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M-TEST 5.0

1. 99 RETURNING MAGTROL EQUIPMENT FOR REPAIR AND OR CALIBRATION eee 99 Returning Equipment to Magtrol Inc United States essen nennen 99 Returning Equipment to Magtrol SA Switzerland eese nennen emen enne eere 99 vi Magtrol M TEST 5 0 Motor Testing Software Table of Contents TABLE OF FIGURES 2 INSTALLATION Figure 2 1 M TEST 5 0 Software Installation e E R annone 6 Figure 2 2 Installation Complete 15 corte teretes a aa elder e I COR Ce Pe 7 Figure 2 3 NI DAQmx Data Acquisition Driver Software Installer eese 8 Figure 2 4 NI 488 2 Getting Started Figure 2 5 NI 488 2 Troubleshooting Wizard Figure 2 0 GPIB Conflguration nias secs reete ete d ti da eddy e treten 3 M TEST 5 0 INTERFACE Figure Sal Window etti aer E ONEN UI E EEEE PEEL In ees 14 Figure 3 2 Inaccessible Controls Example nter iren ra ee 17 4 START Figure 4 1 Statt Window Figure 4 2 Password Prompt 5 CONFIGURE HARDWARE Figure 5 1 Configure Hardware Window si s 5 2 ee e tete TRE ER GE e EYE EREMO E ERE E YR ERR EUER SER 21 6 DISPLAY Figure 6 T Display Setup Window RETE LEGE EXE Peg e 31 7 TEST SEL
2. 70 1 1 SAVE stitit E eR deesse 70 112 PRINT TEST DATA EE 71 12 5 AXIS GRAPH 72 121 SELECT PLOTTED PARAMBTBERS eri ttt eher re ehe eive ee te e P e eei rera ed 72 12 2 SAVE DATA bs taeda MILLIUM LEE 72 13 FAXIS 73 134 PARAMETERS rire eS cupa URN cays 73 132 SAVEDATA 73 jnre lim TE 74 141 LOAD DATA P 74 14 2 SELECT PLOTTED PARAMETERS o eer 74 15 REPORTS afe 75 154 CONFIGURE REPORT te 76 152 VIEW REPORT e TI 15 3 SAVBAREPORT iti ER ERE REB EUM Dir pini eed rese E aa DRM EN TI 15 4 77 Table of Contents Magtrol M TEST 5 0 Motor Testing Software 16 SECURITY 79 16 1 PASSWORD ADMINISTRATION eite tpi e
3. 1 159 00210 BHL CEU DEUS Uo 1 12 SYSTEM REQUIREMENTS rue pieta Ute 1 13 SSOBEWARE BEATUNRES a a a PEU EUN Seed 2 1 3 New Features of M TES T 10 enata eno esee tee en eeu i ma eo te oia ea e ee 2 13 2 Other Beaturnes tm FRED TO are ate MR e ERE END UE OE OHIO e eect e 2 14 DATA SHEE Mr 3 MEDIAE E ja 6 21 INSTALLATION PROCEDUNRE tir EE E ter ro eye E e nd eee ebore aevo ves teak 6 2 2 INSTALLING M TEST 5 0 PRODUCT SOFTWARE AND DRIVERS eese 6 221 Creating Desktop Shortc t encre tcs erp t be Te ERR 7 2 3 INSTALLING NI DAQMX DATA ACQUISITION DRIVER SOFTWARE eerte nennen 8 24 IN PRAMA OE SELUD etre rr D UE Ue Ut p EQUI REO REEF ag 9 2 4 1 Installing the GPIB Board esee e Nee Ee b PR VAR EN UR UNE Ue Medie eU PEERS cae 9 2 12 Confhpunng GPIB Devices sicrie oc m C Do RUE a aeaii 10 2 4 5 5 232 SenalInterface rte nente eee ene eel eeu va evans e HERE RE ERU TR e pU XE EU a we FER vive 10 2 5 SENSOR INPUT TEMPERATURE MEASUREMENT eee eor peh ea Ene e LEN ER RES En EU
4. RERRERRRRREERRE 33 Ti RAMPE TESTING ER 33 Goll Me as nne Methods N T UI e ORR 33 Thiz JAyerage D U DOWD epe T REPRE REESE DP Eoo avery E IET DO Yet EIS ELO iret 34 Tks CBE uos neo EEG UO ERE EU tete EIE 36 152 CURVE edere aiti dde edet uomen eem ccu ee uv Su 38 4 3 NMDANUAIDUESTINGE TE FEE terit rerit sir dta tiem ERU nete e 40 14 PASSIEAIE TESTING cett REG E ERE Ebr RE PEE EE RE E Eo Or ee pea re DEEP d ESPERE E OT Eg 40 7 4 1 Pass Fail Test Example 41 Magtrol M TEST 5 0 Motor Testing Software Table of Contents mEeopldejLimpclemeE 45 road bummer ees ene eee aen mens neta cp MI MIS ML 45 82 E 46 83 CURVEMANUAL TEST PARAMETERS oe eoe nr rro oid ee rae ie exe tee eade ego 47 8 3 1 Control Data Table snp ua 50 84 RAMP TEST PARAMETERS ect ee CORE e RED evel PES ERE PUR NERA NU REEL E Wa VERON Ve a ERR ERE 51 84 1 Special Data Points Table s ner xe roe res re b o e EORR ex aee euet o tee tnde 54 8 5 PASS PAIL TEST PARAMETERS cerises rN ERE EEr s ase 55 8 5 1 Pass Fail Control Table
