligible at speeds up to 6000 rpm This effect is described more extensively in Section 4 1 5 Windage e Mechanical Friction Generally negligible on HD 400 series dynamometers and larger On HD 106 and HD 100 the user is cautioned to be aware of the effects that friction may cause For more detail refer to Section 4 1 6 Friction 25 O v m gt O 2 Chapter 4 Testing Magftrol Hysteresis Dynamometers 4 1 3 4 1 3 1 BS 8 ae Note None of the above take into account the long term drift effects on digital readout instrumentation This is covered for each instrument by their individual specifications Also many of the above factors are dependent upon motor horsepower fixturing and other circumstances beyond the control of Magtrol If reasonable care is exercised and calibration and maintenance are performed on a regular basis motor test data accuracy better than 0 25 of torque speed value can be expected Power DissiPATION All Magtrol Dynamometers are power absorption instruments As a dynamometer loads a test motor it is absorbs horsepower from the motor into the hysteresis brake The brake then converts this mechanical energy into heat There are finite limits to the amount of energy and resulting temperature rise that any absorption brake can withstand Rapidly rising operating temperatures from excessive power input can cause severe
22. 8 1 2 1 Be TORQUE READOUT PROBLEMS New DyNAMOMETER If the dynamometer is new never operated before and the torque reading is near full scale and constant the probable cause is failure to remove the shipping restraining bolt This applies to all dynamometers with model numbers from 106 to 715 For further instruction refer to Section 3 1 Removal of the Load Cell Shipping Restraining Bolt ZERO BALANCE Zero balance is usually attained by the ZERO control potentiometer on the rear panel of the dynamometer Refer to Section 6 2 Calibration Procedure If you cannot obtain a zero torque reading with zero applied torque you will need to first make sure that your load cell is functional To verify that the strain gauge is stable under stress complete the following steps 1 2 3 Install the calibration beam Set the power supply for full current Install a weight on the beam either side sufficient to apply close to 100 of full scale rated torque If the reading is stable switch the weight to the other side of the beam Steady the weight and the beam to be sure they are motionless Note The torque reading may show activity but hold steady within three or four dynamometer torque digits Steady Torque Reading If the torque reading is active and steady you will need to reestablish the zero load cell balance 1 Adjust zero control on rear panel for approximate mechanical center This is a
23. 9 2 2 zi siepooug 6115 A 001 VIN 8175 T T 14 001 viene xo Hoinio Moti 5 91 wer 6115 Tt WOD v S gy 544 2115 Asc lo of rao anor dAS onbiol ant 19 anor 14001 F 1 ac ray oz sd au 01 PIAS ge T x 0 crew bi Jm 00r 80 XXL oa 124 P lelelelelelelelelelelg 2a m sT HSE woav feje eens enee L 1 a S z S moo 5 2 5 2 8 115 001 ASTE 4 0 puz 4L eBeis 15414 141 S10100uuo9 1so1 56 Magtrol Hysteresis Dynamometers Appenidix B Schematics B 2 SPEED SENSOR BOARD U1 5V Pin 7 of 14 Pin OPB963 Brown Wire FO Pin 10 of 14 Pin White Wire lt GND Pin 8 of 14 Pin Green Wire 2015 and later dynamometers 5V 5V gt Fo OPB963N51 COM GND PA D5 0 0 PAD6 PAD7 C
24. If the reading is within 10 of the value specified in the table proceed to Section 8 1 3 2 Current Check If the reading is not within the values specified contact Magtrol Technical Assistance IS Note The resistance check in the table is accurate for Magtrol HD 106 100 400 500 and 700 Series ED 715 and HD 825 Dynamometers The HD 800 805 810 and 815 Dynamometers have circuitry between the connector and the brake coil The brake coil must be isolated from this circuitry for the resistance in the table to be accurate 8 1 3 2 Current Check 1 Insert an ammeter between the power supply and dynamometer brake 2 Adjust the power supply voltage until the ammeter reading is equal to the value in the following table Dynamometer F S Current Model A HD 106 0 145 HD 100 0 135 HD 400 0 300 HD 500 0 298 HD 510 0 298 HD 505 0 596 HD 515 0 596 HD 700 0 339 HD 710 0 339 HD 705 0 678 HD 715 0 678 HD 800 1 200 HD 810 1 200 HD 805 2 400 HD 815 2 400 HD 825 4 800 ED 715 0 678 ED 815 2 400 3 Attach the appropriate weight for full scale torque and verify whether the brake holds the load If it does not hold the load with proper current flowing in the brake the power supply is not the problem The dynamometer is probably at fault and you will need to contact Magtrol Technical Assistance for further help Z m z gt 2 e
25. SPEED rpm 50 100 150 200 250 Ib in 0 56 113 168 224 28 TORQUE o Figure 4 16 HD 815 Power Absorption Curve HD 825 1 4995 in 1 5000 in Shaft Diameter 38 087 mm 38 100 mm Shaft Height 9 00 in 228 6 mm 500 Ib in Torque Range 565 UU 56 5 N m m Input Inertia 1 85 x 10 Ib ft s2 gt 8 000 Maximum input Pawer continuous duty 12 000 W 2 5 minutes 14 000 W 10000 8000 6000 m 4000 o 2000 0 0 100 200 300 400 500 Ib in 0 113 226 33 9 45 2 56 5 TORQUE Figure 4 17 HD 825 Power Absorption Curve ED 715 0 7490 in 0 7495 in Shaft Diameter 19 025 mm 19 037 mm Shaft Height 6 87 in 174 5 mm 55 0 Ib in Torque Range 62 0 kg cm 6 20 Input Inertia 1 27 x 10 Ib ft s Maximum Speed 25 000 rpm Maximum Input Power continuous duty 3000 W lt 5 minutes 3400 W 35 Chapter 4 Testing Magftrol Hysteresis Dynamometers 30000 25000 2 20000 Q 15000 m 10000 n 5000 0 0 11 22 33 44 55 Ib in 0 1 24 2 48 3 72 4 96 6 20 TORQUE Figure 4 18 ED 715 Power Absorption Curve ED 815 1 4995 1 5000 in
26. Series weights 45 Z i m 2 gt z m Chapter 6 Calibration Magtrol Hysteresis Dynamometers 6 3 CALIBRATION PREPARATION Before beginning the calibration procedure the following items must be checked Be sure all equipment is set for the correct power line input voltage as specified on the original order e Ensure correct earth grounds on equipment e For instructions and operational details on how to set an open loop current refer to your power supply manual e Turn on the controller or readout and power supply and allow 20 minutes for warm up longer if the equipment is below room temperature 6 4 CALIBRATION PROCEDURE The calibration procedure is as follows Sg Note Do not hang the weight until instructed to do so in step 4 1 Place the calibration beam onto the dynamometer shaft inserting the shaft through the center hole of the beam Secure by tightening the clamping screws See Figure 6 2 IESE Note If the shaft has a flat make sure that the flat is facing down and tighten the clamping screw s against the flat only CB Series Calibration Beam Dynamometer shaft Clamping screws WT Series Calibration Weight gt m 2 gt 2 Figure 6 2 Calibration Setup Q 2 Apply full current to the dynamometer brake 3 With the beam perfectly horizontal use a flathead screwdriver to adjust the ZERO trim pot located the rear panel so th
27. Shat Diameter 38 087 mm 38 100 mm Shaft Height 11 00 in 279 4 mm 250 Ib in Torque Range 280 kg cm v 28 0 N m m Input Inertia 9 61 x 10 Ib ft s gt Maximum Speed 12 000 rpm ro Maxi continuous duty 6000 W aximum Input Power 5 minutes 7000 W 15000 12000 9000 m m 6000 3000 0 0 50 100 150 200 250 Ib in 0 5 6 113 168 224 28 TORQUE Figure 4 19 ED 815 Power Absorption Curve 4 1 3 2 Cooling Methods ee Note For additional details on compressed air and blower setup along with extensive information on the Air Flow Sensor feature refer to Section 3 3 3 Air Cooling 4 1 3 2 1 Compressed Air Magtrol s HD 510 515 800 and 805 dynamometers are internally ported for compressed air cooling Always use the filter and line regulator supplied with the unit These elements should be installed 36 Magftrol Hysteresis Dynamometers Chapter 4 Testing as shown in the following diagram SANS Figure 4 20 Dynamometer with Compressed Air Connection For maximum air flow and cooling set the regulator to the following CFM PSI HD Model Cubic Feet Pounds per per Minute Square Inch HD 510 7 1 75 HD 515 10 4 HD 800 13 10 m HD 805 15 7 z WARNING DO NOT EXCEED THE PRESSURES GIVEN The air supply should be enabled whe
28. how the assembly clamps onto the rear support member of the brake LOAD CELL PC BD FINE BALANCE LOCKING SCREW LOAD CELL ASSEMBLY TEMP COMP PIVOT ASSEMBLY STRAIN GAUGES NOTE A coarse balancing resistor located on the torque signal amplification WIRE COLORS BLUE GREEN WHITE RED board may be connected between the blue or green and white wire terminals Figure 5 1 Mechanical Layout of a Load Cell 42 I m 2 lt Magtrol Hysteresis Dynamometers Chapter 5 Operating Principles 5 3 TORQUE SIGNAL AMPLIFICATION A printed circuit board mounted on the dynamometer rear panel identified as part number 234 401 101 xxx contains the torque signal amplifiers IC1 IC2 and IC3 load cell excitation supply consisting of voltage reference DZ1 amplifier IC4 and Transistors Q1 Q4 Voltage reference DZ1 is a precision voltage source and along with IC4 and 01 04 provides 45 00 and 5 00 volts DC excitation to load cell bridge Transistors 1 4 are NPN and PNP transistors serving as series pass elements to boost the current output drive capability to over 30 mA Bipolar bridge excitation is used to improve the noise immunity of the low millivolt range bridge output signal See B Torque Amplification Signal in Appendix B Amplifier IC1 is a precision differential input instrumentation amplifier providing amplification necessary to calibrate the torque sign
29. maximum power ratings given are based on continuous operation under load as well as a maximum of 5 minutes under load To safely dissipate heat and avoid Dynamometer failure the maximum power rating is the most important consideration in selecting a Dynamometer 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 z on 2 Z 5 gt Magftrol Hysteresis Dynamometers Chapter 1 Introduction Rati 2 Ratings HD ED 22 Torque Maximum Drag Torque Nominal Max Power Ratings Maximum Brake or Model Measure Torque De Energized Input Inertia 5 minute continuous Speed Cooling z Unit Code Range at 1000 rpm Ib ft s kg m2 w 0 018 0 056 mN m N 2 50 ozi i HD 106 59 25 7 04 x 107 9 54 x 107 35 7 30 000 Convection 8N 18 00 0 056 mN m 5N 0 08 N m 0 64 mN m 11 00 ozi 09 ozi HD 100 20 m 22 a 340 108 4 61 x 106 75 20 25 000 Convecti
