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2

Magtrol Hysteresis Dynamometers

Chapter 1 – Introduction

GENERAL

INFORMA

TION

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.

•  

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.

• 

easy calibration

Unique features of each series are listed below.

1.2.1 

HD S

erieS

Magtrol’s hD Series Dynamometers 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 torque and speed requirements.

• 

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 S

erieS

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.

• 

specially Reinforced load cell: 

 Stainless steel pin used at contact point to prevent 

premature wear from excess vibration.

• 

Gusseted pillow blocks: 

 Adds additional front and rear support.

• 

brake cooling:

  blower cooled to maximize heat dissipation.

Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Содержание HD Series

Страница 1: ...ss underutilized and idle equipment along with credit for buybacks and trade ins Custom engineering so your equipment works exactly as you specify Critical and expedited services Leasing Rentals Demos...

Страница 2: ...User s Manual HD and ED Series Hysteresis Dynamometers Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Страница 3: ...tion 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 Pur...

Страница 4: ...e 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 a...

Страница 5: ...th 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 C Added new section Calibration Beams and Weights 6 2...

Страница 6: ...dition rev A 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 standard 3 3 3 01 03 03 2nd Edi...

Страница 7: ...puts 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 19 3 1 3 HD 800 Series 19 3 1 4 ED 715 19 3 1 5...

Страница 8: ...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 Rotational Alignment 53 8 2 Speed Readout Problems 54...

Страница 9: ...00 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 Curve 30 Figure 4 8 HD 515 Power Absorption Curv...

Страница 10: ...apter 3 INSTALLATION CONFIGURATION Provides information needed for setup of the dynamometer This includes load cell shipping restraining bolt removal earth ground instruction and configurations for ma...

Страница 11: ...ich if ignored may result in damage to the material being used The associated text describes the necessary precautions to take and the consequences that may arise if these precautions are ignored WARN...

Страница 12: ...re 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 Instrument Cable PLEASE TAKE NOTICE Before pr...

Страница 13: ...w to medium power ranges Features include Accuracy 0 25 to 0 5 full scale depending on size and system configuration Custom Dynamometers For special torque and speed requirements Encoder Switch Option...

Страница 14: ...est systems for a wide array of industries including Appliance Automotive Aviation Computer HVAC Lawn and Garden Medical and Dental Electric Motor Office Equipment and Power Tools eD Description With...

Страница 15: ...namometer 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 develo...

Страница 16: ...400 5N 0 28 N m 2 mN m 1 55 10 5 2 10 10 5 200 55 25 000 Convection 6N 40 0 oz in 0 25 oz in 7N 2 80 kg cm 0 02 kg cm 8N 280 mN m 2 mN m HD 500 5N 0 85 N m 5 mN m 8 05 10 5 1 09 10 4 400 80 25 000 Con...

Страница 17: ...t 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 suffici...

Страница 18: ...rical power anD Fuses Model Voltage VA Style Rating HD 1XX XN 120 V 30 UL CSA 300 mA 250 V SB HD 1XX XNA 240 V 30 IEC 125 mA 250 V T HD 4XX XN 120 V 30 UL CSA 300 mA 250 V SB HD 4XX XNA 240 V 30 IEC 1...

Страница 19: ...8 5 18 5 8 5 0 37 N A 18 0 lb mm 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 These dimensions represent the distance between mounti...

Страница 20: ...E F G H J L M N P Q Weight HD 700 in 1 25 0 4995 0 4999 5 875 11 34 0 09 11 0 625 9 5 10 9 84 9 84 0 35 0 06 0 63 30 lb mm 31 8 12 687 12 692 149 2 288 0 2 2 279 4 15 9 241 3 254 250 0 250 9 1 6 15 9...

Страница 21: ...2 19 09 15 75 0 35 236 0 lb mm 54 25 387 25 400 228 6 584 66 432 50 8 371 356 5 1 485 400 9 107 0 kg E A H J N M F C G L D K B An HD 825 Dynamometer with long base plate is available if ordered with t...

Страница 22: ...in mN m The power absorption curves represent the maximum power heat that the dynamometer can dissipate over time HD 100 HD 400 TORQUE SPEED rpm 0 5000 10000 15000 20000 25000 30000 0 0 2 2 16 4 4 32...

Страница 23: ...HD 800 HD 810 TORQUE SPEED rpm 0 3000 6000 9000 12000 15000 0 0 25 2 8 50 5 6 75 8 4 100 11 2 125 14 0 lb in N m TORQUE SPEED rpm 0 3000 6000 9000 12000 15000 0 0 25 2 8 50 5 6 75 8 4 100 11 2 125 14...

Страница 24: ...est 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...

Страница 25: ...igned and built to meet specific user requirements heavy duty equipment rack M TEST Motor Testing Software AMF Adjustable Motor Fixture Dynamometer Table HD Hysteresis Dynamometer DSP7000 Dynamometer...

Страница 26: ...ers and ED 815 base of dynamometer also serves as the table top TAB 0800L Table for HD 825 long base plate dynamometers TAB 0825L MOTOR FIXTURES Adjustable Motor Fixtures AMF Series Fixed Motor Fixtur...