5. Current Data Creme tore M om Figure 7 10 Pass Fail Test Results Window 42 Magtrol M TEST 5 0 Motor Testing Software Chapter 7 Test Selection In this example at least one parameter failed as indicated by the red FAIL bar above the table Each failed parameter is highlighted in red J M TEST 5 0 Motor Test Software E T MASIRON Current Setup C Magt up Files Ramp msf Revision 1 02 1792 000 1773 000 1749 000 1725 000 wint RPM RPM Max Min Max 25 000 1790 000 1800 000 35 000 1760 000 1800 000 40 000 1740 000 1800 000 45 000 1710 000 1800 000 Index 4 Y Axis B Hide Graph Torque p si Next Test Stop Test Save Data Single Graph D Auto Y Axis Auto X Axis Clear Graph Figure 7 11 Failed Test Example 43 E m o o m E U Chopter 7 Test Selection Magtrol M TEST 5 0 Motor Testing Software The data from the passed test will be sent to the pass xls file that was set up at the beginning of the test Microsoft Excel pass 8 x S File Edit View Insert Format Tools Data Window Help 8 DOSEN SRY XR Rn ooo E ALRL 0 8 05 ACH Arial B ZU E amp E til 9 14 45 A1024 0 278 30 238 17
6. import From Spreadsheet Print Report Save Report Report Folder Pass Filename Fail Filename Control Parameter ozin Speed Range Timebase Sampling Rate sec Number of Cycles Max Brake Current 96 Max Temp Max Current Operator Code Revision 1 03 Torque 99999 00 Seconds 1 00 2 Figure 8 2 Curve Test Setup Window When Manual test is selected the window will appear as follows Jf M TEST 5 0 Motor Test Software 2 5 x J MASTROE Current Setup Select Test 1 Display mm Test Manual SaveData Data Folder Serial Number Include Equipment List Auto Increment Control Data From Time 0 5 10 10 20 20 0 Import From Spreadsheet Print Report Save Report Report Folder Pass Filename Fail Filename 1 Axis Graph Control Parameter oz in Speed Range Timebase Sampling Rate sec Number of Cycles Max Brake Current 90 Max Temp Max Current Operator Code Figure 8 3 Manual Test Setup Window Revision 1 03 Torque 99999 00 Seconds 47 E m o o m E U Chapter 8 Configure Test Magtrol M TEST 5 0 Motor Testing Software The following parameters may be used when setting up a Curve or Manual Test Control Function Options Values Import from Spreadsheet Imports data from an externa
7. Autox asis Figure 7 4 Dynamic CF Test Before Inertial Cancellation The correction can now be applied to the entire deceleration curve For any point on the curve the corrected torque is the measured torque minus the CF value times the speed difference between this point and the previous point T 25 T4 CF x S Sp Corrected Torque 51 Prior Speed at Torque Point Measured Torque Sa Corrected Speed at the Torque Point Correction Factor Because there is no deceleration at free run and locked rotor torque correction is not applied to these points GU Y Ads X Anis Figure 7 5 Dynamic CF Test 37 E m o m E U Chopter 7 Test Selection Magtrol M TEST 5 0 Motor Testing Software 7 2 CURVE TESTING M TEST 5 0 can be used in a way that simulates complex load profiles This may be for heat run or endurance testing simulating a real life usage or just for checking a few specific data points Loading may be accomplished by closing a control loop on Speed Torque or Output Watts plus Amps or Input Watts if a power analyzer is incorporated into the system Because closed loop speed and torque are internal functions of the dynamometer controller the control loops are very fast and highly controllable The remaining functions use a routine in M TEST 5 0 to close the loop and provide control These will not provide as tight of a control as the internal functions but they are q
8. Test Date Test Time Serial Information printed on the report Up to 9 different Number Operator Code Maximum parameters can be selected Current Maximum Efficiency Maximum Horsepower Maximum Input Watts Maximum Output Watts Maximum Torque Maximum Speed Direction of Rotation and Maximum Output kW Comments Displays the comments to be included Type desired comments in the report Show Graph Shows graph on the report Select the check box to show the graph clear check box to omit from report Y axis Selects the parameter to graph on the Any of the parameters previously Y axis selected in the Display window X axis Selects the parameter to graph on the Any of the parameters previously X axis selected in the Display window Curve Fit If the resulting plot has a mathematical