30. mechanical distortion of the rotor assembly This in turn may cause the rotating assembly to contact the stationary members that surround it Once this happens metal transfer and ultimately seizing of the brake assembly may occur Excessive power over extended periods of time may result in more obscure damage including breakdown of bearing lubricants and degradation of magnetic coil insulation Also exposure to temperatures over 690 C 1275 F will alter the rotor s magnetic properties Note Do not instantaneously apply maximum power torque speed to a cold dynamometer High temperature gradients cause differential expansions resulting in misalignment of the running air gaps between the rotor and stator assembly on the load brake Allow all dynamometers to warm up before heavy loading This is accomplished by gradually increasing the load to the motor If a motor must be tested cold warm up the dynamometer with a different motor first Note Operating at the continuous power rating for periods of up to 4 hours is acceptable However operating for extended periods at high temperatures will result in premature component and bearing failure Limiting the length of the cycle and the component temperatures will guard against premature failure Where continuous duty is desired for longer time intervals component temperatures should be maintained less than 100 C monitoring the outside brake surface temperature is a sufficient ref
31. rated speeds long with T slots available HD 800 series only 2 1 0 Mechanical Modifications SPEED ENCODER Magtrol can provide customized base plates riser blocks and 60 bit standard 00 shaft modifications 60 and 600 bit 30 60 and 6000 bit 40 Contact sales regarding speed encoders for HD 100 through HD 500 series dynamometers SYSTEM OPTIONS AND ACCESSORIES CATEGORY DESCRIPTION MODEL PART High Speed Programmable Dynamometer Controller DSP7000 Open Loop Dynamometer Controller 6200 POWER High Speed Single Phase Power Analyzer 6510e ANALYZERS High Speed Three Phase Power Analyzer 6530 M TEST 7 Motor Testing Software M TEST 7 Temperature Testing Hardware HW TTEST POWER T SUPPLIES Power Amplifier included with all HD 825 dynamometers 5241 MISC Manually Controlled Switch Box 5500 ELECTRONICS Direction Indicator 5600 Table with grooved table top for HD 100 400 500 700 series short base plate TAB 1457S dynamometers and ED 715 DYNAMOMETER 1 drilled and tapped for HD 100 400 500 700 series long base plate TAB 1457L TABLES ynamometers Table for HD 800 series long base plate dynamometers and ED 815 TAB 0800L base of dynamometer also serves as the table top Table for HD 825 long base plate dynamometers TAB 0825L MOTOR Adjustable Motor Fixtures AMF Series FIXTURES Fixed Motor Fixtures
32. 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 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 ED DYNAMOMETER SELECTION Magtrol s Hysteresis Dynamometers cover a wide range of Torque Speed and Mechanical Power ratings To select the appropriate size Dynamometer for your motor testing needs you will need to determine the Maximum Torque Speed and Power applied to the Dynamometer Maximum Torque The Magtrol Hysteresis Absorption Dynamometer will develop braking torque at any speed point including low speed and stall conditions 0 rpm
33. the load cell shipping restraining bolt if you have just unpacked a new HD 100 HD 500 HD 515 HD 710 HD 106 HD 505 HD 700 HD 715 HD 400 HD 510 HD 705 ED 715 This does not apply to HD 800 HD 805 HD 810 HD 815 HD 825 or ED 815 Dynamometers For further instruction see Section 3 1 Removal of the Load Cell Shipping Restraining Bolt Note Retain the shipping restraining bolt for future use when moving or shipping your Magtrol Dynamometer Chapter 1 Introduction Magftrol Hysteresis Dynamometers 1 2 FEATURES OF THE HYSTERESIS DYNAMOMETER All Magtrol Hysteresis Dynamometers HD and ED Series feature the following Hysteresis Braking System The dynamometers do not require speed to create torque and therefore can provide a full motor ramp from free run to locked rotor along with precise torque loading gt om 2 Z 5 gt Z e Air Flow Sensor Any Magtrol Hysteresis Dynamometer that is internally ported for compressed air and or blower cooling contains an air flow sensor that provides protection against overheating and operator error Standard Torque Units English metric and SI are available e Easy Calibration Unique features of each series are listed below 1 2 1 HD Series Magtrol s HD Series Dynamometers are versatile and ideal for testing in low to medium power ranges Features include e Accuracy 0 25 to 0 596 full scale depending on size and system configuration e Custom
34. watts in addition to torque and speed A Single or Three Phase Power Analyzer a required component in a test system measuring motor efficiency can be integrated into this system as well as Magtrol s Temperature Testing Hardware Dynamometer with DSP7001 Controller and M TEST Software HD ED DYNAMOMETER PC DSP7001 CONTROLLER oA USB 2 Pin Dynamometer Brake Cable PN88M070 0150 included with dynamometer 14 Pin 14 Pin Instrument Cable 88 007 0150 included with dvnamometer Dynamometer with 6510e Power Analyzer DSP7001 Controller and M TEST Software 6510e POWER ANALYZER AC DC Input Power HD ED DYNAMOMETER GPIB Card USB 2 Pin Dynamometer Brake Cable PN88M070 0150 included with dynamometer 14 Pin 14 Pin Instrument Cable PN88M007 0150 included with dynamometer 13 Chapter 1 Introduction Magtrol Hysteresis Dynamometers System Configurations HD ED CUSTOM MOTOR TEST SYSTEM HD Series Hysteresis Dynamometers can be incorporated into a Customized Motor Test System These PC based turn key systems are custom designed and built to meet specific user requirements z on 2 Z 5 5 gt emergency stop button M TEST Motor Testing Software side panel connectors allow LCD monitor for easy
35. 0 5 for small dynamometers up to HD 500 to 2 of the starting torque value per 1000 rpm of applied speed Note If highly accurate long term torque stability is required consider the Magtrol DSP7000 Dynamometer Controller This is a computer controlled closed loop system capable of maintaining either constant torque or speed O 9 gt O 2 41 5 Operating Principles 5 1 5 2 SPEED Inside the dynamometer enclosure is an optical speed transducer A high speed optical switch consisting of an Infrared IR LED and IR receiver senses the passage of light through a slotted disk that is attached to the end of the dynamometer shaft Light passing through a slot in the disk causes the speed output signal to go to a logic low near 0 VDC As a solid section passes in front of the IR receiver the output signal switches to a logic high near 5 VDC Rotation of the disk results in the optical switch generating a pulse frequency of 60 bits per shaft revolution For schematic see Section B 2 Speed Sensor Board in Appendix B TORQUE Torsional force from the hysteresis brake assembly is measured by a load cell The load cell consists of a flexing beam with four strain gauges The strain gauges are in a bridge configuration producing an analog signal proportional to torque The load cell schematic in Appendix B shows voltage levels and connection identifications The mechanical diagram below illustrates
36. 00 Dynamometer Controller prevents the dynamometer brake from being energized until the blower or air supply has been turned on When the air supply to the dynamometer is turned on the pressure sensor closes an electrical contact Two wires from the sensor run internally to the dynamometer and attach to the torque amplification board One of the wires from the sensor is then passed directly to the back panel connector 14 pin connector pin 1 The other wire is tied on the board to 5 VDC COM 14 pin connector pin 8 When used with the DSP7000 pin 1 is internally pulled high with a resistance to 5 volts If not using a Magtrol controller it is assumed the user will pull pin 1 to the 5 volts supplied to the amplifier board pin 7 with a 1 K to 10 K resistor PRESSURE 1 SWITCH T 2 BACK PANEL c 5 10 10 COM 11 11 TORQUE AMPLIFICATION BOARD Figure 3 9 Air Flow Sensor Schematic 23 Chapter 3 Installation Configuration Magftrol Hysteresis Dynamometers 3 3 3 1 Blower Setup If an HD 710 HD 715 HD 810 HD 815 ED 715 or ED 815 dynamometer is being used a blower input is integrated into the unit n U Figure 3 10 Dynamometer with Blower Connection For more information see Se
37. 000 18000 The power absorption curves 12000 represent the maximum power 5 6000 neat that the dynamometer can 0 dissipate over time 0 0 5 1 1 5 2 2 5 ozin 0 36 7 2 108 14 4 18 mN m TORQUE HD 100 HD 400 30000 30000 25000 25000 20000 20000 15000 15000 10000 10000 5000 5000 0 0 0 2 2 4 4 6 6 8 8 11 0 8 16 24 32 40 oz in 0 16 32 48 64 80 0 56 112 168 224 280 mN m TORQUE TORQUE HD 510 30000 30000 25000 i 25000 5 20000 20000 15000 15000 10000 10000 5 5000 5000 OM 0 0 24 48 72 96 120 ozin 0 24 48 72 96 120 ozin 0 170 340 510 680 850 mN m 0 170 340 510 680 850 mN m TORQUE TORQUE 30000 30000 25000 25000 2 20000 20000 15000 Q 15000 ul ul 10000 10000 5000 5000 0 0 0 48 96 144 192 240 ozin 0 48 96 144 192 240 O 340 680 1020 1360 1700 O 340 680 1020 1360 1700 mN m TORQUE TORQUE 11 Chapter 1 Introduction Magftrol Hysteresis Dynamometers
38. 120V 130 UL CSA 125 250V SB HD ED 815 XNA 240 V 130 IEC 630mA 250V T HD 825 XN 120V N A N A N A HD 825 XNA 240 V N A N A N A BLOWER POWER AND FUSES Models HD 710 HD 715 HD 810 and ED 715 Model Voltage VA Style Rating Blower BL o01 120v ULCSA 63A 250V SB Models HD 815 and ED 815 include the BL 002 BL 001A 240 V 500 IEC 315A 250V T blower BL 002 120V 1000 UL CSA 15A 250V SB Model HD 825 uses two BL 002 blowers for BL 002A 240 V 1000 IEC 63A 250V T cooling its two brake sets BLOWER DIMENSIONS Allow approximately 6 in to 8 in pen Model BL 001 BL 002 152 mm to 203 mm between rear in mm in mm of dynamometer base plate and 6 152 6 152 blower for connection hardware B 11 279 11 279 Required hardware is supplied with the 6 152 6 152 dynamometer D 8 203 15 381 4 102 4 102 BL 002 Blower has two filter 8 203 12 305 elements iac G 1 25 1 25 Rer ES Weight 8 51 39kg 181b 8 1 kg Chapter 1 Introduction Magftrol Hysteresis Dynamometers 4 4 z N lt Dimensions HD ED 29 _ 2 Z NOTE Original dimensions are in English units Dimensions converted to Metric units have been rounded and are for ref
