Model DSP6001High Speed ProgrammableDynamometer ControllerUser’s Manual
viiiMagtrol Model DSP6001 Dynamometer ControllerTable of ContentsFigure 5–4 High Initial P Setting for Torque Control ...
88APPENDICESAppendix C: Front Panel/Display Menu Flow ChartsMODEL DSP6001DYNAMOMETER CONTROLLERPOWERPOWERBRAKE STATUS SET POINT SET POINT P I DTORQUE
89Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2 SECONDARY KEY FUNCTIONSC.2.1 power UnitS
90Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.4 aUx SetUp MenUAUXSETUPSHIFTCLOSELOOP ON
91Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.5 CoM SetUp MenUCOMSETUPSHIFTRS-232BAUDBI
92Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.1 MaxPower Setup MenuSHIFTDYNOSETUPMAXP
93Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.2 Dynamometer Configuration Menu Note:
94Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.2A Hysteresis Dynamometer Setup MenuINP
95Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.2C Aux Setup MenuSHIFTSCALEFACTOR0.000–
96Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.2F Eddy-Current Dynamometer with Eddy-C
97Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.2G Powder Brake Dynamometer with Powder
ixPrefacePURPOSE OF THIS MANUALThis manual contains all the information required for the installation and general use of the Model DSP6001 Dynamometer
98Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.2H Eddy-Current Dynamometer with Powder
99Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.3 Encoder Setup MenuENCODERSDYNOSETUPSH
100Magtrol Model DSP6001 Dynamometer ControllerAppendix C: Front Panel/Display Menu Flow ChartsAPPENDICESC.2.6.4 Alarm Setup MenuAIR FLOWALARMALARMSD
101APPENDICESAppendix D: Remote Configuration Flow ChartsD.1 ADVANCED CONFIGURATIONCommand - ALL0Turn off all alarms while configuring unit Command -
102Magtrol Model DSP6001 Dynamometer ControllerAppendix D: Remote Configuration Flow ChartsAPPENDICESD.2 PRE-TESTSTARTCommand - UR# Select torque read
103Magtrol Model DSP6001 Dynamometer ControllerAppendix D: Remote Configuration Flow ChartsAPPENDICESD.3 RAMPCommand - F Set max speed (calculation p
104Magtrol Model DSP6001 Dynamometer ControllerAppendix D: Remote Configuration Flow ChartsAPPENDICESD.4 SPEEDSTARTCommand - N# Set speed pointCommand
105Magtrol Model DSP6001 Dynamometer ControllerAppendix D: Remote Configuration Flow ChartsAPPENDICESD.5 TORQUESTARTCommand - Q#Set speed pointComman
106Magtrol Model DSP6001 Dynamometer ControllerAppendix D: Remote Configuration Flow ChartsAPPENDICESD.6 MISCELLANEOUSCommand - DIR#Selects quadrature
107APPENDICESAppendix E: SchematicsE.1 DYNAMOMETER POWER SUPPLYA_GNDA_+5VDL71uHL81uHTP12TP180.1uFC131+5VD+5VA1uHL31uHL2TP11uFC3+5VDTP2AGND$G_DGND$G_D
xMagtrol Model DSP6001 Dynamometer ControllerPrefaceChapter 10: TROUBLESHOOTING - Solutions to common problems encountered during setup and testing.
