Dyn-Loc V Quick Start Guide
Contents
1. Dyn Loc V Quick Start Guide Dyne Systems Inc Rev 1 0 Page 4 of 10 Power shall NEVER be applied to the Dyn Loc V during the wiring process TORQUE Connector Wiring Options Load Cell Belden 9534 Item 3 in Cable table Pin Wire Function 4 Red Excitation 10 VDC 16 Black Excitation Common 14 Green Input 1 White Input 2 Shield Install a jumper wire between each of the following pairs of pins 5 6 17 18 3 13 In Line Torque Sensor Belden 8761 Item 1 in Cable table Pin Wire Function 13 Clear Torque Sensor Input 25 Black Torque Sensor Input Common 12 Shield NOTE Additional hardware may be required if using an In Line torque sensor If the torque sensor was provided by Dyne Systems reference the associated system drawings else reference the torque sensor manufacturer s documentation Setup Parameters The torque transducer must be properly configured in order to produce accurate readings Power up the Dyn Loc V Then press the SETUP button to access all configuration parameters Navigate to the following folder which contains all torque configuration parameters Dyn Loc V Control Variables Torque For the installed torque transducer set the Transducer Type Load Cell or Torque Sensor as needed This setting determines exactly which of the remaining settings need to be configured For a load cell get the ful2. and D Read Chapter 6 of the Dyn Loc V User Manual before attempting to tune the controller this chapter explains how to configure the tuning page enter setpoints enter tuning parameters etc Do NOT attempt to tune the controller until you are familiar with all aspects of the tuning page user interface General Tuning Information A basic square wave input is used to tune each controller mode The square wave consists of alternating manually or automatically between two pre selected setpoints therefore two reasonably safe setpoint values should be selected prior to starting the tuning process Note that the square wave step changes to the setpoint value is limited by the configured up and down ramp rate values During tuning it may be desirable to set the ramp rate slightly higher i e faster than during normal operation Higher ramp rates may expose systems with marginal stability Use a zone based tuning method where the P parameter is tuned first while the I and D parameters are each set 0 Then after the P parameter has been set the I parameter will need to be tuned The D parameter is rarely necessary and will not be discussed here it should be set 0 Always start with a small value of P and increase very slowly until the amount of overshoot after a setpoint change becomes unacceptable A sample set of PID parameters are listed below Note the P value for torque mode is ext
3. is properly set NOTE The Invert Polarity parameter can be used to temporarily avoid re wiring however all wiring mistakes should be corrected Incorrect drawings and all system prints should be updated as well Do not continue until valid speed readings are obtained 4 Connect and Configure a TORQUE Transducer Wiring and configuring a torque transducer is described in the Dyn Loc V User Manual Chapter 7 section 2 0 All torque transducers are wired to the TORQUE connector located on the back of the Dyn Loc V on the DYNAMOMETER CONTROLLER card A mating 25 pin female DSUB connector is required and can be created using items 2 5 and 7 listed in the Connector Components table Wiring Two types of torque transducers are supported Load Cells and In Line torque sensors Each is wired as listed below A complete list of all pins on the TORQUE connector is shown in the Dyn Loc V User Manual Chapter 13 section 4 1 2 NOTE Some in line torque sensors are really load cell type devices thus they should be wired and configured as a load cell Contact Dyne Systems for assistance with this configuration When using shielded cable the shield connections must NEVER be connected at both ends of a cable The TORQUE connector provides dedicated pins for the connection of all shields thus all shields should be grounded at the TORQUE connector while leaving all shields UNCONNECTED at the transducer