39. 20 turn control so rotate it clockwise more than 20 turns and then counterclockwise for 10 turns Disconnect the dynamometer line cord from the line power source Turn off the digital readout device or dynamometer controller Lower the rear panel Note It is a good idea to clamp the rear panel to the dynamometer base plate This will decrease the possibility of pulling on the fragile interconnection lead wires Remove resistor R20 from the torque amplification circuit board Turn on the digital readout instrument While observing or recording the torque reading start with a 100 K to 200 K resistor and temporarily connect it in the R20 position on the circuit board Temporarily jumper solder link SL14 If the reading becomes larger remove the jumper and bridge solder link SL 17 If the reading becomes smaller remove the jumper and bridge solder link SL 14 50 Z m 2 gt Z Ie m Magftrol Hysteresis Dynamometers Chapter 8 Troubleshooting 9 Select resistors until two adjacent resistance values within 190 or 290 of each other cause the reading to swing through zero Do not use any resistance below 10K 10 Once the correct resistance value has been established a high quality 50 ppm C 190 or better precision resistor RN60C or RN65C must be obtained Permanently solder it onto the board in the R20 position 11 The ZERO control potentiometer which was previously set to a mechanical center shoul
40. 3 ah 9 E O O O Figure 3 5 HD 800 Series Top View 20 Magftrol Hysteresis Dynamometers Chapter 3 Installation Configuration 3 3 SYSTEM CONFIGURATIONS After the load cell shipping restraining bolt has been removed and the dynamometer has been earth grounded the unit is ready for connection to the appropriate readout instrument and power supply 3 3 1 MaNuaL Test SYSTEMS The dynamometer can be set up as a manual test system for quick pass fail testing on the production line or at incoming inspection A typical manual test system will consist of a Magtrol Hysteresis Dynamometer used in conjunction with a Magtrol 6200 Open Loop Controller Magtrol s Single or Three Phase Power Analyzer may be included as an option The following diagram illustrates the required cable sets and connections for a manual test system setup HD ED DYNAMOMETER 6200 CONTROLLER 2 Pin Dynamometer Brake Cable PN88M070 0150 included with dynamometer 14 Pin 14 Pin Instrument Cable PN88M007 0150 included with dynamometer Figure 3 6 Dynamometer with 6200 Controller 21 Chapter 3 Installation Configuration Magftrol Hysteresis Dynamometers 3 3 2 PC Basep Test Systems In a PC based motor test system data is collected on a personal computer using Magtrol s M TEST Software a DSP7000 Programmable Dynamometer Controller and requisite interface cards and c
41. 3379 54K T tuF com 4 8 in out 1 6 40 LM320T15 15 5 15 U1 SZ 11 T 1 35 60 gt 0 0 2 index A Accuracy 24 Air Cooling 22 Blower Connection 36 Input 16 Setup 23 Brake Control Power 43 Brake Control Power Supply HD 800 to HD 815 57 HD 825 58 Calibration 44 Calibration Beams 44 Calibration Potentiometer 16 Calibration Record 54 Calibration Weights 44 Cogging 39 Compressed Air Connection 35 Input 16 Setup 23 Cooling Methods 35 Coupling Losses 24 Couplings 37 Current Check 51 D Damper Cylinder 43 Data Sheet 3 Decimal Point Control 42 Dynamometer Brake Input 15 Dynamometer Connector 15 E Earth Ground 19 Eddy Currents 39 Encoder Switch 16 Erratic Torque Reading 50 F Features 2 Fixtures 37 Friction 38 Full Scale Torque 50 Full Scale Torque Calibration 24 Inputs 15 Blower 16 Compressed Air 16 Dynamometer Brake 15 L Load Cell 41 Load Cell Schematic 56 M Manual Test Systems 20 Mechanical Alignment 52 O Outputs 15 P PC Based Test Systems 21 Power Absorption Curves 25 Power Dissipation 25 R Rear Panel 15 Resistance Check 50 Rotational Alignment 52 S Safety 24 Shaft Misalignment 37 Shipping Bolt 1 17 Speed 41 Speed Encoder 48 Speed Readout Problems 53 Speed Sensor Board 56 System Configurations 20 Manual 20 PC Based 21 T Temperature
42. 5 387 25 400 228 6 978 587 432 50 8 371 356 526 927 381 13 5 105 3 HD 805 in 2 13 0 9995 1 0000 9 38 5 20 57 17 2 14 6 14 18 21 36 5 151 0 54 287 016 54 25 387 25 400 228 6 978 522 4321 50 8 371 356 462 927 S381 13 7 129 7 HD 815 in 2 25 0 9995 1 0000 9 38 5 18 19 17 2 14 6 141 15 7 36 5 151 0541 288 0 Ib 57 25 387 25 400 228 6 978 462 432 50 8 371 356 3991 927 381 137 130 1 HD 800 SERIES WITH SHORT BASE PLATE ON Model OB D E F G H J K L M ON Weight HD 800 in 2 13 0 9995 1 0000 9 17 251 2 56 17 2 14 6 141 0 15 13 78 15 75 0 35 168 0 Ib 541 25 387 25 400 228 6 438 65 4321 50 8 371 3561 3 81 3501 400 9 76 2 HD 810 in 2 05 0 9995 1 0000 9 18 00 2 59 17 21 14 6 14 0 18 14 06 15 75 0 35 164 0 Ib mm 521 25 387 25 400 228 6 457 66 432 50 8 371 356 4 5 3571 400 9 74 4 kg HD 805 in 2 13 0 9995 1 0000 9 20 50 2 57 17 2 14 6 141 0 1 15 75 15 75 0 35 228 0 Ib mm 541 25 387 25 400 228 6 520 65 4321 50 81 371 356 251 4001 400 9 103 4 kg HD 815 in 2 12 0 9995 1 0000 9 23 00 2 59 17 21 14 6 14 0 2 19 09 15 75 0 35 236 0 Ib 541 25 387 25 400 228 6 584 66 432 50 8 371 356 5 1 485 400 91 107 0 kg An HD 825 Dynamometer with long base plate is available if ordered with the acc
43. 50 mm Shaft Height 3 50 in 88 9 mm 40 0 oz in Torque Range 2 80 g cm 280 mN m Input Inertia 1 55 x 10 Ib ft s Maximum Speed 25 000 rpm continuous duty 55 Maximum Input Power lt 5 minutes 200 W 28 Magtrol Hysteresis Dynamometers Chopter 4 Testing 30000 25000 20000 15000 10000 SPEED rpm 5000 8 16 0 56 112 24 168 32 224 40 oz in 280 mN m TORQUE Figure 4 4 HD 400 Power Absorption Curve HD 500 0 3745 in 0 3750 in Sha Diameter 9 512 mm 9 525 mm Shaft Height 4 00 in 101 6 mm 120 0 oz in Torque Range 8 50 kg cm D 850 Input Inertia 8 05 x 10 Ib ft s2 gt Maximum Speed 25 000 rpm ro continuous duty 80 2 lt 5 minutes 400 W 0 1 1 0 24 48 72 96 120 oz in 0 170 340 510 680 850 mN m TORQUE Figure 4 5 HD 500 Power Absorption Curve HD 510 0 3745 in 0 3750 in Shatt Diameter 9 512 mm 9 525 mm Shaft Height 4 00 in 101 6 mm 120 0 oz in Torque Range 8 50 kg cm 850 mN m Input Inertia 8 05 x 10 Ib ft s Maximum Speed 25 000 rpm continuous duty 375 W Maximum Input Power a5 Minutes 750 W 29 Chapter 4 Testing Magftrol Hysteresis Dynamometers
44. 6000 The power absorption curves 4000 represent the maximum power 2000 heat that the dynamometer can dissipate over time 0 0 100 200 300 400 500 Ib in 0 113 226 33 9 45 2 56 5 N m TORQUE Magftrol Hysteresis Dynamometers Chapter 1 Introduction System Configurations HD ED OPEN LOOP SYSTEMS Magtrol offers both open loop manual test systems and PC based closed loop test systems A typical open loop system will consist of a Dynamometer and a Magtrol 6200 Open Loop Controller A Magtrol Single or Three Phase Power Analyzer which allows for the capturing of volts amps watts and power factor can be included as an option open loop system is often used for quick pass fail testing on the production line or at incoming inspection Magtrol s 6200 Controller provides pass fail testing as a standard feature z om 2 Z 5 gt Z Dynamometer with 6200 Controller HD ED DYNAMOMETER 6200 CONTROLLER 2 Pin Dynamometer Brake Cable PN88M070 0150 included with dynamometer 14 Pin 14 Pin Instrument Cable PN88M007 0150 included with dynamometer CLOSED LOOP SYSTEMS In a closed loop motor test system data is collected on a PC using Magtrol s M TEST Software DSP7000 Programmable Dynamometer Controller and requisite interface cards and cables Magtrol s Model 6200 and DSP7000 Controllers compute and display mechanical power in horsepower or
45. Dynamometers For special torque and speed requirements e Encoder Switch Optional feature that allows the user to switch between a 60 and 600 bit encoder or a 60 and 6000 bit encoder 1 2 2 ED Series Magtrol s ED Series Dynamometers are high performance dynamometers specifically designed to address the severe high vibration conditions inherent in internal combustion engine testing Features include Accuracy 0 25 full scale High Speed Capabilities 12 000 to 25 000 rpm depending on model Rugged Stainless Steel Shaft Larger shaft for additional strength e Specially Reinforced Load Cell Stainless steel pin used at contact point to prevent premature wear from excess vibration e Gusseted Pillow Blocks Adds additional front and rear support Brake Cooling Blower cooled to maximize heat dissipation Magftrol Hysteresis Dynamometers Chapter 1 Introduction 1 3 DATA SHEET HD Hysteresis Dynamometers ED Engine Dynamometers HD FEATURES e 16 Standard Models with Maximum Torque from 2 5 ozin to 500 Ib in 18 mN m to 56 5 N m Hysteresis Braking System provides precise torque loading independent of shaft speed Motor Testing from no load to locked rotor Standard Torque Units English Metric and SI e Accuracy 0 25 to 0 5 full scale Flow Sensor For protection against overheating and operator error e Base Plates available in long or short versions e Custom Dyna
46. ENCES THAT MAY ARISE IF THESE PRECAUTIONS ARE IGNORED STOP WARNING THIS INTRODUCES DIRECTIVES PROCEDURES PRECAUTIONARY MEASURES ETC WHICH MUST BE EXECUTED OR FOLLOWED WITH THE UTMOST CARE AND ATTENTION OTHERWISE THE PERSONAL SAFETY OF THE OPERATOR OR THIRD PARTY MAY BE AT RISK THE READER MUST ABSOLUTELY TAKE NOTE OF THE ACCOMPANYING TEXT AND ACT UPON IT BEFORE PROCEEDING FURTHER WHEN HEARING PROTECTION IS REQUIRED THE STOP SIGN IS REPLACED WITH THE EAR MUFF SYMBOL vii 1 Introduction 1 1 UNPACKING YOUR HYSTERESIS DYNAMOMETER Your Hysteresis Dynamometer was packaged in reusable shock resistant packing material that will protect the instrument during normal handling gt 2 Z 5 gt Z 1 Make sure the carton contains the following Magtrol User Manual CD Rom Line Cord ka not included with 700 series or HD 825 Certificate of Calibration QN INS PB 14 Pin Instrument Cable Brake Cable Calibration Certificate 2 Inspectthe contents for any evidence of damage in shipping In the event of shipping damage immediately notify the carrier and Magtrol s Customer Service Department Save all shipping cartons and packaging material for reuse when returning the instrument for calibration or servicing 3 Remove the Shipping Bolt PLEASE TAKE NOTICE Before proceeding any further you will need to remove
