Magtrol HD-106 User Manual Download Page 31 | Manualshive

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Magtrol HD-106 User Manual Download Page 31

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SETUP

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.

Note:

Retain the shipping/restraining bolt for future use when moving or
shipping your Magtrol Dynamometer.

3.1.1

HD-100, -400

anD

-500 S

erieS

The shipping/restraining bolt is located on the bottom of the HD 100-500 Series Hysteresis
Dynamometers as shown in Figure 3–1.

SHIPPING

BOLT

Figure 3–1 HD 100–500 Series Shipping/Restraining Bolt Location

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Summary of Contents for HD-106

Page 1: ...User s Manual HD and ED Series Hysteresis Dynamometers...

Page 2: ...s 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 regi...

Page 3: ...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...

Page 4: ...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...

Page 5: ...ons for HD 106 1 3 1 08 19 03 2nd Edition rev B New schematic drawing for HD 800 815 Brake Control Supply B 4 03 17 03 2nd Edition rev A New F dimension for HSD 610M 1 3 5 03 17 03 2nd Edition rev A N...

Page 6: ...1 REAR PANEL 16 2 2 REAR PANEL INPUTS AND OUTPUTS 16 3 INSTALLATION CONFIGURATION 18 3 1 REMOVAL OF THE LOAD CELL SHIPPING RESTRAINING BOLT 18 3 1 1 HD 100 400 AND 500 SERIES 18 3 1 2 HD 700 SERIES 1...

Page 7: ...Y 48 7 OPTIONAL FEATURES 49 7 1 SPEED ENCODER 49 8 TROUBLESHOOTING 50 8 1 TORQUE READOUT PROBLEMS 50 8 1 1 NEW DYNAMOMETER 50 8 1 2 ZERO BALANCE 50 8 1 3 FULL SCALE TORQUE 51 8 1 4 MECHANICAL ROTATION...

Page 8: ...100 Power Absorption Curve 28 Figure 4 4 HD 400 Power Absorption Curve 29 Figure 4 5 HD 500 Power Absorption Curve 29 Figure 4 6 HD 510 Power Absorption Curve 30 Figure 4 7 HD 505 Power Absorption Cu...

Page 9: ...ocated on the rear panel of the dynamometer Chapter 3 INSTALLATION CONFIGURATION Provides information needed for setup of the dynamometer This includes load cell shipping restraining bolt removal eart...

Page 10: ...on to information directives procedures etc which if ignored may result in damage to the material being used The associated text describes the necessary precautions to take and the consequences that m...

Page 11: ...he instrument during normal handling 1 Make sure the carton contains the following Hysteresis Dynamometer Line Cord not included with 700 series or HD 825 Magtrol User Manual CD Rom Brake Cable 14 Pin...

Page 12: ...ters are versatile and ideal for testing in low to medium power ranges Features include Accuracy 0 25 to 0 5 full scale depending on size and system configuration Custom Dynamometers For special torqu...

Page 13: ...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...

Page 14: ...d and the rotor is magnetically restrained providing a braking action between the pole structure and rotor DYNAMOMETER SELECTION Magtrol s Hysteresis Dynamometers cover a wide range of Torque Speed an...

Page 15: ...ORQUE RANGE DRAG TORQUE DE ENERGIZED AT 1 000 RPM NOMINAL INPUT INERTIA MAX POWER RATINGS MAXIMUM SPEED BRAKE COOLING METHOD 5 MINUTE CONTINUOUS b lb ft s2 kg m2 W W RPM N m HD 106 5N 0 018 0 056 mN m...

Page 16: ...less than 100 C monitoring the outside brake surface temperature is a sufficient reference c Requires air cooling provided by user Regulator and filter package is provided as standard equipment on th...

Page 17: ...D ED 815 XN 120 V 130 UL CSA 1 25 A 250 V SB HD ED 815 XNA 240 V 130 IEC 630 mA 250 V T HD 825 XN 120 V N A N A N A HD 825 XNA 240 V N A N A N A Allow approximately 6 in to 8 in 152 mm to 203 mm betwe...