4. e Inafew more seconds the main computer will start up and the front panel will display readings If the Dyn Loc V starts up as described above disconnect power from the controller and proceed to the next step If the main screen does not appear or if it does not appear as described above contact Dyne Systems before proceeding Optional Step Press the SETUP button to explore many of the Dyn Loc V configuration parameters Familiarity with the organization of all parameters will be helpful in later steps 3 Connect and Configure a SPEED Transducer Wiring and configuring a speed transducer is described in the Dyn Loc V User Manual Chapter 7 section 1 0 All speed transducers are wired to the SPEED connector located on the back of the Dyn Loc V on the DYNAMOMETER CONTROLLER card A mating 15 pin male DSUB connector is required and can be created using items 1 4 and 6 listed in the Connector Components table Wiring Three types of speed transducers are supported Magnetic Pickup Units MAGPU s as well Single Ended and Differential output optical encoders Each is wired as listed below A complete list of all pins on the SPEED connector is shown in the Dyn Loc V User Manual Chapter 13 section 4 1 1 When using shielded cable the shield connections must NEVER be connected at both ends of a cable The SPEED connector provides dedicated pins for the connection of all shields thus all shields shoul
5. reduce noise in the feedback signal to an acceptable level Do not add any more filtering than absolutely necessary Dyn Loc V Quick Start Guide Dyne Systems Inc Rev 1 0 Page 9 of 10 NOTE This filter only affects the feedback signal that is used by the control loop The Dyn Loc V also provides a configurable Display Filter which performs a completely different function i e to provide a more visually stable readable version of the feedback signal Tuning Torque Mode To tune Torque mode control enable the DUT and spin the system at some reasonable speed The DUT is responsible for controlling the speed of the system at all times Put the Dyn Loc V into Torque mode enable the controller press the TUNE button and begin the tuning process Tuning Speed Mode To tune Speed mode control enable the DUT and spin the system at some reasonable speed NOTE Since the Dyn Loc V will be in Speed mode the DUT must be in torque mode or more likely at a constant throttle position Regardless extra care must be taken to ensure the system does not run away until the Dyn Loc V is properly tuned and able to accurately control speed Before enabling the controller check that the Hard Over speed limit has been properly set Also be prepared to punch the ESTOP button at all times When prepared put the Dyn Loc V into Speed mode enable the controller press the TUNE button an
6. the dynamometer nameplate This is an important parameter allowing the Dyn Loc V controller to protect the dynamometer from excessive power absorption for extended periods of time 6 Dyn Loc V Controller Setup Before the controller can be successfully enabled other wiring and setup requirements must be satisfied Specifically the GENERAL PURPOSE I O connector on the back of the Dyn Loc V contains an ESTOP input and a Master Enable input see Chapter 13 section 4 3 4 of the Dyn Loc V User Manual Each of these inputs must be correctly wired or appropriately bypassed NOTE If your Dyn Loc V is integrated into an overall safety system the GENERAL PURPOSE I O connector will most likely be utilized and needs to be correctly wired per the electrical system prints By Passing the ESTOP Input The ESTOP input can be by passed by connecting a wire from any 24 VDC output i e pin 18 19 36 or 37 to pin 17 on the GENERAL PURPOSE I O connector Alternatively a shunt can be installed at location JP6 on the GENERAL PURPOSE I O board Setup Parameters The Master Enable input can be by passed by connecting a wire from any 24 VDC output i e pin 18 19 36 or 37 to pin 16 on the GENERAL PURPOSE I O connector Alternatively the Master Enable input can also be disabled in software as follows Press the SETUP button and locate the following folder Dyn Loc V General Purpose I O Set the va
7. Below is a list of the steps required to complete this quick start guide Perform the steps in the listed order 1 Safety Review 2 Connect Power to the Dyn Loc V 3 Connect and Configure a SPEED Transducer 4 Connect and Configure a TORQUE Transducer 5 Connect the Eddy Current Power Amplifier Unit 6 Dyn Loc V Controller Setup 7 Enable the Device Under Test 8 Enable the Dyn Loc V Controller 9 Tuning Dyn Loc V Quick Start Guide Dyne Systems Inc Rev 1 0 Page 1 of 10 1 Safety Review Read all of Chapter 1 in the Dyn Loc V User Manual This chapter provides important notices regarding safety electrocution hazards inspection of your new controller etc Do not proceed if you are not comfortable making basic electrical decisions and electrical connections The use of a licensed electrician is highly recommended for all power connections exceeding 50 Volts 2 Connect Power to the Dyn Loc V Basic controller operation can be verified by applying power as follows e Place the Dyn Loc V controller on a table or workbench e Verify ALL connectors on the back of the Dyn Loc V are disconnected e Connect the 24 VDC power supply to the 24 VDC input power connector on the back of the controller e Plug the 24 VDC supply into a standard 120 VAC wall outlet e The cooling fan is immediately heard starting up e In about 7 seconds the front panel display will appear The message line will say Connecting to DLS