47. FMF Series CALIBRATION Calibration Beam Assemblies and Calibration Weights CB and WT Series Mounting of ED Engine Dynamometers to dynamometer tables requires certain modifications Contact Magtrol for details Due to the continual development of our products we reserve the right to modify specifications without forewarning 15 2 Inputs Outputs 2 1 REAR PANEL gt Of 2 2 5 gt Z The rear panel provides connectors and receptacles for connecting to appropriate equipment 3 2 Figure 2 1 Rear Panel 2 2 REAR PANEL INPUTS AND OUTPUTS DYNAMOMETER Connect dynamometer brake cable here BRAKE INPUT Figure 2 2 Dynamometer Brake Input DYNAMOMETER Connect dynamometer signal cable here CONNECTOR 14 13 12 11 10 9 8 1 FLOW CLUTCH 8 45 0 VDC COM 2 TACH B 9 D P A 3 24 VDC 10 TACH A 4 24 VDC COM 11 INDEX 5 24 VDC COM 12 D P B 6 24 VDC 13 TORQUE COMMON 7 5 0 VDC 14 TORQUE SIGNAL Figure 2 3 Dynamometer Connector Magftrol Hysteresis Dynamometers Chapter 2 Controls CALIBRATION Adjust clockwise CW zero and counterclockwise CCW calibration POTENTIOMETER here See Chapter 6 Calibration 0 m 2 m 2 gt CW Calibration m CCW Calibration T O 2 Figure 2 4 Calibration Potentiometers ENCODER SWITCH Opti
48. IBRATION FREQUPEN GCY 5 25 uet e tt e ai eet e Lo COE HR pedale 48 T OPTIONAL FEATURES pe ded X b 49 T SPEED ENCODER roter etude e E der o ot 49 8 TROUBLESHOOTING RE ER 50 8 1 TORQUE READOUT PROBLEMS ett e Ee EE EHE ERO RU HO e Ree abun 50 82 2 NEW eee ER de t ERE Hebe 50 812 ZERO BALANCE DUE eee 50 8 13 FULL SCALE TORQUE 2 te ge Pag e PR 51 8 1 4 MECHANICAL ROTATIONAL 53 8 2 SPEED READOUT PROBLEMS iterare bete Fev a Lee p e eee boe Ee Ee e eere hee e Ae bae tid oen 54 APPENDIX A CALIBRATION 24 idi dro a exin eua noc d Pa RR E Re di 55 APPENDIX B SCHEMATICS ta rep tuia M ru tU 56 B 1 TORQUE AMPLIFICATION BOARD 1 4 reete R a A A A 56 2 SPEED SENSOR BOARD tact i ettet e t HR EUM Re Pack E t Pe et p I o Bere 57 B 3 EOAD e e detener re eee pid 58 B 4 HD 800 815 BRAKE CONTROL SUPPLY 59 5 HD 825 BRAKE CONTROL SUPDPEX ret ea ede dede e e d le Raids ay 60 INDEX
49. MAGTROL HD and ED Series Hysteresis 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 Inc Magtrol SA 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 2002 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 TRADEMARKS LabVIEW is a trademark of National Instruments Corporation Microsoft is a registered trademark of Microsoft Corporation National Instruments is a trademark of National Instruments Corporation Windows is a registered trademark of Microsoft Corporation 4th Edition revision M June 2015 MAGTROL Safety Precautions Several w
50. Rise 40 Torque 41 Torque Amplification Board 55 Torque Readout Problems 49 Torque Signal Amplification 42 Troubleshooting 48 49 U Unpacking 1 l Magftrol Hysteresis Dynamometers Vv Vibration 38 W Windage 24 37 Z Zero Balance 49 Zero Offset 24 62 Service Information RETURNING MAGTROL EQUIPMENT FOR REPAIR AND OR CALIBRATION Before returning equipment to Magtrol for repair and or calibration please visit Magtrol s Web site at http www magtrol com support rma htm to begin the Return Material Authorization RMA process Depending on where the equipment is located and which unit s will be returned you will be directed to either ship your equipment back to Magtrol Inc in the United States Magtrol SA in Switzerland Returning Equipment to Magtrol Inc United States When returning equipment to Magtrol Inc s factory in the United States for repair and or calibration a completed Return Material Authorization RMA form is required 1 Visit Magtrol s Web site at http www magtrol com support rma htm to begin the RMA process 2 Complete the RMA form online and submit 3 An RMA number will be issued to you via e mail Include this number on all return documentation 4 Ship your equipment to MAGTROL INC 70 Gardenville Parkway Buffalo NY 14224 Attn Repair Department 5 After Magtrol s Repair Department receives and analyzes your equipment a quotation listing all
51. ables SE Note Magtrol s Single or Three Phase Power Analyzer can be integrated into this system as well as Magtrol s Temperature Testing Hardware and Software The following diagrams illustrate the required cable sets and connections for a PC based test system setup HD ED DYNAMOMETER DSP7001 CONTROLLER 2 Pin Dynamometer Brake Cable PN88M070 0150 included with dynamometer 14 Pin 14 Pin Instrument Cable 88 007 0150 included with dynamometer Figure 3 7 Dynamometer with DSP7001 Controller and M TEST Software 6510e POWER ANALYZER HD ED DYNAMOMETER 2 Pin Dynamometer Brake Cable PN88M070 0150 included with dynamometer 14 Pin 14 Pin Instrument Cable PN88M007 0150 included with dynamometer Figure 3 8 Dynamometer with 6510e Power Analyzer DSP7001 Controller and M TEST Software 22 Magtrol Hysteresis Dynamometers Chapter 3 Installation Configuration 3 3 3 Ain CooLiNG Magtrol s HD 510 515 710 715 ED 715 and any 800 Series Dynamometer are all internally ported for compressed air or blower cooling and may be integrated with a manual or PC based test setup in order to provide air cooling of the dynamometer brake An air flow sensor has been added to these dynamometers to protect against operator error With the air flow sensor the dynamometer comes equipped with a pressure sensor ported into the cooling airway The sensor when used in combination with Magtrol s DSP70
52. al IC2 and IC3 provide additional amplification and scaling along with the counterclockwise calibration CCW CAL control The torque signal is calibrated by adjusting the rear panel trim potentiometers P1 and P2 labeled CW CAL and CCW CAL Torque signal zero is adjusted by using the rear panel trim potentiometer P3 labeled ZERO when no torque is applied The load cell on all dynamometers except the HD 106 produce an output signal of 15 mV at full torque The HD 106 output is 7 5 mV full scale Amplifiers IC1 IC3 calibrate this so the output in millivolts equals the dynamometer full scale torque The torque signal zero may be affected thermally and may need periodic readjustment Therefore the ZERO adjustment can be readjusted as needed The clockwise calibration CW CAL adjustments should not typically need readjustment In the event that a CAL adjustment is needed a precision calibration beam and weight must be used The calibration beam may be purchased from Magtrol Cm Use only an insulated screwdriver or a plastic trim pot adjustment tool when adjusting the CW CAL CCW CAL or ZERO trim potentiometers I m 2 lt For example the HD 400 6 Dynamometer lists full scale torque at 40 0 oz in Therefore amplifier gain will be set to produce 0 400 VDC output when the load cell input is 0 011 VDC 5 4 DECIMAL POINT CONTROL Two solder links on the circuit boar
53. amometer Then decrease the current to zero while simultaneously rotating the dynamometer shaft CURRENTS There is some Eddy current generation within the brake rotor These magnetically induced currents cause an increase in brake torque proportional to speed The larger the hysteresis brake the higher the rotor surface velocity Additionally as brakes become larger the rotor cross sectional area increases Each of these factors increase Eddy current generation The combination results in speed related torque increase exhibiting a more pronounced effect on larger dynamometers With the HD 800 through 815 models the Eddy current torque component adds approximately 10 1000 rpm to a static fixed current torque value On the smaller dynamometer sizes 2 to 4 1000 rpm is typical 40 O v m gt Magftrol Hysteresis Dynamometers Chapter 4 Testing 4 1 10 8 TEMPERATURE RISE Temperature rise has a more complex effect on hysteresis brake load torque and is difficult to quantify As the temperature of the brake increases differential expansions cause dimensional changes that tend to increase torque Conversely electrical resistance in the rotor increases with temperature resulting in decreased Eddy current generation and torque all in a variable frame Where current and speed remain fixed there may be a gradual torque increase over a period of a few moments This will generally stabilize at
54. arning labels are affixed directly to the dynamometer These warnings are discussed in further detail below Please take the time to read this page thoroughly before connecting and using your dynamometer 1 Make sure that all Magtrol dynamometers and electronic products are earth grounded to ensure personal safety and proper operation 2 Check line voltage before operation on any dynamometer that uses AC input power 3 Make sure that dynamometers are equipped with a protective cover to prevent contact with the rotating shaft and coupling The protective cover must be equipped with a safety interlock to disable the test motor if the cover is removed 4 Make sure that all motors under test are equipped with appropriate safety guards 5 Use caution with exposed brake surfaces They have a tendency to become very hot during long periods of operation AN ACAUTION A 6 Do not lift the unit by the brake assembly as it may cause damage to the torque sensor A CAUTION A LIFTING BY BRAKE ASSEMBLY MAY CAUSE DAMAGE TO TORQUE SENSOR 7 When operating dynamometers with blowers hearing protection must be worn Revisions This Manual The contents of this manual are subject to change without prior notice Should revisions be necessary updates to all Magtrol User s Manuals can be found at Magtrol s web site at www magtrol com support manuals htm Please compare the date of this manual with the r