Page 18: ...4 763 88 9 432 231 9 254 12 7 159 216 394 216 9 4 0 64 9 53 5 7 kg HD 400 in 0 67 0 2495 0 2497 3 5 17 9 13 10 0 5 6 3 8 5 15 5 8 5 0 37 0 03 0 438 15 0 lb mm 17 0 6 337 6 342 88 9 432 231 9 254 12 7...

Page 19: ...1 279 4 12 7 159 216 152 4 250 9 0 76 11 13 5 0 kg HD 500 in 0 88 0 3745 0 3750 4 0 7 0 0 08 11 0 5 6 3 8 5 6 0 9 84 0 35 0 047 0 375 12 0 lb mm 22 2 9 512 9 525 101 6 177 8 2 1 279 4 12 7 159 216 15...

Page 20: ...3 50 kg HD 715 in 1 25 0 4995 0 4999 5 875 30 14 29 11 0 625 9 5 10 28 5 9 5 0 375 N A 59 lb mm 31 8 12 687 12 692 149 2 762 0 363 0 279 4 15 9 241 3 254 723 9 241 3 9 5 26 60 kg HD 700 SERIES WITH SH...

Page 21: ...sent the distance between mounting holes There are four 4 mounting holes on each base plate C B A H M F N G L D E Q P B R SHAFT END DETAIL 2 1 SQUARE KEY HD 800 SERIES WITH LONG BASE PLATE E A H J N M...

Page 22: ...D E F G H J La Ma N P Q R S T WEIGHT HD 800 in 2 83 1 4995 1 5000 11 38 5 38 93 17 2 16 6 14 36 5 15 0 54 1 287 2 0 376 2 1 400 0 lb mm 72 38 087 38 100 279 4 978 989 432 50 8 422 356 927 381 13 7 32...

Page 23: ...Five Minutes Area under curve equals the maximum speed and torque combinations for a motor test of less than five minutes Maximum Torque for Dynamometer HD 106 HD 100 HD 400 0 6000 12000 18000 24000 3...

Page 24: ...0 30000 TORQUE SPEED rpm HD 700 HD 710 oz in N m 0 5000 10000 15000 20000 25000 30000 0 0 88 0 62 176 1 24 264 1 86 352 2 48 440 3 10 TORQUE SPEED rpm 0 5000 10000 15000 20000 25000 30000 oz in N m 0...

Page 25: ...100 11 3 200 22 6 300 33 9 400 45 2 500 56 5 lb in N m TORQUE SPEED rpm SYSTEM CONFIGURATIONS OPEN LOOP SYSTEMS Magtrol offers both open loop manual test systems and PC based closed loop test systems...

Page 26: ...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 Har...

Page 27: ...rs 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 heavy duty equipment rack M TEST Motor Testi...

Page 28: ...Speed Programmable Dynamometer Controller DSP7000 Open Loop Dynamometer Controller 6200 POWER ANALYZERS High Speed Single Phase Power Analyzer 7510 High Speed Three Phase Power Analyzer 7530 SOFTWARE...

Page 29: ...1 Rear Panel 2 2 REAR PANEL INPUTS AND OUTPUTS DYNAMOMETER BRAKE INPUT Connect dynamometer brake cable here Figure 2 2 Dynamometer Brake Input DYNAMOMETER CONNECTOR Connect dynamometer signal cable he...

Page 30: ...tches between a 60 and 600 bit encoder or a 60 and 6000 bit encoder Speed Encoder xxxx Bit 60 Bit Figure 2 5 Speed Encoder Switch BLOWER INPUT Connect blower tube here For HD 710 HD 715 HD 810 HD 815...

Page 31: ...e identified with red heads Refer to the diagrams below for the bolt location on your model Note Retain the shipping restraining bolt for future use when moving or shipping your Magtrol Dynamometer 3...

Page 32: ...G BOLT Figure 3 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 restra...

Page 33: ...located on the top of the dynamometer as indicated in the following diagrams by the earth ground symbol EARTH GROUND Figure 3 4 HD 100 500 Series Top View The following diagram is to be referenced for...

Page 34: ...ng 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 Note Magt...