8. En Inc Midwest amp Dynamatic Dynamometers Dyn Loc V QUICK START GUIDE www dynesystems com DPD 010 QS1 Dyn Loc V Quick Start Guide This quick start guide will assist you in getting a Dyn Loc V eddy current dynamometer controller configured and running as efficiently as possible The Dyn Loc V User Manual is referenced many times in the upcoming sections and should be consulted as needed to obtain additional information regarding each and every aspect of the Dyn Loc V controller The following items are required to complete this quick start guide Review the list and begin after all necessary items have been procured e Dyn Loc V User Manual e DS820 Eddy Current Power Amplifier Unit User Manual e Various types of multi conductor shielded cable for transducer connections see table at end of this document e DSUB connectors pins connector shells and crimping tool see table at end of this document To complete all steps in this quick start guide it is also required that the dynamometer be connected to a device under test DUT The DUT must be capable of rotating via some type of speed control or throttle position control If the DUT is not yet operational is it generally not advisable to energize the eddy current dynamometer Feel free to connect the speed and torque transducers and perform many of the other configuration tasks but wait until the DUT is operational before enabling and tuning the Dyn Loc V controller
9. d begin the tuning process REFERENCE Cable Item Description Manufacturer P N 1 Multi conductor cable 1 twisted pair 22 AWG shielded Belden 8761 2 Multi conductor cable 4 twisted pairs 24 AWG individual shields Belden 9728 3 Multi conductor cable 4 conductors 24 AWG shielded Belden 9534 Connector Components Item Description Manufacturer P N 1 15 Pin DSUB Connector Plug AMP 205206 9 2 25 Pin DSUB Connector Receptacle AMP 5205207 1 3 37 Pin DSUB Connector Plug AMP 205210 8 4 Male Crimp Pin for DSUB Connector AMP 205089 1 5 Female Crimp Pin for DSUB Connector AMP 205090 1 6 Metalized Plastic Shell for 15 Pin DSUB Connector 3M 3357 6515 1C 7 Metalized Plastic Shell for 25 Pin DSUB Connector 3M 3357 6525 1C 8 Metalized Plastic Shell for 37 Pin DSUB Connector 3M 3357 6537 1C Dyn Loc V Quick Start Guide Dyne Systems Inc Rev 1 0 Page 10 of 10
10. d be grounded at the SPEED connector while leaving all shields UNCONNECTED at the transducer Power shall NEVER be applied to the Dyn Loc V during the wiring process Dyn Loc V Quick Start Guide Dyne Systems Inc Rev 1 0 Page 2 of 10 SPEED Connector Wiring Options Magnetic Pickup Belden 8761 Item 1 in Cable table Pin Wire Function 6 Clear MAGPU 14 Black MAGPU 7 Shield Encoder Differential Output Belden 9728 Item 2 in Cable table Pin Wire Function 2 Red Encoder Excitation 12 VDC 9 Black Encoder Excitation Common 8 Shield 3 Green Clock A 11 Black Clock A 8 Shield 4 White Clock B 12 Black Clock B 8 Shield 5 Blue Index Pulse 13 Black Index Pulse 8 Shield Encoder Single Ended Output Belden 9534 Item 3 in Cable table Pin Wire Function 2 Red Encoder Excitation 12 VDC 1 Black Encoder Excitation Common 3 Green Clock A 4 White Clock B or Direction 8 Shield NOTE Single ended encoders require additional hardware adjustments to the Dyn Loc V DYNAMOMETER CONTROLLER card Specifically shunts must be installed at locations JP3 JP4 and JP5 Also a single turn potentiometer VR1 must be adjusted to provide a proper bias voltage for the single ended inputs Contact Dyne Systems for assistance in determining the pro