55. at the torque reading is zero 1 least significant dynamometer torque digit 46 Magftrol Hysteresis Dynamometers Chapter 6 Calibration CW Calibration Zero CCW Calibration Figure 6 3 Calibration Potentiometers 4 Hang the weight from the clockwise right pin and level the calibration beam IS Note To hang bottleneck weights Magtrol recommends using only lightweight but strong line Simply fashion a loop and attach it to the weight D English D SI gt CCW Torque Weight W x Distance D Weight W Torque Distance D Figure 6 4 Calibration Calculation 5 Adjust the CW Calibration trim pot so that the torque reading equals the weight times the distance ee Note If using Magtrol CB Calibration Beams in conjunction with WT Calibration Weights simply calibrate to the full scale torque listed in the table in Section 6 1 Calibration Beams Weights Z i m 2 gt Z O m 6 Transfer the weight to the counterclockwise left pin and level the dynamometer 7 Adjust the CCW Calibration trim pot so that the torque reading equals the weight times the distance See Note in step 5 8 Remove the weight from the calibration beam 47 Chapter 6 Calibration Magftrol Hysteresis Dynamometers 6 5 9 Reduc
56. ction 4 1 3 2 2 Blower WARNING DUE TO THE NOISE LEVELS OF THE BLOWERS HEARING PROTECTION MUST BE WORN DURING OPERATION 3 3 3 2 Compressed Air Setup If a Model 510 515 800 or 805 dynamometer is being used a compressed air input is integrated into the unit The connection is illustrated in the following diagram ISD HEHH Figure 3 11 Dynamometer with Compressed Air Connection For more information see Section 4 1 3 2 1 Compressed Air 4 Testing 4 1 TESTING CONSIDERATIONS A number of factors must be taken into consideration before running a test including safety accuracy power dissipation fixturing couplings windage friction vibration cogging eddy currents and temperature rise The following sections describe these factors and their effects in further detail 4 1 1 SAFETY For general safety considerations please follow these few common sense rules sure that your coupling is adequately rated for the speed and torque that you intend to run e Make sure all rotating elements are covered Always wear safety glasses when working around dynamometer test equipment Do not wear loose clothing or ties when working around dynamometer test equipment Never allow anyone to stand close to the side of or lean over a rotating shaft coupling e Insulate e
57. d now trim out any remaining imbalance Note If something has caused the original balance to shift to such an extent that the rear panel ZERO balancing control is out of range it is probable that more difficulties lie ahead Whereas a new load cell might offer the best solution these instructions may get the dynamometer operational 8 1 2 2 Erratic Torque Reading If the torque reading is erratic then the problem could be a defective load cell or electronic component in the dynamometer or readout device It will be necessary to establish specifically what is defective At this time contact Magtrol Technical Assistance 8 1 3 FuLL SCALE TORQUE If the dynamometer cannot obtain full torque and will not support the beam and weight at full scale a resistance or current check may be used to help locate the problem 8 1 3 1 Resistance Check 1 Disconnect the 2 pin connector and the dynamometer line cord 2 Measure the resistance across the 2 pin male plug at the dynamometer 3 Check the reading to the table below Dynamometer Resistance 20 C Model Q HD 106 171 HD 100 180 HD 400 80 HD 500 75 HD 510 75 HD 505 37 5 HD 515 37 5 HD 700 80 HD 710 80 HD 705 40 HD 715 40 HD 800 20 HD 810 20 HD 805 10 HD 815 10 HD 825 5 ED 715 40 ED 815 13 5 Z i 2 gt z Chapter 8 Troubleshooting Magftrol Hysteresis Dynamometers
58. d indicate to the digital readout instrument where the decimal point belongs The chart below shows how this is accomplished by jumping the appropriate link on the board Digital output represents the result of the analog output in millivolts with the decimal point properly located Digital Output SL13 SL12 X XX Closed Open XX X Open Closed XXX Closed Closed 43 Chapter 5 Operating Principles Magftrol Hysteresis Dynamometers 5 5 5 6 5 6 1 5 6 2 DAMPER CYLINDER Hysteresis brakes machined from solid bar magnetic material represent a heavy mass The load cell behaves somewhat like a spring A mass supported by a spring will resonate at the system s natural frequency For this reason the dynamometer brake assembly must be dampened to filter out torque data and to avoid stress and fatigue The damper cylinder arm attached to the brake connects to a piston within the hydraulic cylinder When the load cell shipping restraining bolt was removed see Section 3 1 Removal of the Load Cell Shipping Restraining Bolt the brake load cell assembly was centered and the damper became functional BRAKE CONTROL POWER Any Magtrol Dynamometer Controller is universal in that it must operate all dynamometers Due to the higher level of current required by Magtrol s larger dynamometers a booster power amplifier is used to increase the control current These supplies contained within th
59. e Note The current check is accurate for all Magtrol Dynamometers 52 Magftrol Hysteresis Dynamometers Chapter 8 Troubleshooting 8 1 4 MECHANICAL ROTATIONAL ALIGNMENT Refer to the drawing and the instructions below if the dynamometer will apply torque but the torque reading will not calibrate full scale even though the zero balance is within tolerance See Figure 5 1 Mechanical Layout of a Load Cell 1 Disconnect all inputs and outputs on the dynamometer rear panel 2 Disconnect the dynamometer line cord from the line power source if applicable 3 Carefully remove the rear panel S Note It is a good idea to clamp the rear panel to the dynamometer base plate Remove the socket head cap screw retaining the pulse disk to the shaft Remove the pulse disk Loosen but do not remove the load cell clamping screw cg Carefully grasp the brake assembly and slowly rotate the assembly in both directions Please note several degrees of free swing restrained by the damper cylinder in both directions Do not force this assembly The objective is to reposition the load cell in such a manner to re establish the center of allowable rotation restricted by the damper assembly Devise a shim of sufficient thickness that when inserted between the top of the damper cylinder and the damper arm the arm will be parallel to the top of the cylinder MAINTAIN PARALLEL DAMPER CYLINDER
60. e Pin Location represents distance between the pin and the center of the calibration beam See Figure 6 4 Calibration Calculation calibrati E English Metric and SI alibration r Hysteresis Weights Full Scale Torque TM Weights Assembly Dynamometer 6N series in Size Model 7N series 8N series cm Size Model CB 106 HD 106 2 50 oz in 2 500 10z WT 106 183 5 18 00 mN m 9 18 209 1 106 100 HD 100 11 00 ozin 5 500 2 oz WT 100 815 8 80 0 mN m 8 16 100 WT 100M 400 HD 400 40 0 oz in 5 000 8 2 400 2 86kgcm 280 14 28 200 g 400 HD 500 120 0 7 500 1 01b WT 500 8 67kg cm 850 17 34 500g WT 500M CB 500 240 7 500 2 01b WT 505 17 34 1700 mN m 17 34 1 0 kg WT 505M 440 oz in 11 000 2 5Ib WT 700 31 61 3 10 N m 31 61 1 0 WT 700M CB 700 55 0 Ib in 11 000 5 0 Ib WT 705 63 22 kg cm 6 20 N m 31 61 2 0 kg WT 705M 125 0 Ib in 15 625 8 05 800 142 76 14 00 47 59 3 0 kg WT 800M CB 800 250 Ib in 15 625 16 0 Ib WT 805 285 52 kg cm 28 0 47 59 6 0 kg WT 805M HD 815 CB 825 HD 825 500 Ib in 20 000 25 0 Ib WT 825 576 14 kg cm 56 5 38 41 15 0 kg WT 825M The 7N Full Scale Torque values are not exactly equivalant to the dynamometer ratings but are instead representative of the actual torque produced by the WT
61. e dynamometer enclosures are in operation when the cooling fans are on HD 800 815 ED 815 A booster power amplifier is used to increase control current by a factor of 2 with the HD 800 and 810 and a factor of 4 with the HD 805 815 and ED 815 dynamometers The schematic in Section B 4 HD 800 815 Brake Control Supply details the HD 800 805 810 and 815 brake power amplifier HD 825 An HD 825 uses a 5241 power amplifier to increase the control current For the schematic see Section B 5 HD 825 Brake Control Supply 44 m 2 lt 6 Calibration 6 1 INITIAL CALIBRATION All Magtrol instruments are calibrated prior to shipment There is a calibration label on each unit as shown in the following figure 7 MAGTROL INC CALIBRATION DATE DUE SIN BY BUFFALO NY 716 668 5555 Figure 6 1 Calibration Label This label tells the user when the next calibration is required although Magtrol does recommend that calibration be completed after the dynamometer readout instrumentation and power supply are set up for the first time 6 2 CALIBRATION BEAMS AND WEIGHTS To perform a successful dynamometer calibration a precision weight heavy enough to apply a torque at or close to the full scale rating is required Magtrol offers precision weights WT Series and calibration beams CB Series rated specifically for each Hysteresis Dynamometer 587 Th
62. e ett d t e opinati cie 19 3 4 19 3 15 EDSSTS RE eed ag ihe At A tees 19 3 2 EARTH GROUND is eem teo t e ET deans poses Save este el 20 3 39 5 ueni o v Reine ED di e nU ei aiii 21 3 3 1 MANUAL TEST SYSTEMS eene t cbe ei a te eei ED oe tata edo 21 3 32 PC BASBD TEST SYSTEMS ette e Ed ee ito indie Nee Seales 22 333 COOLING ii certi cere eret eee ete eet e ce e ast bec a re aedes 23 A TESTING S Luc 25 4 1 TESTING CONSIDERATIONS 2 va eee e Ue oe eoo dede 25 4 1 1 t Re d REOR I aeo eed ti A Se eee ies 25 41 25 ACCURACY enema ret etr et aree ceteri eee maru d d eet 25 4 13 POWER DISSIPATION cr e md addit pi n eed miedo 26 414 FIXTURES AND COUPLINGS ie ee en tee reitera a has edd esae o e cae eue anid 38 415 eee niet QM 38 41 65 gt ERICTION E nee 39 ALT en data odin erste ies tenir epe iier 39 418
63. e the current to zero while pumping the calibration beam CW CCW moving it up and down This will ensure that the rotor does not remain magnetized in one specific location becoming cogged thus preventing the shaft from rotating freely For more information refer to Section 4 1 8 Cogging 10 Remove the calibration beam The dynamometer is calibrated and ready for motor testing CALIBRATION FREQUENCY Magtrol load cells are temperature compensated and designed for stability It is a good idea to calibrate frequently at first maintaining a record see Appendix A Calibration Record until you have established a history If there appears to be excessive drift contact Magtrol Technical Assistance 48 Z m 2 gt Z O m 7 Optional Features 7 1 SPEED ENCODER All Magtrol dynamometers come standard with a 60 bit speed encoder best suited for high speed systems For low speed motors with maximum speeds of less than 200 rpm Magtrol offers several additional encoder options which include e 600 bit single encoder e 6000 bit single encoder e 60 600 bit dual encoder e 60 6000 bit dual encoder With the single higher resolution encoder option five wires from the 600 or 6000 bit encoder run internally to the torque amplification board five of the wires from the encoder are then passed directly to the back panel connector 14 pin Speed Connector Encode