108Magtrol Model DSP6001 Dynamometer ControllerAppendix E: SchematicsAPPENDICESE.2 DYNAMOMETER DSP & MEMORYPSC_1200R7434C100+25V13456789102J10111
109Magtrol Model DSP6001 Dynamometer ControllerAppendix E: SchematicsAPPENDICESE.3 DSP DYNAMOMETER ANALOG I/OJ6121FUSEF1HEADER_SIP2A1A2A3A4A5J12A7A8A
110APPENDIXAPPENDICESAppendix F: Additional Scale Factor TableThe Additional Scale Factor Table is the same as the M-TEST Defaults file, which contains
111IndexAAccessory Torque-Speed Output 12,37,80Additional Scale Factor 42,110Advanced Configuration 101Air Flow Alarm 56AlarmCommands 69Operation
112Magtrol Model DSP6001 Dynamometer ControllerIndexGPIB 65Integral 40,42LLabVIEW Programming Examples 83Line Voltage 15MMaximum Speed Alarm 53Ma
113Magtrol Model DSP6001 Dynamometer ControllerIndexTesting Instrumentation Setup 17Timeout 69TorqueConfiguration 105Torque Commands 74Torque Contr
114Service InformationRETURNING MAGTROL EQUIPMENT FOR REPAIR AND/OR CALIBRATIONBefore returning equipment to Magtrol for repair and/or calibra
www.magtrol.comTesting, Measurement and Control of Torque-Speed-Power • Load-Force-Weight • Tension • DisplacementMAGTROL INC70 Gardenville ParkwayBuf
1GENERALINFORMATIONCalibration Certificate1. Introduction1.2 NEW FEATURES OF THE DSP6001Magtrol’s new Model DSP6001 Dynamometer Controller is an upg
2Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – IntroductionGENERALINFORMATION1.3 DATA SHEETDSP6001Data SheetDSP6001 High-Speed Programmable
3Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – IntroductionGENERALINFORMATION2DSP6001MAGTROLSpecificationsFRONT PANELREAR PANELSet Desired P
4Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – IntroductionGENERALINFORMATION3DSP6001MAGTROLSystem ConfigurationsMotorUnderTestOPTIONAL:±10
5Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – IntroductionGENERALINFORMATION4DSP6001MAGTROLSystem ConfigurationsDYNAMOMETER / TSC1AUX / TSC
6Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – IntroductionGENERALINFORMATION5DSP6001MAGTROLDYNAMOMETER / TSC1AUX / TSC2SUPPLY 2SUPPLY 1RS-2
7Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – IntroductionGENERALINFORMATIONDSP6001Due to the continual development of our products, we res
1st Edition, revision J – March 2010While every precaution has been exercised in the compilation of this document to ensure the accuracy of its conten
8GENERALINFORMATION2. Controls2.1 FRONT PANELThe front panel provides a power switch, nine control buttons, a Decrease/Increase Dial, and Vacuum Flu
9Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – ControlsGENERALINFORMATION2. Press any control button to enable the function shown in blue l
10Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – ControlsGENERALINFORMATION2.2.3.2 Double-Function ButtonsButton To Use FunctionPOWER UNITS
11Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – ControlsGENERALINFORMATION2.3.1 contraSt SEttingSThe DSP6001 is shipped with the Contrast S
12Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – ControlsGENERALINFORMATION2.4 REAR PANELThe rear panel provides connectors and receptacles
13Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – ControlsGENERALINFORMATIONDYNAMOMETER/TSC1Connect dynamometer signal cable here.14. TORQUE
14Magtrol Model DSP6001 Dynamometer ControllerChapter 2 – ControlsGENERALINFORMATIONSUPPLY 2 Connect WB/PB DES supply for TSC2. 3. CLUTCH 8. W FLOW_2
15SETUP3. Installation/Configuration Note: Before installing the DSP6001, you should become familiar with the front and rear panels, as outlined in
16Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.1.2 SeLf-teStAfter turning the power on to the DSP6001, the
17Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2 TESTING INSTRUMENTATION SETUPThe DSP6001 has the abil
i1. Make sure that all Magtrol dynamometers and electronic products are earth-grounded, to ensure personal safety and proper operation.2. Check lin
18Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.1 DynaMoMeter ConfigUration MenUTo reach the dynamometer
19Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.2 HyStereSiS DynaMoMeter SetUp3.2.2.1 Hardware Connectio
20Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.3 HyStereSiS DynaMoMeter witH torqUe tranSDUCer SetUp3.2.
21Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.3.2 Software Configuration1. Turn on the DSP6001 and proc
22Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.4 HyStereSiS DynaMoMeter witH aUxiLiary inStrUMentation S
23Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.4.2 Software Configuration1. Turn on the DSP6001 and proc
24Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.5 HyStereSiS DynaMoMeter witH eDDy-CUrrent or powDer Brak
25Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.5.2 Software Configuration1. Turn on the DSP6001 and proc
26Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.6 eDDy-CUrrent or powDer Brake DynaMoMeter SetUp3.2.6.1
27Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.7 eDDy-CUrrent or powDer Brake DynaMoMeter witH torqUe tr
iiThe contents of this manual are subject to change without prior notice. Should revisions be necessary, updates to all Magtrol User’s Manuals can be
28Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.8 eDDy-CUrrent or powDer Brake DynaMoMeter witH aUxiLiary
29Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.9 two eDDy-CUrrent/powDer Brake DynaMoMeterS (inDepenDent
30Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.9.2 Software Configuration1. Turn on the DSP6001 and proc
31Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.10 two eDDy-CUrrent/powDer Brake DynaMoMeterS (tanDeM Set
32Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.10.2 Software Configuration1. Turn on the DSP6001 and pro
33Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.11 eDDy-CUrrent DynaMoMeter witH powDer Brake DynaMoMeter
34Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP8. Press SHIFT 2 times to get to the TSC2 Powder Brake Setup
35Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.2.12 in-Line torqUe tranSDUCer CroSS Loop fUnCtion3.2.12.1
36Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP8.a. If choosing a Hysteresis or Powder Brake Type, press SHIF
37Magtrol Model DSP6001 Dynamometer ControllerChapter 3 – Installation/ConfigurationSETUP3.4 TORQUE/SPEED ANALOG OUTPUTSTorque and Speed DAC Outputs p
iiiTable of ContentsSAFETY PRECAUTIONS ...
38SETUP4. Digital FiltersThe Digital Filters of the DSP6001 are used to remove undesired noise from the TSC inputs. This noise could be conducted fro
39Magtrol Model DSP6001 Dynamometer ControllerChapter 4 – Digital FiltersSETUP4.2 FILTER SETUPNote: Filter setup should take place after hardware in
40SETUP5. PID Settings5.1 ABOUT THE PID LOOPThe DSP6001 has PID adjustment capability for both the speed and torque modes to provide the best system
41Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUP5.3 HOW THE PID LOOP WORKSThe following diagram demonstrates the correlati
42Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUP5.3.3 eqUationSWhere Skp, Ski and Skd are system coefficients…Yd(t) = (e(t)
43Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUP5.4.1.3 Setting Additional Scale Factor for D (Derivative)1. Starting fro
44Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUPFigure 5–3 Initial P Setting for Torque Control at 25%Figure 5–4 High Ini
45Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUPa. If the response was too slow, increase the I term in 1-5% increments an
46Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUP5.5.3 Setting tHe piD for SpeeD ControL1. With the motor and brake OFF, s
47Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUPFigure 5–8 Initial I Setting for Speed Controlc. If there is too much ove
ivMagtrol Model DSP6001 Dynamometer ControllerTable of Contents3.3 SPEED ENCODER SETUP ...
48Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUP5.5.4 Setting tHe piD for raMp DownIt is nearly impossible to select a PID
49Magtrol Model DSP6001 Dynamometer ControllerChapter 5 – PID SettingsSETUPFigure 5–11 Ramp Down High IRamp shows higher value for I term. Note “bum
50SETUP • OPERATION6. Alarm System6.1 GENERAL INFORMATIONNew to the DSP6001 is a built-in alarm system, designed to caution the user when problems o
51Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATIONThe relay contacts are made accessible on the Accessory Torque/
52Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.1.3 aLarM priorityWhile in an alarm condition, a higher prio
53Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.2.2 power aLarM aCtionWhen the power exceeds that of the max
54Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.3.2 MaxiMUM SpeeD aLarM aCtionA. If speed is greater than
55Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATIONPOWERBRAKE STATUS SET POINT SET POINT P I DTORQUE SPEED STATUSF
56Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.5 AIR FLOW ALARM• Usedtoindicatealackofairowfroma
57Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.6 WATER FLOW ALARM• Usedtoindicatelackofwaterow• O
vMagtrol Model DSP6001 Dynamometer ControllerTable of Contents6.6 WATER FLOW ALARM ...
58Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.7 EXTERNAL ALARM• Usedtoshutdownsystembasedonadditio
59Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.8 TEMPERATURE ALARM• Toalertuserwhendynamometergetsto
60Magtrol Model DSP6001 Dynamometer ControllerChapter 6 – Alarm SystemSETUP • OPERATION6.9 ELECTRICAL ALARM• UsedtoprotecttheDESsupply• Monito
61OPERATION7. Manually Controlled Operation Note: Using the DSP6001 without a computer will limit its testing capabilities.7.1 HOW TO CHOO
62Magtrol Model DSP6001 Dynamometer ControllerChapter 7 – Manually Controlled OperationOPERATION7.2 HOW TO SET DESIRED POWER UNITS To select the desi
63Magtrol Model DSP6001 Dynamometer ControllerChapter 7 – Manually Controlled OperationOPERATION Note: If the response is too slow or oscillatory, a
64Magtrol Model DSP6001 Dynamometer ControllerChapter 7 – Manually Controlled OperationOPERATION4. Press the SHIFT button to exit the MAX SPEED funct
65OPERATION8. Computer Controlled OperationThe DSP6001 can be used with a computer to control a dynamometer and to transmit data from the motor testi
66Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.1.2 CHanging tHe gpiB priMary aDDreSSEach instrumen
67Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION Note: If the desired results did not occur, p
viMagtrol Model DSP6001 Dynamometer ControllerTable of Contents9.3.2 TSC1 Offset and Gain ...
68Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.4 DATA FORMATSpeed-torque data is a fixed-length str
69Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.5.1.2 Codes for CR - LFBASIC HEX DECCR = CHR$(13) 0
70Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.6.2 CoMMUniCation CoMManDSCommand CodeFunction Expl
71Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.6.3 raMp CoMManDSCommand CodeFunction ExplanationDI
72Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.6.4 SetUp CoMManDSCommand CodeFunction ExplanationA
73Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATIONCommand CodeFunction ExplanationUA# Sets auxiliary inp
74Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.6.5 SpeeD CoMManDSCommand CodeFunction ExplanationF
75Magtrol Model DSP6001 Dynamometer ControllerChapter 8 – Computer Controlled OperationOPERATION8.6.7 MiSCeLLaneoUS CoMManDCommand CodeFunction Expla
76MAINTENANCE9. Calibration9.1 CLOSED-BOX CALIBRATIONThe DSP6001 features closed-box calibration. The advantage of closed-box calibration is that t
77Magtrol Model DSP6001 Dynamometer ControllerChapter 9 – CalibrationMAINTENANCEPOWERBRAKE STATUS SET POINT SET POINT P I DTORQUE SPEED STATUSFigure 9
viiMagtrol Model DSP6001 Dynamometer ControllerTable of ContentsTABLE OF FIGURES2. CONTROLSFigure 2–1 Front Panel ...
78Magtrol Model DSP6001 Dynamometer ControllerChapter 9 – CalibrationMAINTENANCE9.3.3 tSC2 offSet anD gain1. Connect the external voltage reference
79Magtrol Model DSP6001 Dynamometer ControllerChapter 9 – CalibrationMAINTENANCE15. N/C14. CURRENT SET POINT (ANALOG 0V)13. +5.0 VDC COM12. SUPPLY +24
80Magtrol Model DSP6001 Dynamometer ControllerChapter 9 – CalibrationMAINTENANCE8. Connect volt meter to Pin 3 (negative) and Pin 1 (positive) of ACC
81Magtrol Model DSP6001 Dynamometer ControllerChapter 9 – CalibrationMAINTENANCE9.3.6 DeCiMaL point CHeCk1. Connect a 0.5 VDC source to pins 14 (TOR
82MAINTENANCE10. TroubleshootingIf you require additional assistance, please contact Magtrol Customer Service at 1-716-668-5555.Problem Reason Soluti
83APPENDICESAppendix A: LabVIEW Programming Examples0 [0..1]1 [0..1]Magtrol offers a comprehensive motor testing software program to satisfy most of y
84Magtrol Model DSP6001 Dynamometer ControllerAppendix A: LabVIEW Programming ExamplesAPPENDICES0 [0..2]1 [0..2]1 [0..2]2 [0..2]A.2 TORQUE STABILIZE
85Magtrol Model DSP6001 Dynamometer ControllerAppendix A: LabVIEW Programming ExamplesAPPENDICESA.3 SPEED STABILIZED0 [0..2]1 [0..2]2 [0..2]2 [0..2]
86APPENDICESAppendix B: Inertia CorrectionB.1 INERTIAL EFFECT ON MOTOR TEST DATAA major advantage of the DSP6001 is its ability to obtain full motor
87Magtrol Model DSP6001 Dynamometer ControllerAppendix B: Inertia CorrectionAPPENDICESB.2.1 key ConDitionS• Select appropriate value. The test poin
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