Enabled select check box and function its shape may be smoothed _ Disabled clear check box by enabling curve fitting The program will apply a general polynomial curve fit routine to the data set and re plot the data NOTE The curve fit applies to the graph only and not the tabular data Polynomial Sets the order of polynomials in the 0 to 100 Order curve fitting routine NOTE The default of 2 should be sufficient for most curves but may be increased to achieve a truer representation It is recommended to experiment with the curve fitting in the 5 Axis Graph window to find the best fit and then use the same value fo
9. s gt 2 4 m 5 E TEMERE Chapter 2 Installation Magtrol M TEST 5 0 Motor Testing Software 2 5 2 2 5 2 1 10 11 12 13 14 15 16 17 18 Expand FP com1 folder Expand FP 1000 0Bank Click FP TC 120 X X represents 1 2 3 or 4 the module to be configured Click Channel Configuration tab Select check box for the channel to be configured Select temperature range in either or Under Channel Attributes select thermocouple type in Value box Repeat steps 11 13 for each channel Note If all channels use the same thermocouple type deselect One channel at a time check box and click the All button This will allow changes to be made to all the channels at once Click Apply Note If additional TC modules are installed steps 8 through 16 will need to be repeated for modules FP TC 120 2 FP TC 120 3 and FP 120 4 where applicable Close FieldPoint Explorer The program will prompt you to save changes to untitled Select Yes Close Windows Explorer NarioNAL INSTRUMENTS USB 9211A Features 4 thermocouple inputs Built in isolation on all channels Connects to computer through USB port Installing Hardware 1 Plug in USB cable 4 gt 2 m 5 SNILLAD Magtrol M TEST 5 0 Motor Testing Software Chapter 2 Installation 2 6 2 6 1 NATIONAL INSTRUMENTS NI 6521 RELAY ACTUATOR CARD As an option Magtrol off
10. 144 870 0 277 146 868 0 254 951 000 152 965 0 050 6 549 0 939 1300 149163 0229 901000 5144 0 046 6890 1319 150916 0207 850 000 49840 0042 7 152 317 1 351 153 871 0168 1 364 154 953 0 152 1 377 156 223 0 136 1 387 157073 0 122 159 216 48 277 46 765 45 355 43 876 42 663 40 093 Figure 15 3 Sample Motor Test Report 78 16 Security Click the Security tab to open the Password Administration window J M TEST 5 0 Motor Test Software 74 MAGTRO Current Setup msf Revision 1 03 Start Configure Hardware 1 Axis Graph Compare Reports Security Config Hardware Config Display Run Test View Graph Security Spare 2 User Name Config Test Adjust PID View Data Reports Spare 1 Spare 3 Dodge Dee Tom Macao Delete Delete r pace pace BEEN A nmm i Figure 16 1 Password Administration Window The Security feature allows M TEST 5 0 to be run in either a single or multi user environment With password protection enabled the primary user can assign user access rights and determine who within their departments will have access to specific program windows 16 1 PASSWORD ADMINISTRATION 1 To add a new user go to the next available row and click anywhere ins
11. 81 18 Troubleshooting Problem Reason Solution Clicked Start Test and there was no response M TEST 5 0 has not been properly configured The hardware and software must be configured before a test may be run The testing instrument model was changed in the Configure Hardware window and the values did not update Did not load defaults Must click Load Defaults button to automatically update all values and program the torque units into the controller NOTE If necessary once the defaults are set they can be adjusted When starting M TEST 5 0 the following message appears M TEST DEFAULTS TXT FILE NOT FOUND The M Test Defaults txt file is missing from the M TEST 5 0 program folder Click Stop and quit M TEST 5 0 Find the M Test Defaults txt file and save it to the directory where M TEST 5 0 is located No serial communication with controller Setup error and or hardware fault Check cabling baud rate and COM port of controller Screen plot does not look exactly as it did during the curve test During the test data is acquired and plotted at the maximum system sample rate but data is stored at the user defined rate Increasing the sample rate will store more data points and the plot will look more like the original The Desired Data Columns in the Reports window only show Torque and Speed The software needs to be configured according