Page 35: ...te the required cable sets and connections for a PC based test system setup 1 o o o HD ED DYNAMOMETER PC USB M TEST DSP7001 CONTROLLER 2 Pin Dynamometer Brake Cable PN88M070 0150 included with dynamom...

Page 36: ...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 internal...

Page 37: ...e information see Section 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 dy...

Page 38: ...it 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 li...

Page 39: ...ssive 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...

Page 40: ...inetic Power Rating Curve for Less Than Five Minutes Area under curve equals the maximum speed and torque combinations for a motor test of less than five minutes Maximum Torque for Dynamometer HD 106...

Page 41: ...800 g cm 80 00 mN m Input Inertia 3 40 10 6 lb ft s Maximum Speed 25 000 rpm Maximum Input Power continuous duty 20 W 5 minutes 75 W TORQUE SPEED rpm 0 5000 10000 15000 20000 25000 30000 0 0 2 2 16 4...

Page 42: ...kg cm 850 mN m Input Inertia 8 05 10 5 lb ft s Maximum Speed 25 000 rpm Maximum Input Power continuous duty 80 W 5 minutes 400 W TORQUE SPEED rpm 0 0 24 170 48 340 72 510 96 680 120 850 oz in mN m 0...

Page 43: ...cm 1700 mN m Input Inertia 1 61 10 4 lb ft s Maximum Speed 25 000 rpm Maximum Input Power continuous duty 160 W 5 minutes 800 W TORQUE SPEED rpm 0 0 48 340 96 680 144 1020 192 1360 240 1700 oz in mN...

Page 44: ...nge 440 oz in 31 0 kg cm 3 10 N m Input Inertia 5 51 10 4 lb ft s Maximum Speed 25 000 rpm Maximum Input Power continuous duty 150 W 5 minutes 700 W TORQUE SPEED rpm oz in N m 0 5000 10000 15000 20000...

Page 45: ...kg cm 6 20 N m Input Inertia 1 101 10 3 lb ft s Maximum Speed 25 000 rpm Maximum Input Power continuous duty 300 W 5 minutes 1400 W TORQUE SPEED rpm lb in N m 0 5000 10000 15000 20000 25000 30000 0 0...

Page 46: ...0 kg cm 14 00 N m Input Inertia 4 43 10 3 lb ft s Maximum Speed 12 000 rpm Maximum Input Power continuous duty 1800 W 5 minutes 2800 W TORQUE SPEED rpm 0 3000 6000 9000 12000 15000 0 0 25 2 8 50 5 6...

Page 47: ...g cm 28 0 N m Input Inertia 8 81 10 3 lb ft s Maximum Speed 12 000 rpm Maximum Input Power continuous duty 3000 W 5 minutes 5300 W TORQUE SPEED rpm 0 3000 6000 9000 12000 15000 0 0 50 5 6 100 11 3 150...

Page 48: ...m 56 5 N m Input Inertia 1 85 10 2 lb ft s Maximum Speed 8 000 rpm Maximum Input Power continuous duty 12 000 W 5 minutes 14 000 W TORQUE SPEED rpm 0 2000 4000 6000 8000 10000 0 0 100 11 3 200 22 6 30...

Page 49: ...aximum Input Power continuous duty 6000 W 5 minutes 7000 W TORQUE SPEED rpm 0 3000 6000 9000 12000 15000 0 0 50 5 6 100 11 3 150 16 8 200 22 4 250 28 lb in N m Figure 4 19 ED 815 Power Absorption Curv...

Page 50: ...unds per Square Inch HD 510 7 1 75 HD 515 10 4 HD 800 13 10 HD 805 15 14 WARNING DO NOT EXCEED THE PRESSURES GIVEN The air supply should be enabled whenever the unit is in operation 4 1 3 2 2 Blower M...

Page 51: ...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 soli...

Page 52: ...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 corre...

Page 53: ...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...

Page 54: ...es 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...

Page 55: ...see Section B 2 Speed Sensor Board in Appendix B 5 2 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 gaug...

Page 56: ...nel 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 s...

Page 57: ...bly was centered and the damper became functional 5 6 BRAKE CONTROL POWER Any Magtrol Dynamometer Controller is universal in that it must operate all dynamometers Due to the higher level of current re...