11. l scale value and units and the sensitivity MvV from the load cell datasheet Enter these values into the Load Cell Full Scale Value Setup Force Units and Load Cell MvV configuration parameters NOTE The units of the final torque reading can be different from the units used now during setup Dyn Loc V Quick Start Guide Dyne Systems Inc Rev 1 0 Page 5 of 10 Next determine the radius of the load cell mounting point and units This value is typically found on the dynamometer nameplate or on a manufacturer supplied dynamometer drawing Enter these values into the Load Cell Radius and Setup Length Units configuration parameters For an in line torque sensor compute the output sensitivity i e volts per some torque unit from the transducer data sheet Enter this value into the Torque Sensor Sensitivity parameter Then set the Setup Force Units and Setup Length Units as needed to define the torque units used in the sensitivity calculation Other settings related to the display appearance e g Display Resolution Display Units etc can be set within this folder as well Testing a Load Cell To test a load cell attach the calibration arm to the dynamometer and hang the calibration weights Calculate the expected torque reading Verify that the actual torque reading is within a few percent of the expected torque reading Also verify the polarity of the reading By definition when
12. lue of the Ignore Master Enable Input to Yes Dyn Loc V Quick Start Guide Dyne Systems Inc Rev 1 0 Page 7 of 10 7 Enable the Device Under Test An eddy current dynamometer is an absorbing device and hence is not capable of spinning motoring the system That is the responsibility of the Device Under Test DUT presumably some type of gasoline engine diesel engine AC or DC motor etc At this time enable the DUT and spin the system to a safe speed The DUT must be capable of keeping the system at a safe speed either via a dedicated speed controller or by keeping for example the throttle position at 0 throttle idle speed Do not proceed to the next step until the DUT is capable of rotation There is no value in continuing as the dynamometer is incapable of generating any torque at zero or even very low RPM 8 Enable the Dyn Loc V Controller Before enabling the controller for the first time several run time parameters must be configured Press the SETUP button and locate the following folder Dyn Loc V Enter reasonable values for Hard Over speed Limit and Hard Over torque Limit The default value for each parameter is 0 0 which will cause an immediate fault when the controller is initially enabled if left as is Put the controller into Torque mode by touching the torque reading The LOCK and setpoint indicators will move to the torque reading Enable the controller b
13. per bias voltage as well as how to set and measure this voltage Dyn Loc V Quick Start Guide Dyne Systems Inc Rev 1 0 Page 3 of 10 Setup Parameters The speed transducer must be properly configured in order to produce accurate speed readings Power up the Dyn Loc V Then press the SETUP button to access all configuration parameters Navigate to the following folder which contains all speed configuration parameters Dyn Loc V Control Variables Speed For the installed speed transducer set the Transducer Type Encoder or MAG Pickup as needed Then set the Transducer PPR value to the PPR pulses per revolution value listed on the transducer datasheet If the transducer is an encoder set the Direction Type as needed Most encoders provide Quadrature encoded direction information however some provide a binary clockwise counter clockwise output Other settings related to the display appearance e g Display Resolution Display Units etc can be set within this folder as well Testing The simplest test is to manually rotate the system by hand if possible If encoder pulses are detected RPM readings will appear on the display If an encoder is installed rotate the system in both directions and verify the correct polarity of the readings in each direction If the polarity of the readings is incorrect or missing the Clock A and Clock B signals may be reversed Check that the Direction Type
14. remely small therefore increases to the P value must be extremely small as well The PID parameters for torque mode are generally all integral Mode P l D Speed 10 15 0 Torque 0 1 10 0 Also note that with I set 0 no integral the steady state value will not reach the commanded setpoint For torque mode the steady state error i e the difference between commanded setpoint and the actual reading can be extremely large due to the small P value The steady state error will be removed when the integral term is tuned At this point your goal is to get the controller to respond with minimal acceptable overshoot The integral term can initially be tuned without using step changes in the setpoint Command any safe setpoint and wait for the controller to reach steady state Then increase the I term until the steady state error is removed Do not add any more I than necessary When done begin alternating setpoints again Increase I as needed to improve response But again do not increase the I term any more than necessary Filtering Filtering is often needed to remove electrical noise from the feedback signal Unfortunately filtering introduces delays which can lead to control loop instability Early in the tuning process or before doing any tuning at all use the tuning page to look carefully at the feedback signal Increase the value of the feedback filter in order to