12. NIR Er ERI eR cages ETE TEO AERE 79 16 1 1 Password Visible ie eere aa roe ei a ee eub Ve EE VRBE e Ere e cR QA Re CS eee n dea Re 80 10 1 2 Disable Password A EU Ne veau eM eee 80 17 81 18 TROUBLESHOOTING isos c 82 APPENDIX A GRAPH TOOLS cccrinnncn on tue aUa KR SP RXXXASEER XRRRRRN Ge Rue 83 Ad pt taro en Pr rer T per Hd RE ees e D eR 83 A AUIOSGALDB53eesencenume end mede 85 CURVE BUD e 85 AGI Polynomial Ordet eir ERGO 85 4 86 AAS Cursor Movement oo ret uet EXER RETO S RE DUIS UE pee PER EC N CETERO edet 86 LM 86 A4 3 Panning Tool see nta to RR RETO 87 CURSOR EBEGEND rre ab eta a mtt ene ei En Satori e 87 Cursor Moyement Selector us enr Ere xS REPRE ESO ERR de PUER RISE NM TE 88 ASZ qpormattne Button EE DOPO ERR EIU OE n
13. NOTE For repetitive cycling of a load profile enter one complete cycle in the Pass Fail Control table Maximum Sets the maximum brake current necessary to O to 99 99 Brake Current lock the rotor NOTE If locked rotor is not desired this control is irrelevant Maximum Sets the desired maximum temperature when Any Temperature using temperature acquisition hardware NOTE The temperature units NOTE If any thermocouple exceeds the value are the same as what was entered in this field the test in progress will selected in the hardware setup abort For FieldPoint Units are configured within FieldPoint Explorer See Section 2 4 1 3 Thermocouple Type and Temperature Unit Changes For USB 9211 Units are set up in the Configure Hardware window under Sensor Input Maximum Sets the desired maximum current Any Current NOTE If the measured current exceeds the value entered in this field the test in progress will abort Speed Range Sets the desired speed range 0 to 99999 Pass FaAiL TABLE From Starting value for the Control Parameter To Ending value for the Control Parameter Time Dwell time for the Control Parameter Volts Setsthe voltage for each step when using a DC or regulated AC power supply The power supply will be programmed to the voltage desired at the beginning of each step Min Minimum allowable value for the Pass Fail parameter displayed directly above Ma
14. SPEED CORRECTION FACTOR 0 0001x2 0 0203x 0 005 limited to 0 051 to 1 RPM Where x NOMINAL SPEED 100 Note NOMINAL SPEED is set by the user and obtained from the data sheets for the dynamometer or brake The speed correction factor is calculated on each entry into the PID loop equations B 2 3 Equations Where Skp Ski and Skd are system coefficients Yd t e t e t 3 3 e t 1 e t 2 10 Skd D Yp t e t Yd t 10 Skp P Yi t Yi t 1 e t Yd t 10 Ski 190 Yt t Yp t Yi t Ys t 2 Scale Yt t B 4 DYNAMIC PI SCALING In some cases PI values that have been fine tuned for best system response at higher speeds will not be suitable at lower speeds The DSP6001 allows the use of dynamically changed PI values to correct this When the DPL or DIL controls are set at 1 000 the PI coefficients remain constant between the free run speed and minimum speed Changing any control to a value less than 1 000 dynamically changes the P or I from 1 000 at free run to the control value times the starting value at minimum speed For example a DIL of 0 010 produces an I term of 1090 of the starting value at the end of the ramp S Note This feature is available only during a ramp test gt 0 0 m 2 gt lt 92 Magtrol M TEST 5 0 Motor Testing Software Appendix B PID Scaling B 4 1 SETTING THE Dynamic PI Ramp Down It is nearly impossible to sel