64. erence Power Absorption Curves The following graphs Figures 4 1 through 4 15 represent the maximum power heat that the dynamometer can dissipate over time The specifications shown are conditional upon the following 26 O gt Magtrol Hysteresis Dynamometers Chapter 4 Testing Maximum brake temperature 100 C 212 F e Maximum rotor temperature 460 C 860 F e Ambient temperature 25 C 77 F The dynamometer cooling system is running The following values are sufficiently accurate within 1 to establish watts W for use in the heat rise curves where P power watts T torque and n speed rpm P watts T N m x n rpm x 1 047 x 10 P watts T lbin n rpm x 1 183 x 10 P watts T kgcm x n rpm x 1 027 x 107 ee Note Please take a moment to familiarize yourself with any limitations that may apply to your specific dynamometer and motor testing requirements e m Maximum Rated 36000 Maximum Kinetic Power Rating 2 Speed for 30000 Curve for Less Than Five gt Dynamometer 5 amp 24000 e equals the maximum speed and z torque combinations for a motor test of less than five minutes a Maximum Kinetic Power B 12000 Pai Rating Curve for Continuous 9 6000 Duty Area under curve E equals the maximum speed 0 and torque combinations
65. erence only gt gt HD 100 400 500 SERIES WITH LONG BASE PLATE 2 F SHAFT END DETAIL 2 1 FLAT B L D Model OB D E F G H J L M ON P Weight HD 106 in 0 50 0 1245 0 1247 35 9 38 101 0 5 6 3 8 5 15 5 8 5 0 37 0 015 0 375 12 016 12 7 3 162 3 167 88 9 432 238 3 254 12 7 159 216 394 216 9 4 0 38 9 53 5 4 HD 100 0 75 0 1870 0 1875 3 5 17 9 13 101 0 5 6 3 85 1555 8 5 0 37 0 025 0 375 12 5 Ib 19 1 4 750 4 763 88 9 432 231 9 254 12 7 159 216 3941 2161 94 064 9 531 5 7 HD 400 0 67 0 2495 0 2497 3 5 ire 1913 10 051 6 3 8 5 15 5 8 5 0 37 0 03 0 438 15 0 Ib 17 0 6 337 6 342 88 9 432 231 9 254 12 7 1591 216 394 216 9 4 0 76111 13 6 8 HD 500 in 0 88 0 3745 0 3750 401 17 9 13 101 051 6 3 85 15 5 8 5 0 37 0 047 0 375 16 0 Ib 22 2 9 512 9 525 101 6 432 231 9 254 12 7 159 216 394 216 94 1 191 9 53 7 3kg HD 510 in 0 88 0 3745 0 3750 4 0 17 9 13 101 0 5 6 3 8 5 15 5 8 5 0 37 N A 16 0 Ib mm 22 2 9 512 9 525 101 6 432 231 9 254 12 7 159 216 394 216 9 4 7 3 kg HD 505 in 0 88 0 3745 0 3750 401 201 9 64 10 05 63 8 5 185 8 5 0 37 0 05 0 375 18 0 Ib mm 22 2 9 512 9 525 101 6 508 244 9 254 12 7 159 216 470 216 94 1 27 953 8 1kg HD 515 i
66. etween connector and brake coil 8 1 3 1 06 11 07 4th Edition rev D Deleted Analog Outputs 7 2 1 3 03 12 07 4th Edition rev C Updated calibration drawings and procedure 6 4 03 12 07 4th Edition rev Added new section Calibration Beams and Weights 6 2 02 02 07 4th Edition rev New P and dimensions for HD 700 series dynamometers 1 3 02 02 07 4th Edition rev Change in torque speed and power ratings 1 3 4 1 3 1 06 28 06 4th Edition rev A Change in power and speed ratings for HD 805 1 3 4 1 3 1 01 23 06 4th Edition All HD and ED data sheets condensed to one single data sheet 1 3 1 3 2 2 3 3 3 3 3 3 2 4 1 3 1 01 23 06 4th Edition HD 515 compressed air cooled dynamometer added to product line 41321 8131 8 1 3 2 01 23 06 4th Edition New resistance and current values for HD 500 and HD 505 8 1 3 1 8 1 3 2 10 12 05 Edition rev D Note to call factory for HD 805 power and speed ratings 1 3 3 4 1 3 1 10 12 05 3rd Edition rev D Change in power rating 5 minutes for HD 800 1 3 3 4 1 3 1 02 24 05 3rd Edition rev C Hearing safety warnings added 4 12 09 04 Edition Electrical power fuse ratings added to data sheets 1 3 1 1 3 4 03 11 04 Edition rev A 5410 Torque Speed Readout and 5200 5210 Power Supply removed 1 3 1 1 3 4 3 3 1 from manual open loop test system configurations 12 08 03 3rd Edition HSD Series Hi
67. eve maximum capability and ensure proper use of the dynamometer 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 those operators who are planning to use any of Magtrol s Hysteresis Dynamometers MANUAL ORGANIZATION This section gives an overview of the structure of the manual and the information contained within it Some information has been deliberately repeated in different sections of the document to minimize cross referencing and to facilitate understanding through reiteration The structure of the manual is as follows Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Appendix Appendix B INTRODUCTION Contains the technical data sheets for Magtrol s Hysteresis Dynamometers which describe the units and provide detailed technical characteristics INPUTS OUTPUTS Description of the elements located on the rear panel of the dynamometer INSTALLATION CONFIGURATION Provides information needed for setup of the dynamometer This includes load cell shipping restraining bolt removal earth ground instruction and configurations for manual computer controlled and air cooled test setups TESTING Provides information on how to run a test along with considerations that should be taken when operating the dynamometer
68. evision 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 4th Edition revision M June 2015 TABLE OF REVISIONS Date Edition Change Section s 06 11 15 4th Edition rev M Speed sensor board schematic added for 2015 and later 2 dynamometers 05 11 15 4th Edition rev L Compressed air regulator setting changed for HD 800 dynamometer 1 3 4 1 3 2 1 09 04 14 4th Edition rev Updated description of booster power amplifier 5 6 1 06 09 14 4th Edition rev J Note added concerning operation at continuous power rating for long 434 intervals and high temperatures 02 26 14 4th Edition rev All referneces to DSP6001 changed to DSP7000 throughout manual 06 01 12 4th Edition rev Dimensions were updated on the data sheet for the HD 800 and HD 810 model dynamometers e Part number for the 88 007 and 88 070 cables was changed to 05 21 12 4th Edition rev 88M007 0150 and 88M070 0150 9 1 3 3 3 1 3 3 2 10 07 08 4th Edition rev Temperature conditions for maximum power absorption 4 1 3 1 08 31 07 4th Edition rev E Updated electrical power and fuse ratings 1 3 08 31 07 4th Edition rev E New resistance and current values for HD 106 8 1 3 1 8 1 3 2 08 31 07 4th Edition rev Added note about circuitry b
69. for 0 0 5 1 1 5 2 2 5 oz in continuous duty motor test 0 3 6 7 2 10 8 14 4 18 mN m TOROIIF Maximum Torque for Dynamomete Figure 4 1 Power Absorption Curve Parameters HD 106 0 1245 in 0 1250 in shalt Diameter 3 163 mm 3 175 mm Shaft Height 3 50 in 88 9 mm 2 50 oz in Torque Range 180 0 g cm 18 00 mN m Input Inertia 7 04 x 107 Ib ft s Maximum Speed 30 000 rpm continuous duty 7 W Maximum Input Power zB minutes 35 W 27 Chapter 4 Testing Magftrol Hysteresis Dynamometers 36000 30000 2 24000 18000 m 12000 a 6000 0 0 0 5 1 1 5 2 2 5 oz in 0 3 6 7 2 10 8 14 4 18 mN m TORQUE Figure 4 2 HD 106 Power Absorption Curve HD 100 0 1870 in 0 1875 in Shaft Diameter 4 750 mm 4 763 mm Shaft Height 3 50 in 88 9 mm 11 00 oz in Torque Range 800 g cm 80 00 mN m m Input Inertia 3 40 x 10 Ib ft s gt Maximum Speed 25 000 rpm ro Maximum Input Power Ontinuous duty 20 W 2 lt 5 minutes 75 W 30000 25000 20000 Q 15000 m 10000 a 5000 0 0 2 2 4 4 6 6 8 8 11 oz in 0 16 32 48 64 80 mN m TORQUE Figure 4 3 HD 100 Power Absorption Curve HD 400 0 2495 in 0 2500 in 6 338 mm 6 3
70. gh Speed Dynamometers discontinued throughout manual 10 27 03 2nd Edition rev Change in maximum torque rating for HSD 710 8N 1 3 5 4 1 3 1 10 27 03 2nd Edition rev Added short base plate option 1 3 1 1 3 3 10 27 03 2nd Edition rev E Change in speed encoder options 1 3 1 1 3 4 10 02 03 2 Edition rev D New dimensions for HD 700 series dynamometers 1 3 2 09 25 03 2nd Edition rev New B dimension for HD 400 1 3 1 09 25 03 2 Edition rev New and E dimensions for HD 106 1 3 1 08 19 03 2nd Edition rev New schematic drawing for 800 815 Brake Control Supply B 4 03 17 03 2nd Edition rev New dimension for HSD 610M 1 3 5 03 17 03 2nd Edition rev New Dynamometer Table added to System Options and Accessories 1 3 1 1 3 5 01 03 03 2nd Edition Added more information about air cooling air flow sensor now 3 3 3 standard 01 03 03 2nd Edition Inserted new chapter about optional features chapter 7 01 03 03 2nd Edition HSD High Speed Dynamometer information added throughout manual Table of Contents SAFETY PRECAUTIONS alten eo REVISIONS TO THIS MANUAL TABLE OF CONTENTS a IV TABLE OF BIGURES nob VI PREFACE
71. hook up 6530 Power Analyzer HD Hysteresis Dynamometer DSP7000 Dynamometer Controller AMF Adjustable Motor Fixture space for rackmounted third party power supply and computer keyboard drawer Dynamometer Table 14 Magftrol Hysteresis Dynamometers Chapter 1 Introduction Ordering Information HD ED 2 Z ES DYNAMOMETER OPTIONS ORDERING INFORMATION Encoder Options For Low Speed Testing MODEL NUMBER D ONO 0 For low speed motors such as gear motors with maximum speeds DYNAMOMETER TYPE of less than 200 rpm Magtrol offers additional encoder options Hysteresis HD 100 825 that allow for increased resolution of the speed signal Engine ED 715 815 T Slot Base Plate TORQUE UNITS 5 V Output 5N To accommodate Magtrol AMF 3 Adjustable Motor Fixtures English U S 6N a grooved base plate with three M12 T slots one centered Metric 7N and two 250 mm apart is available on all HD 800 series SI 8N dynamometers POWER OPERATION 120 VAC standard blank CUSTOM DYNAMOMETERS 240 VAC option A High Speed Testing BASE PLATE For certain models Magtrol can provide Dynamometers which can operate at higher than