15. s and weights are available follow the instructions listed above for testing a load cell 2 Performa shunt calibration as described below Many in line torque sensors contain an internal precision shunt calibration resistor When enabled a precise known torque reading will be displayed Shunt calibration may require additional wiring Contact Dyne Systems for additional information if this is the case To perform shunt calibration follow the procedure described in Dyn Loc V Quick Start Guide Dyne Systems Inc Rev 1 0 Page 6 of 10 Chapter 7 section 2 5 of the Dyn Loc V User Manual At this time calibration is not the ultimate goal the immediate goal is to verify correct sensor wiring and correct parameter setup Do not continue until valid torque readings are obtained 5 Connect the Eddy Current Power Amplifier Unit Before proceeding to the Dyn Loc V Controller Setup the Eddy Current Power Amplifier Unit ECPAU the dynamometer coil external transformers etc need to be wired Several safety inputs on the ECPAU also need to be wired All of these tasks are described in detail in the DS820 Eddy Current Power Amplifier Unit User Manual Setup Parameters Press the SETUP button to access all configuration parameters Navigate to the following folder which contains all dynamometer configuration parameters Dyn Loc V Dynamometer Set the value of the Dyno Rated Horsepower to the value obtained from
16. the eddy current dynamometer is absorbing and the system is spinning with positive speed values the torque readings should be positive as well If not a wiring error may exist NOTE The Invert Polarity parameter can be used to temporarily avoid re wiring however all wiring mistakes should be corrected Incorrect drawings and all system prints should be updated as well If the readings are NOT within a few percent of the expected value re check the configuration values obtained from the load cell datasheet Ensure they were entered correctly Also re check your expected torque reading calculation as well as the value of the variables used in the calculation i e the value of the calibration weights and the calibration arm length If the readings are acceptable remove the calibration weights and calibration arm from the dynamometer The torque reading should return to zero or near zero NOTE An alternate testing procedure is to perform a complete load cell calibration as described in Chapter 7 section 2 4 of the Dyn Loc V User Manual If you do so verify that the actual span value is within a few percent of the expected span value BEFORE performing the span calibration Span calibration should NOT be used to compensate for significant error often cause by errors in the setup parameters Testing an In Line Torque Sensor An in line torque sensor can be tested in one of two ways 1 If the shaft can be locked and calibration arm
17. y pressing the ON OFF button The reading will turn yellow indicating an enabled controller running in torque mode NOTE Notice that upon enabling the Dyn Loc V the current torque setpoint is automatically set to the current torque reading This functionality is referred to as a bumpless enable This action occurs whenever a controller is enabled as well as whenever a controller mode change occurs e g from torque to speed mode providing bumpless operation in all cases Enter a small torque set point value using the numeric keypad and press the ENTER key Absolutely nothing should happen i e no torque developed since the controller has not yet been tuned i e all PID tuning parameters are set 0 Let the controller run in this state for about 1 minute to ensure that all ECPAU control and status signals as well as various safety inputs are valid and stable If any signal loss faults or signal timeout faults occur contact Dyne Systems and or consult the Dyn Loc V User Manual for more information regarding the specific fault s Press the ON OFF button again to disable the controller Proceed to the next step Tuning Dyn Loc V Quick Start Guide Dyne Systems Inc Rev 1 0 Page 8 of 10 9 Tuning Initially the controller is not capable of commanding the ECPAU to generate a load because all tuning parameters are set 0 Tuning is the process of establishing reasonable values for each tuning parameter P
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