15. Timebase Sets the timebase for all the time values in the control table Seconds and Minutes Sampling Rate sec Sets the time interval at which a data point will be sampled and stored NOTE When using the Manual Test and timed storage the data will be stored automatically at the rate selected here The fastest rate is 100 samples per second 0 01 s Any NOTE The fastest rate allowed in a curve test is 10 samples per second 0 10 s This rate is necessary in order to maintain accurate timing for the ramp and dwell parameters If you wish to acquire data only at the end of each dwell period type 99999 Number of Cycles Selects the number of times to repeat the load cycle 1 to 32767 48 E m o o m E U Magtrol M TEST 5 0 Motor Testing Software Chapter 8 Configure Test Control Function Options Values Maximum Brake Current Sets the maximum amount of current necessary that will lock the rotor if desired during the test sequence Different size dynamometers require different amounts of DC current to produce full torque or enough torque to lock the rotor of a motor being tested The hysteresis dynamometer s rotor will become magnetized if current is applied while the shaft is not turning This produces residual magnetism also known as a bump If too much current is applied the bump may be sufficiently large as to not allow the mo
16. e Select language from English French Spanish German or user created dictionary e Load save current setup file data file and report file 3 2 2 CowricuRE HARDWARE e Search for and display GPIB addresses of devices communicating with M TEST 5 0 e Configure the system for all connected hardware including dynamometer controller power analyzer power supply and sensor input device Load default testing instrument parameters based on model number s gt 2 m 5 SNILLAD 3 2 3 DisPLAY e Select parameters to be tested and displayed 3 2 4 CONFIGURE TEST e Select test type and set up corresponding test parameters e Enable and set up data logging to automatically store acquired data at the end of each test 3 2 5 ApJusr PID e Adjust PID proportional gain integrative and derivative settings and scaling on the DSP6000 6001 Controller 3 2 6 TEST e test e Graphically display live test data 3 2 7 View Data e Display test data in a tabular spreadsheet format with option to print 3 2 8 5 Axis GRAPH e Display up to five different test parameters on the same graph 3 2 9 1 Axis GRAPH e Display up to three separate 1 graphs one for each tested parameter in the same window 3 2 10 CoMPARE e Overlay data from two separate saved tests on the same graph 3 2 11 REPORTS e Configure view print and save test reports Chapter 3 M TEST 5 0 Interface Magtrol M TEST 5 0 Motor Testing
17. 0 88 Psi a IS A psi A peu 9 1000 bi jj 1o High Value 15 00 Low Value 9 0 00 Dwell 9 Increase PS until actual value is approximately 2590 of ideal value Use the P slider for finer adjustment When optimal setting is reached the result will appear similar to the following example J M TEST 5 0 Motor Test Software J MASTRS Current Setup C Mag p msf Figure 9 3 Curve P at 25 Revision 1 02 Pst F 169 05 A bet High Value jj 1500 Low Value J 0 00 Dwell y 2 60 E m o o m E U Magftrol M TEST 5 0 Motor Testing Software Chapter 9 Adjust PID 10 Set Ito 35 11 Increase IS until actual value reaches ideal value Use the I slider for finer adjustment When optimal setting is reached the result will appear similar to the following example J M TEST 5 0 Motor Test Software E aee Current Setup C Magtrol Setup Files Ramp msf Revision 1 02 PS Isi G DSi A bet ome Gf x000 High Value 1500 Low Value 9 0 00 Jz E m o o m E U Figure 9 4 Curve with P and I 12 Set D to 35 13 Increase DS until the actual curve matches or is as close to the ideal curve as possible Use the D slider for finer adjustment The final result will appear similar to the following example Jf M TEST 5 0 Motor Test Software 7 KAAGTROL M TEST 5 0 Current Setu File Psi F 15 6 05 F High Value jj