72. l Hysteresis Dynamometers Chapter 3 Installation Configuration 3 1 2 HD 700 Series The shipping restraining bolt is located on the front side of the HD 700 Series Hysteresis Dynamometers as shown in Figure 3 2 SHIPPING BOLT Figure 5 2 HD 700 Series Shipping Restraining Bolt Location 3 1 3 HD 800 Series There is no shipping restraining bolt on an HD 800 Series Hysteresis Dynamometer 3 1 4 ED 715 The shipping restraining bolt is located on the front side of the ED 715 dynamometer as shown in Figure 3 3 SHIPPING BOLT Figure 3 3 ED 715 Shipping Restraining Bolt Location 3 1 5 ED 815 There is no shipping restraining bolt on an ED 815 dynamometer Chapter 3 Installation Configuration Magftrol Hysteresis Dynamometers 3 2 EARTH GROUND Before proceeding any further the dynamometer must be connected to earth ground The earth ground is located on the top of the dynamometer as indicated in the following diagrams by the earth ground symbol O 1 L Co O EARTH GROUND r3 Q I Figure 3 4 HD 100 500 Series Top View The following diagram is to be referenced for all HD 700 800 series and ED dynamometers yi EARTH A GROUND p 3 ay
73. lectrical internal and external motor connections CAUTION POWER LINE FAULT INTO THE DYNAMOMETER FRAME COULD PASS TRANSIENT SURGE THROUGH ALL INTERCONNECTED INSTRUMENTS ANY COMPUTER IN USE OR OPERATING PERSONNEL WITH DANGEROUS AND COSTLY CONSEQUENCES e Always connect the motor frame to a high current capacity water pipe earth ground e Be sure the motor control circuit breakers cannot be bypassed by accident Variable auto transformers are especially hazardous When operating dynamometers with blowers hearing protection must be worn 4 1 2 ACCURACY Following is a list of several factors that affect the apparent accuracy of the torque readout e Full Scale Torque Calibration This setting will be affected by an internal temperature rise of up to 0 0015 FS C For more information on full scale torque setup and troubleshooting refer to Section 6 4 Calibration Procedure and Section 8 1 3 Full Scale Torque e Zero Offset This setting is affected by an internal temperature rise of up to 0 002 Reading C For more information on zero offset setup and troubleshooting refer to Section 6 4 Calibration Procedure and Section 8 1 2 Zero Balance Coupling Losses If the coupling becomes hot to the touch or if the dynamometer or motor vibrate after a period of running coupling loss error could occur up to several percent depending on the size of the motor and dynamometer For more detail refer to Section
74. mometers for special torque and speed requirements e Easy Calibration HD DESCRIPTION Hysteresis Brake Dynamometers HD Series are versatile and ideal for testing in the low to medium power range maximum 14 kW intermittent duty With a Hysteresis Braking system the Dynamometers do not require speed to create torque and therefore can provide a full motor ramp from free run to locked rotor Brake cooling is provided by convection no external source by compressed air or by dedicated blower depending on the model All Magtrol Hysteresis Dynamometers have accuracy ratings of 0 25 to 0 596 full scale depending on size and system configuration To better integrate dynamometers into systems Magtrol offers both long and short base plates The shorter base plate facilitates easier motor mounting when used with T slot tables and Magtrol Adjustable Motor Fixtures where as the long base plates are better suited for table top testing HD APPLICATIONS Magtrol motor test systems can be found in test labs at inspection stations and on the manufacturing floors of most of the world s leading manufacturers users and certifiers of small to medium sized electric pneumatic and hydraulic motors as well as internal combustion engines Magtrol supplies motor test systems for a wide array of industries including Appliance Automotive Aviation Computer HVAC Lawn and Garden Medical and Dental Electric Motor Office Equipment and P
75. n 0 88 0 3745 0 3750 4 0 20 9 64 101 0 5 63 8 5 18 5 8 5 0 37 18 0 22 2 9 512 9 525 101 6 508 244 9 254 12 7 159 216 470 216 9 4 8 1 kg HD 100 400 500 SERIES WITH SHORT BASE PLATE j J SHAFT END DETAIL 2 1 FLAT Model OB D E F G H J L ON P Weight HD 106 0 50 0 1245 0 1247 3 5 7 0 0 33 11 0 5 6 3 8 5 6 0 9 84 0 35 0 015 0 375 7 516 12 7 3 162 3 167 88 9 177 8 8 4 279 4 12 7 159 216 152 4 250 9 0381 9 53 3 4 HD 100 in 0 75 0 1870 0 1875 3 5 7 01 0 08 11 0 5 6 3 85 6 0 9 84 0 35 0 025 0 375 8 010 mm 19 1 4 750 4 763 88 9 177 8 2 1 279 4 12 7 159 216 152 4 250 9 0 641 9 53 3 6kg HD 400 0 67 0 2495 0 2497 3 5 7 0 0 08 11 0 5 63 85 6 0 9 84 0 35 0 03 0 438 11 0 Ib 17 0 6 337 6 342 88 9 177 8 2 1 279 4 12 7 159 216 152 4 250 9 0 76 11 13 5 0kg HD 500 0 88 0 3745 0 3750 4 0 7 01 0 08 11 05 63 8 5 6 0 9 84 0 35 0 047 0 375 12 0 Ib mm 22 2 9 512 9 525 101 6 177 8 2 1 279 4 12 7 159 216 152 4 250 9 1 19 9 53 5 4kg HD 510 0 88 0 3745 0 3750 4 0 8 0 0 13 11 0 5 63 8 5 7 0 9 84 0 35 12 5 Ib mm
76. never the unit is in operation 4 1 3 2 2 Blower Magtrol s HD 710 715 8 10 8 15 825 and ED 715 815 dynamometers are internally ported for blower cooling The following diagram illustrates the connection Figure 4 21 Dynamometer with Blower Connection HEARING PROTECTION MUST BE WORN DURING WARNING DUE THE NOISE LEVELS THE BLOWERS OPERATION Chapter 4 Testing Magftrol Hysteresis Dynamometers 4 1 4 Re FixTURES AND COUPLINGS When mounting the test motor please consider the following Construct precise fixtures that provide proper shaft alignment Secure the test motor in the fixture to prevent torsional movement and bolt the fixture to the dynamometer base plate Give consideration to the interaction of materials between the motor and test fixture For example a magnetic steel plate placed against the exposed lamination of an open frame motor can significantly influence performance Some thin shell PM permanent magnet motors may be similarly affected The dynamometer base plate material is an aluminum tool plate that is easily drilled and tapped The use of helix thread inserts is a good idea if you are going to interchange fixtures often Note For an additional charge Magtrol can perform base plate modifications The follo
77. ng life with low maintenance Magtrol provides a NIST traceable certificate of calibration and calibration beam with each Engine Dynamometer ED APPLICATIONS The Engine Dynamometers are ideally suited for emissions testing as set forth in CARB and EPA Clean Air Regulations The Dynamometers will offer superior performance on the production line at incoming inspection or in the R amp D lab z og 2 Z 5 gt Z Chapter 1 Introduction Magftrol Hysteresis Dynamometers Principles and Selection OPERATING PRINCIPLES ROTOR Drag Cup HUB Magtrol Hysteresis Dynamometers absorb power with a unique Hysteresis Braking System which provides frictionless torque loading independent of shaft speed The Hysteresis Brake provides torque by the use of two basic components a reticulated pole structure and a specialty steel rotor shaft assembly fitted together but not in physical contact Until the pole structure is energized the drag cup can spin freely on its shaft bearings When a magnetizing force from the field coil is applied to the pole structure the air gap becomes a flux field and the rotor is magnetically restrained providing a braking action between the pole structure and rotor COMPLETE PC CONTROL Magtrol s M TEST 7 Software is a state of the art motor testing program for Windows based data acquisition Used with a Magtrol Programmable Dynamometer Controller Magtrol M TEST 7 Software provides
78. nt If this signal is correct examine your digital readout instrument for the problem 54 Z m 2 gt Z O m Appendix A Calibration Record DATE DYNAMOMETER MODEL SERIAL APPLIED TORQUE INDICATED TORQUE ERROR TESTER 55 gt 0 0 2 m Schematics Appendix B TORQUE AMPLIFICATION BOARD B 1 oor 9011 IC901L z 8 ASI ueid WOO l au 001 001 vd 10 1 9 d O onbro x 0007 T 19 001 z z 1eeus ejeg eos AS Hd 8M L AST jese 12 dt STA xx 9 15 Jong VLOGCLH au 001 so Ajddns 20 162 MOD f ETA py w s AST AULT 6201 5115 95 1 e 001 YO APPENDICES 00L V LIN olo i pam 19 2 S 001 V LIN sHovrl VHV 19 8
79. ompanying dynamometer table p TAB 0825L Contact Magtrol for details SHAFT END DETAIL 2 1 SQUARE KEY Model 5 A OB 5 T Weight 2 83 1 4995 1 5000 11 38 5138 93 17 16 61 14 36 5 15 0 54 1 287 210 376 2 1 400 0 Ib mm 72138 087 38 100 279 4 978 9891432150 8 422 356 9271381 13 7 32 69 50 8 9 53 50 8 25 4 181 4 kg These dimensions represent the distance between mounting holes There are four 4 mounting holes on each base plate 10 N HD 825 Magtrol Hysteresis Dynamometers Chapter 1 Introduction z Power Absorption Curves ED 98 3 3 3 3 3535 gt Maximum Rated 36000 Maximum Kinetic Power Rating Speed for 30000 Curve for Less Than Dynamometer 5 24000 Minutes Area under curve equals the maximum speed and m 18000 torque combinations for a motor Maximum Kinetic Power m 12000 Bi test of less than five minutes Rating Curve for Continuous 6000 Duty Area under curve Em Maximum Torque equals the maximum speed 0 1 for Dynamometer and torque combinations for 0 0 5 1 1 5 2 2 5 oz in a continuous duty motor test 0 3 6 7 2 10 8 14 4 18 mN m TORQUE 36000 30000 amp 24
80. on 8N 80 0 mN m 0 64 mN m 5N 0 28 N m 2 mN m N 40 0 021 25ozi HD 400 E cm z 155 105 210 105 200 55 25 000 Convection 8N 280 mN m 2 mN m 5N 0 85 5 mN m N 120 0 ozi HD 500 20 2 us T 8 05 105 1 09 x 104 400 80 _ 25 000 Convection 8N 850 mN m 5 mN m 5N 0 85 N m 5 mN m Compressed 6N 120 0 2 0 5 oz in Air 5 4 ir HD 510 T 805 10 1 09 10 750 8N 850 mN m 5 mN m isles 5N 1 7 10 mN m HD 505 722 161 104 2 18 104 800 160 25 000 Convection 8N 1700 mN m 10 mN m 1 7 10 mN m mE 6N 240 oz in 1 0 oziin A 4 Air HD 515 om pete 1 500 900 25 000 ocima 8N 1700 mN m 10 mN m 0 013 HD 700 XT ae 551 104 7 47 x 10 700 150 25 000 Convection 8N 310 0 013 0 013 6N 440 oz in 2 0 oz in zi v Blower HD 710 N 1 500 986 25000 8N 310 0 013 6 20N m 0 023 N 0 Ibi 2 Ibi HD 705 555 es M E 1 10 103 1 49 x 103 1 400 300 25 000 Convection 8N 620 0 023 5N 6 20 0 023 6N 55 0 Ibin 0 2 Ib in Blower 3 3 HD 715 N 3 400 3 000 25000 8N 620 0 023 Requires air cooling provided by user Regulator and filter package is provided as standard equipment on the