Страница 27: ...DYNAMOMETER BRAKE INPUT Connect dynamometer brake cable here Figure 2 2 Dynamometer Brake Input DYNAMOMETER CONNECTOR Connect dynamometer signal cable here 14 TORQUE SIGNAL 13 TORQUE COMMON 12 D P B...

Страница 28: ...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 HD 825 ED 715 and ED 815 Dynamometers only War...

Страница 29: ...ams 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 Series The shipping res...

Страница 30: ...aining 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...

Страница 31: ...ated 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 all HD 700 800 series and ED dynamometers Cau...

Страница 32: ...ction A typical manual test system will consist of a Magtrol Hysteresis Dynamometer used in conjunction with a Magtrol 6200 Open Loop Controller Note Magtrol s Single or Three Phase Power Analyzer may...

Страница 33: ...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 dynamometer 14 Pin 14 Pin Instrument Cable PN88M007 01...

Страница 34: ...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...

Страница 35: ...ning 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...

Страница 36: ...iable 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...

Страница 37: ...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 prop...

Страница 38: ...ORQUE SPEED rpm 0 6000 12000 18000 24000 30000 36000 0 0 0 5 3 6 1 7 2 1 5 10 8 2 14 4 2 5 18 oz in mN m Power Absorption Curves HD 106 TORQUE SPEED rpm 0 6000 12000 18000 24000 30000 36000 0 0 0 5 3...

Страница 39: ...b 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 4 32 6 6 48 8 8 64 11 80 oz in mN m Figure 4...

Страница 40: ...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 5000 10000 15000 20000 25000 30000 Figure 4 5...

Страница 41: ...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 m 0 5000 10000 15000 20000 25000 30000 Figure...

Страница 42: ...a 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 25000 30000 0 0 88 0 62 176 1 24 264 1 86 352...

Страница 43: ...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 11 1 24 22 2 48 33 3 72 44 4 96 55 6 20 Figur...

Страница 44: ...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 75 8 4 100 11 2 125 14 0 lb in N m Figure 4 13...

Страница 45: ...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 16 8 200 22 4 250 28 lb in N m Figure 4 15 HD...

Страница 46: ...imum 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 6 300 33 9 400 45 2 500 56 5 lb in N m Figure 4 17...

Страница 47: ...nutes 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 Curve 4 1 3 2 Cooling Methods Note For additional...

Страница 48: ...HD 800 13 10 HD 805 15 7 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 Magtrol s HD 710 715 810 815 825 and ED 715 815...

Страница 49: ...h 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 o...

Страница 50: ...ssive 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 T...

Страница 51: ...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 dynamometer Then decrease the current t...

Страница 52: ...y 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 0 5...

Страница 53: ...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 gauges The strain gauges are in a bridge configura...

Страница 54: ...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...

Страница 55: ...nal 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 required by Magtrol s larger dynamometers a boos...

Страница 56: ...ghts 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 18 00 mN m 9 18 20 g WT 106M CB 100 HD 100 11...

Страница 57: ...llows 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 tighteni...

Страница 58: ...bration Calculation 5 Adjust the CW Calibration trim pot so that the torque reading equals the weight times the distance Note If using Magtrol CB Calibration Beams in conjunction with WT Calibration W...

Страница 59: ...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 load cells are temperature compensated and des...

Страница 60: ...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 p...

Страница 61: ...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 the torque reading is active and steady you wil...

Страница 62: ...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 de...

Страница 63: ...ynamometer 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 HD 106 0 145 HD 100 0 135 HD 400 0 300 HD 500...

Страница 64: ...veral 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 cell in such a manner to re establish the cente...

Страница 65: ...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...

Страница 66: ...PENDICES Appendix A Calibration Record DATE DYNAMOMETER MODEL SERIAL APPLIED TORQUE INDICATED TORQUE ERROR TESTER Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisant...

Страница 67: ...Vref 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 C17 100 nF 5VD FLOW_CLUTCH OK TACH_B 25V 25V 15V...

Страница 68: ...e 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 PAD8 BRAKE CONNECTION PAD9 PAD10 MOUNT HOLES CO...

Страница 69: ...l 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 42K OHM 1 OHM 2 TRIMPOT S G 4 350 OHM Artisan Te...

Страница 70: ...RANS1 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 BUL45 Transistor 35 Volts MT3 MT4 MT1 MT2 Resisto...

Страница 71: ...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 to 10V b 0 to 3V a 15 c 15 15 15 PD05 IF 6 40 1...

Страница 72: ...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 41 Load Cell Schematic 56 M Manual Test Systems...

Страница 73: ...62 Magtrol Hysteresis Dynamometers Index V Vibration 38 W Windage 24 37 Z Zero Balance 49 Zero Offset 24 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Страница 74: ...ts 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 r...

Страница 75: ...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 Fax 41 0 26 407 3001 E mail magtrol magtrol c...

Страница 76: ...uipment Have surplus equipment taking up shelf space We ll give it a new home Learn more Visit us at artisantg com for more info on price quotes drivers technical specifications manuals and documentat...

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