18. Control Data 50 Configuration 10 Controls Device Detection 21 Inaccessible 17 Graph Palette 86 Correction Factor Calculation 36 Graphs Crosshairs button 86 87 1 73 Current Data Filename 20 5 72 Current Report Filename 20 Compare 74 Current Setup Filename 20 Graph Tools 83 Cursor Legend 87 H Cursor Movement Selector 88 Cursor Movement Tool 86 Hardware Configuration 21 Cursor Mover 88 Help 16 Curve Fit 85 Hide Grid 89 Curve Test Configuration 66 Controller Adjustment 5964 Description 38 Parameters 47 Setup Routine 57 Indicators 17 Installation GPIB Board 9 M TEST Software 6 Procedure 6 D Temperature Board 11 Data Integral 90 Interface Filename 20 GPIB 9 die RS 232 10 Data Acquisition Driver Software 8 Data Logging 46 L Data Points 54 Data Sheet 3 Defaults File 23 Derivative 90 Description and Tip 16 Display 15 31 Display Setup 31 Drivers 6 Language Dictionaries 19 Selection 19 Translation 19 Language Dictionaries 19 Language File csv 19 Load Defaults 23 96 Magtrol M TEST 5 0 Motor Testing Software Index Lock Button 88 Login 18 M M TEST4 0 2 M TEST Defaults File 23 Manual Test Configuration 67 Description 40 Parameters 47 Measurement amp Automation Explorer 7 Motor Parameters 31 N Navigating M TEST 5 0 16 NI 488 2 9 NI 488 2 Troubleshooting Wizard 9 NI DAQmx 8 NI6521 13 p Panning Tool 87 Parameters 31 Pass Fail Test Configuration
19. 11 Type 11 Torque Correction Factor CF 36 Troubleshooting 82 U USB 9211A 12 28 Vv View Data 15 70 W Windows 1 Axis Graph 73 5 Axis Graph 72 Adjust PID 57 Compare 74 Configure Display 31 Configure Hardware 21 Configure Software 45 Configure Test 45 Exit 81 Reports 75 Security 79 Start 14 18 Test 66 View Data 70 Z Zoom 86 98 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 or 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 Depa
20. 68 Controller Adjustment 59 Description 40 Parameters 55 Password 18 Password Administration 79 PCI GPIB 9 PID Adjustment 57 Adjust PID 15 Loop 90 91 Scaling 91 Settings 90 93 Plot Legend 83 Polynomial Order 85 Power Measurement 26 Power Supply 27 Print Test Data 71 Proportional Gain 90 Quit 81 R Ramp Down 93 Ramp Test Configuration 67 Controller Adjustment 6264 Description 33 Parameters 51 Relay 13 Report Filename 20 Save 20 Reports 15 75 Revision History Software Program 95 Users Manual ii RS 232 Interface 10 S Save Hardware Configuration 30 Save Data 20 Save Report 20 Save Setup 20 30 32 Save Test Data 69 Security 16 79 Select Language 19 Sensor Input 28 Sensor Input Temperature Testing Hardware Installation 11 Serial Interface 10 Setup Filename 20 Save 20 Software Configuration 31 33 45 57 74 75 Software Installation 6 Software Revision History 95 Speed Correction 92 Speed Correction Factor 92 Start 14 15 18 Start Window 18 System Requirements 1 T Tabs 16 Temperature Board 11 Temperature Measurement Option 11 Temperature Unit Changes 11 Test 15 65 Test Parameters Curve 47 Manual 47 Pass Fail 55 Ramp 51 Tests Average D U 34 Curve 38 Dynamic CF 36 Manual 40 Pass Fail 40 Ramp 33 Test Selection 33 97 Index Magtrol M TEST 5 0 Motor Testing Software Test Setup 45 Text Boxes 16 Thermocouple Connections 11 Input Module
21. 7500 8000 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6800 Time ms gt 0 0 m 2 gt lt Figure B 3 Ramp Down High 93 Appendix B PID Scaling Magtrol M TEST 5 0 Motor Testing Software Ramp shows higher value for I term Note bump at beginning of ramp has been reduced but there are poor results toward end of ramp 3500 3400 3200 3000 2800 2600 2400 2200 IDEAL RAMP 1600 1400 1200 1000 800 600 400 2000 1800 ACTUAL z 2 3500 3400 R 3200 3000 2800 2600 1600 1400 1200 1000 800 600 400 1 IDEAL RAMP ACTUAL RAMP 7 5 7 O 500 1000 1500 2000 2500 3000 3500 4000 4500 500 5500 6000 6500 7000 7500 8000 Time ms Figure B 4 Ramp Down Dynamic I Ramp shows Dynamic Scale effect Note bump at beginning of ramp has been reduced and there are good results toward end of ramp DIL was set to 0 01 At the end of the ramp the I term is 1096 of the starting value 94 gt 0 0 m z gt lt Appendix C Software Revision History Missing Setup Files folder and startup msf added to install Outline box removed from Auto X Axis control on Test tab Fixed several bugs Contact factory for more details In View Data 5 Axis and 1 Axis screens add field to display current data path Changed allowable range of PID values Control power