Page 58: ...tric and SI Full Scale Torque Pin Location Weights Full ScaleTorque Pin Location Weights 6N series in Size Model 7N series 8N series cm Size Model CB 106 HD 106 2 50 oz in 2 500 1 oz WT 106 183 5 g cm...

Page 59: ...N PROCEDURE The calibration procedure is as follows 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...

Page 60: ...e 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 Note If using Magtrol CB Calibrat...

Page 61: ...aft 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 6 5 CALIBRATION FREQUENCY Magtrol...

Page 62: ...oder 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...

Page 63: ...teady 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 8 1 2 1 Steady Torque Reading If t...

Page 64: ...ffer 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 electro...

Page 65: ...sert 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 Model F S Current A...

Page 66: ...the assembly in both directions Please note several degrees of free swing restrained by the damper cylinder in both directions Note Do not force this assembly The objective is to reposition the load c...

Page 67: ...l 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 o...

Page 68: ...65 APPENDICES Appendix A Calibration Record DATE DYNAMOMETER MODEL SERIAL APPLIED TORQUE INDICATED TORQUE ERROR TESTER...

Page 69: ...f R40 100 K R39 10 K R38 10 15V C24 1 nF 0VA 5Vref Q4 BCV48 3 1 2 4 IC5 LM317 2 3 1 4 IC6 LM337 Torque_O P R36 220 R37 220 R34 2 4 K R35 2 4 K 0VA C20 10 uF C21 10 uF C18 10 uF C19 10 uF C16 100 nF C1...

Page 70: ...n 7 of 14 Pin Brown Wire Pin 10 of 14 Pin White Wire Pin 8 of 14 Pin Green Wire 5V F0 GND R1 470 R2 220 U1 0PB963 3 5 1 2 4 2015 and later dynamometers 200 R1 470 R2 470 R3 GND GND 5V PAD5 PAD7 PAD6 P...

Page 71: ...Appenidix B Schematics APPENDICES B 3 LOAD CELL SCHEMATIC 0 15 mVDC 5 VDC 5 VDC RED BLUE GREEN WHITE VOLTAGE LEVELS TEMP COMP 50 OHM FINE BALANCE 100 OHM 0 11 MILLIVOLT SIGNAL LEVEL BLUE TO GREEN 4 42...

Page 72: ...5625 D8 1N5625 D4 5KP13A C1 1000UF C2 1000UF TRANS1 TRANS2 TRANS3 D3 1N5625 R1 2 2K R4 680 IN POS R5 680 D1 1N4004 D2 1N4004 D5 5KP13A D6 5KP13A R3 3 R2 COLLECTOR BASE EMITTER IN NEG BR1 BR2 BRAKE BUL...

Page 73: ...4 2 Q4 out LM340T15 com in C1 1uF C2 1uF R1 5 1K D4 1N5225A J3 5 C12 001uF C3 1uF T1 6 5 2 1 8 7 4 3 C10 1uF C9 1uF U1 4 11 BR1 C15 1000uF R10 1 00K J1 2 1 4 5 3 R11 1M R28 50K C14 1000uF G S 15 D 0 t...

Page 74: ...witch 16 Erratic Torque Reading 50 F Features 2 Fixtures 37 Friction 38 Full Scale Torque 50 Full Scale Torque Calibration 24 I Inputs 15 Blower 16 Compressed Air 16 Dynamometer Brake 15 L Load Cell 4...

Page 75: ...72 Magtrol Hysteresis Dynamometers Index V Vibration 38 W Windage 24 37 Z Zero Balance 49 Zero Offset 24...

Page 76: ...ment a quotation listing all the necessary parts and labor costs if any will be faxed or e mailed to you 6 After receiving your repair estimate provide Magtrol with a P O number as soon as possible A...

Page 77: ...ardenville Parkway Buffalo New York 14224 USA Phone 1 716 668 5555 Fax 1 716 668 8705 E mail magtrol magtrol com MAGTROL SA Route de Montena 77 1728 Rossens Fribourg Switzerland Phone 41 0 26 407 3000...

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