81. onal feature switches between a 60 and 600 bit encoder or a 60 and 6000 bit encoder Speed Encoder XXXX 60 Bit Bit Figure 2 5 Speed Encoder Switch BLOWER INPUT Connect blower tube here For HD 710 HD 715 HD 810 HD 815 HD 825 ED 715 and ED 815 Dynamometers only BLOWERS HEARING PROTECTION MUST BE WARNING DUE TO THE NOISE LEVELS THE WORN DURING OPERATION Figure 2 6 Blower Input COMPRESSED AIR Connect compressed shop air line here For HD 510 HD 515 HD 800 INPUT and HD 805 Dynamometers only Figure 2 7 Compressed Air Input 3 Installation Configuration 3 1 REMOVAL OF THE LOAD CELL SHIPPING RESTRAINING BOLT Within the dynamometer enclosure there is a load cell shipping restraining bolt that must be removed before dynamometer operation The bolts are identified with red heads Refer to the diagrams below for the bolt location on your model Retain shipping restraining bolt for future use when moving shipping your Magtrol Dynamometer 3 1 1 HD 100 400 500 Series The shipping restraining bolt is located on the bottom of the HD 100 500 Series Hysteresis Dynamometers as shown in Figure 3 1 SHIPPING d BOLT 2 Figure 3 1 HD 100 500 Series Shipping Restraining Bolt Location Magftro
82. orption Curve Figure 4 14 HD 810 Power Absorption Curve Figure 4 15 HD 805 Power Absorption Curve Figure 4 16 HD 815 Power Absorption Curve Figure 4 17 HD 825 Power Absorption Curve Figure 4 18 ED 715 Power Absorption Curve Figure 4 19 ED 815 Power Absorption Curve Figure 4 20 Dynamometer with Compressed Air Connection 527 Figure 4 21 Dynamometer with Blower 37 Figure 4 22 Examples of Possible Shaft Misalignment eese eterne eene 38 Figure 4 23 Hysteresis Brake Cross Section eee esee entente nennen tenete eene tenni nenne 40 5 OPERATING PRINCIPLES Figure 5 1 Mechanical Layout of a Load Cell 42 6 CALIBRATION Figure 6 1 Calibration Label er ede i e pde 45 Figuye 6 2 Calibration Setup s en el eed et eee ues 46 Figure 6 3 Calibration Potentiometers eee 47 Figure 0 4 Calibration Calculation 5 re En dip etre e tee oe a iere e tbi pne 47 7 OPTIONAL FEATURES Figure 7 1 Speed Encoder Schemalic ca ete toe A e e EX 49 8 TROUBLESHOOTING 1 Damper Contiection eere et ei esee taroen et tee e eee en ea 53 Preface PURPOSE OF THIS MANUAL This manual contains all the information required for the setup and general use of Magtrol s Hysteresis Dynamometers To achi
83. ower Tools ED FEATURES e Maximum Torque from 55 Ibin to 250 Ib in 6 5 N m to 28 N m Hysteresis Braking System Motor Testing from no load to locked rotor e Standard Torque Units English Metric amp SI available e Accuracy 0 25 full scale e Blower Cooled to maximize heat dissipation e Flow Sensor for protection against overheating and operator error e Specially Reinforced Load Cell stainless steel pin at contact point prevents premature wear from excess vibration e Larger Shaft for additional strength e Gusseted Pillow Blocks for additional front and rear support e Easy Calibration ED DESCRIPTION With Magtrol s Engine Dynamometers high performance motor testing is available to manufacturers and users of small engines Magtrol s Engine Dynamometers have been designed to address the severe high vibration conditions inherent in internal combustion engine testing Magtrol s Engine Dynamometers are highly accurate x 0 2596 of full scale and can be controlled either manually or via a PC based Controller For a small engine test stand Magtrol offers a full line of controllers readouts and software As with all Magtrol Hysteresis Dynamometers engine loading is provided by Magtrol s Hysteresis Brake which provides torque independent of speed including full load at O rpm excellent repeatability frictionless torque with no wearing parts other than bearings and long operati
84. r pin 11 index pulse pin 10 TACH A pin 2 TACH B pin 7 5 8 5 With the dual encoder option dynamometer comes equipped with a standard 60 bit encoder and an additional 600 or 6000 bit encoder The user can select which encoder to use via a back panel switch See Figure 2 1 Rear Panel Five wires from the 600 6000 bit encoder run the torque amplification board Three of the wires from the encoder are then passed directly to the back panel connector 14 pin connector pin 11 index pulse pin 2 TACH_B pin 8 5 VDC COM Two of the wires route to a double pole double throw switch The switch selects which encoder will be powered up and routes the appropriate Tach A signal to the 14 pin connector 14 pin connector pin 10 TACH pin 7 5VDC 600 6000 BIT ENCODER cover I ENCODER BACK PANEL c 00 5 4 414 TORQUE AMPLIFICATION BOARD Figure 7 1 Speed Encoder Schematic The 60 bit encoder may be used for high speed systems and the 600 6000 bit encoder for lower speed applications Additionally the TACH_A and TACH_B signals can be quadrature decoded to give even higher resolutions and direction of rotation 49 O 2 7 8 Troubleshooting 8 1 8 1 2
85. rkway Buffalo New York 14224 USA Phone 1 716 668 5555 Fax 1 716 668 8705 E mail magtrol magtrol com Tension Displacement MAGTROL SA Route de Montena 77 1728 Rossens Fribourg Switzerland Phone 41 0 26 407 3000 Fax 41 0 26 407 3001 E mail magtrol magtrol ch www maodgtrol com Subsidiaries in Germany France China India Worldwide Network of Sales Agents BUREAU VERITAS Certification
86. s will produce excessive data errors and are a safety hazard ABOVE THEIR DESIGN LIMITS ARE EXTREMELY HAZARDOUS MANY COUPLINGS CONTAIN SOMEWHAT LOOSELY SUPPORTED FLEXURE ELEMENTS WHEN OVERDRIVEN EXCESSIVE CENTRIFUGAL FORCE MAY DISPLACE THEM OUT OF AXIAL ALIGNMENT AS THIS HAPPENS THEY IMMEDIATELY BEGIN TO ABSORB ENERGY RESULTING IN SEVERE VIBRATION AND DESTRUCTION OF THE COUPLING STOP WARNING SHAFT COUPLINGS OPERATING AT SPEEDS 39 Chapter 4 Testing Magftrol Hysteresis Dynamometers 4 1 8 Rotor Poles Figure 4 23 Hysteresis Brake Cross Section This cross section shows by one tooth the magnetic relationship of the hysteresis brake elements If the dynamometer shaft is at rest with torque applied and if the torque control is then reduced to zero a magnetic salient pole will be temporarily imposed on the rotor of the brake If the shaft is then rotated slowly the magnetic poles on the rotor will attempt to align with the adjacent case pole tooth form This is often referred to as cogging The action is sinusoidal first it tries to resist rotation and then as the rotor passes through the tooth form it subsequently supports rotation At a few hundred rpm these forces integrate resulting in an effective torque of nearly zero To avoid magnetic cogging before the shaft comes to rest reduce the torque control to zero To remove cogging once established reapply current on the dyn
87. se units 5 Volt output NOTE Operating at the continuous power rating for periods of up to 4 hours is acceptable However operating for extended periods at high temperatures will result in premature component and bearing failure Limiting the length of the cycle and the component temperatures will guard against premature failure Where continuous duty is desired for longer time intervals component temperatures should be maintained less than 100 C monitoring the outside brake surface temperature is a sufficient reference 5 Chapter 1 Introduction Magftrol Hysteresis Dynamometers a z Ratings HD ED 2 gt D 5N 14 00 0 10N m Conia gt 6N 125 0 Ib in 0 8 Ib in is 3 3 Ir 2 HD 800 N 4 43 x 1038 6 01 x 10 2 800 1 800 12 000 8N 14 00 0 10 101980 5N 14 00 0 10 6N 125 0 Ib in 0 8 Blower 443 x 103 6 01 x 103 12 HD 810 OESTE qoe 3x103 6 01 x 10 3 500 3 000 1000 noticed 8N 14 00 0 10 5N 28 0 0 14 nem 6N 250 Ib in 1 2 Ib in Air 3 2 HD 805 1m 8 81 x 103 1 19x 10 5 300 3 000 12 000 8N 28 0 0 14 28 0 0 14 6 250 Ib in 1 2 Ibin Blower 81 103 1 19x 102 7 12 HD 815 EN eeu TIT 8 81 x 10 9 x 10 000 6 000 8N 28 0 0 14 N m 5N 56 5 0 22
88. the necessary parts and labor costs if any will be faxed or e mailed to you 6 After receiving your repair estimate provide Magtrol with a P O number as soon as possible A purchase order confirming the cost quoted is required before your equipment can be returned Returning Equipment to Magtrol SA Switzerland If you are directed to ship your equipment to Switzerland no RMA form number is required Just send your equipment directly to Magtrol SA in Switzerland and follow these shipment instructions 1 Ship your equipment to MAGTROL SA After Sales Service Route de Montena 77 1728 Rossens Fribourg Switzerland VAT No 485 572 2 Please use our forwarder TNT 1 800 558 5555 Account 154033 Only ship ECONOMIC way 3 days max within Europe 3 Include the following documents with your equipment e Delivery note with Magtrol address as listed above Three pro forma invoices with e Your VAT number Value for customs purposes only 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 63 Testing Measurement and Control of Torque Speed Power Load Force Weight j MAGTROL INC 70 Gardenville Pa
89. wing diagram illustrates examples of possible shaft misalignment ANGULAR PARALLEL OFFSET Figure 4 22 Examples of Possible Shaft Misalignment The use of high quality double flexure couplings is recommended to help correct any misalignment problems This type of coupling two flexing elements separated by a solid link inherently tolerates greater parallel offset If you would like more specific coupling recommendations contact Magtrol Technical Assistance For precise misalignment tolerances consult your coupling manufacturer WINDAGE Windage is proportional to the square of speed and magnifies rapidly above rated speed The air friction is tangential to the surface and impinges upon the stationary field assembly This acts as viscous drag and becomes part of the motor load and torque reading However there is a small amount of air dissipated as pumping loss Since this appears as a load on the motor not measured by the dynamometer it becomes a source of error Windage effects on accuracy tests have been conducted on all Magtrol dynamometers The percentage of torque loss due to windage ranges between 0 025 and 0 20 of full scale at maximum rated rpm Windage is proportional to the square of speed and magnifies rapidly above rated speed Conversely at one half of the rated speed the effect becomes immeasurably small 38 O 70 gt O 2 Magtrol Hysteresis Dynamometers Chapter 4 Testing 4 1 6

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