22. 835 120 541 56 026 0 581 1627 000 27 070 0 044 32 569 120 497 57 045 0 584 1614 000 27 919 0 045 33 322 120 502 57 717 0 586 1610 000 28 435 0 045 33 854 Figure 11 1 View Data Window Use the scroll bars to the right and at the bottom of the table to view all the data 11 1 SAVE TEST DATA If data logging is enabled test data is automatically saved as a Microsoft Excel file using the motor s serial number as the file name Refer to Section 5 2 Data Logging for more information 4 m o 2 m o o To save test data as a file that can be recalled later by M TEST 5 0 click Save Data The Save As dialog box will open to prompt for a file name with an mdf file extension The data is then saved as a tab delimited file that can be imported into any spreadsheet program 70 Magtrol M TEST 5 0 Motor Testing Software Chapter 11 View Data 11 2 PRINT TEST DATA 1 Click Configure Print The window will appear as follows J 5 0 Motor Test Software T MASIRON Current Setup C Maatrol Setup Files Ramp msf Revision 1 02 Configure Hardware Configure Test Adjust PID TEST View Data 5 Axis Graph 1 Axis Graph olts 1 Watts IN 1 Efficiency Speed RPM Torque ozin Horsepower Watts OUT 120 642 30 502 0 027 1792 000 0 632 0 001 0 838 120 800 31 309 0 064 1786 000 1 505
23. ER STEREO Eee eects 88 4359 3EOCK BUON oen eto ae fece taedis mcam t te dices IS 88 ASA Cursor MOVED feast x 88 6 89 APPENDIX B PID SCALING 90 B l ABOUT THE PID EOOP 2 2 e trt rrr Ee dre p bo iH OR e OD RR 90 B L1l ertet yap e Ea Fee UE RE Se eV 90 BP MERFdiniuclic Eme 90 B13 D D tiyatiye E 90 B 2 HOW THE PID LOOP WORKS ebore er tenente irren tbe erbe ree aree iei a yet vaga veces 91 B 2 1 Scaling for Hysteresis Eddy Current and Powder Brake Dynamomeeters esses 91 B 2 2 Speed Correction for WB Eddy Current Brake Dynamometers eee 92 B 2 3 Equat0ns ERE IH iG E 92 BA DYNAMIC PI SCALING D 92 Setting the Dynamic Pl for Ramp cette rent eire tr ere rt hie i rh tn n e CER eto ipee 93 APPENDIX C SOFTWARE REVISION HISTORY innata tantu unu ana Yuan tnu E ku ndn ussu NA REDI X PME E CERE 95 HO 96 SERVICE
24. Ert E 56 9 ADJUST PID 57 91 BID PARAMPBETERS 58 9 2 ADJUSTING THE CONTROLLER FOR A CURVE OR PASS FAIL TEST sees 59 9 3 ADJUSTING THE CONTROLLER FOR A RAMP 62 jill de 65 10 1 CONFIGURE HARDWARE netto to ca eerte OEC E ERE QE RECIENTE UR eel TR EE 65 10 2 CONFIGURE DISPLAY tes pedo modeste oerte tee edad durada te M cede ates eas esu vade qud 65 10 3 CONFIGURE AND RUN TEST nhi die ree rib een iE Ep ets ev ec er eee e Ee Sb FO Ee Eve 66 103 1 GIVE D 66 10 32 Ramp lest e roten sees e eere Pe DHT ENIM Pr Hl edt reete sr Fee etes Feci Fe HERE e 67 1033 Manual E U M 67 10 3 4 Pass Fail 68 104 VIEW TEST DATA MEME 68 1041 Tabular Display itp rene ete tena teer EEEE tte epe eor EEEE E EEANN NENA 68 LOAD Graphical Display siccsteccsseicssicc rerom DEED OU 68 10 5 CONFIGURE REPORT I erecto EUER RR EUER RTT ERS EE bee 68 10 6 SAVE TEST DATA ette ehe denen e tue ete ren res tee reae oov ees etui ew ere adea tera Lua cx Mode eu 69 11
25. Figure 10 1 Test Window Example 10 3 1 Curve TEST Curve testing is best used for heat run or endurance testing simulating a real life usage or just for checking a few specific data points Click the Configure Test tab to open the Configure Test window Under Select Test select Curve Under Curve Test Parameters select Control Parameter Enter values in control data table Click Test tab to open Test window NN PWN Select which parameters will be plotted from the X and Y axis drop down lists located in the lower right corner of the Test window 7 Click Start Test The Test data table to the left will appear based on the parameters selected in the Display window The Test graph will display the plot for the selected X and Y parameters 66 Magtrol M TEST 5 0 Motor Testing Software Chapter 10 Test To display additional test curves simply change the X and Y axis parameters and click Start Test again S Note If results are unacceptable see Section 9 1 Adjusting the Controller for a Curve or Pass Fail Test 10 3 2 Ramp Test Ramp testing is best used for obtaining a full performance curve in a short period of time 1 Click the Configure Test tab to open the Configure Test window 2 Under Select Test select Ramp 3 Under Ramp Test Parameters choose Ramp Method 4 Set Ramp Rate to approximately 10 of free run speed of motor 5 Set Minimum Speed S Note For initial test achieving locked
26. M TEST 5 0 Motor Testing Software 7 1 2 AvERAGE D U Doww Up When a motor is placed under controlled deceleration the torque produced at any given point will be greater due to stored energy When the motor is then accelerated the torque produced will be less at any given point If the deceleration and acceleration rates are equal the corrected data is simply an average of the two curves M TEST 5 0 accomplishes this by ramping the motor down to a user defined minimum speed Because of system limitations any speed less than 150 rpm with the standard 60 bit encoder will cause the motor to ramp down to 150 rpm and then begin accelerating The motor will continue the controlled ramp until it has reached free run or until it no longer exhibits acceleration 7 M TEST 5 0 Motor Test Software Current Setup C Maatro ramp msf Revision 1 00 Amps 1 0318 38 0 Volts 1 120 613 36 0 Watts IN 1 33 712 34 0 PF 1 0 880 aas Efficiency 0 183 Speed RPM 1771 000 Torque oz in 4 701 Horsepower 0 008 Time 19 671 30 0 28 0 26 0 24 0 F220 20 0 E 18 0 5 16 0 14 0 12 0 10 0 8 0 6 0 4 0 2 0 0 0 1 1 i 1 1 0 0 0 0 0 0 100 0 200 0 300 0 400 0 500 0 600 0 700 0 800 0 900 0 1000 0 1100 0 1200 0 1300 0 1400 0 1500 0 1600 0 1700 0 1800 Speed RPM FER A Y Axis X Axis Torque Speed zc Start Test Stop Test Save Data AutoY Axis D AutoXAwis
27. TEST 5 0 Interface 3 3 4 3 3 5 INDICATORS When an indicator is illuminated in green that function is enabled If the indicator is dimmed dark gray the correspnding function is disabled autoY Axis auto x Axis INACCESSIBLE CONTROLS Controls buttons text boxes etc will be available as needed If there is no selection needed for a specific item the control will be dimmed and no access may be gained to that control For example when None is selected as the Device in the Power Measurement section of the Configure Hardware window there is no further input needed Therefore the remainder of the controls in that section are inaccessible to the user a seen in the figure below IGPIB Address 0 Units Watts External Shunt No Shunt 1 Scaling 0 0000 Shunt 2 Scaling 0 0000 Shunt Scaling 0 0000 Figure 3 2 Inaccessible Controls Example 17 SNILLAD s gt 2 4 m 5 4 Start 4 1 The Start window 15 the first window that appears when M TEST 5 0 is launched M TEST 5 0 Motor Test Software T MASTROM Current Setup Ci Files Ramp msf Revision 1 02 ViewData 5 AxisGraph 1 Axis Graph Compare Reports Security ton Select Language 9 English Current Setup Filename 3 C Magtrol Setup Files Ramp msf Load Setup 1 Current Data Filename 3 C Temp 88888 mdf Load Data 1 Current Report Filename 3 C Temp 88888 rpt Load Report j Figur
28. a different folder click the Browse button and select another folder You can choose not to install M Test 5 0 by clicking Cancel to exit the installation izard Destination Folder C Program Files M Test 5 0 Browse 3 Cancel Figure 2 1 M TEST 5 0 Software Installation 4 Select the Destination Folder then click Next The default is C Program Files M Test 5 0 To install into a different folder click the Browse button and select another folder Magtrol M TEST 5 0 Motor Testing Software Chapter 2 Installation 5 After installation is complete the MS DOS command prompt will open and run in the background The M TEST 5 0 Setup window will indicate that the program has been successfully installed ill be installed at this time iG M Test 5 0 Setup M Test 5 0 has been successfully installed Click the Finish button to exit this installation Figure 2 2 Installation Complete 6 Click Finish The required M TEST 5 0 drivers will be automatically installed at this time National Instruments Measurement amp Automation Explorer software will also be automatically installed Sg Note Measurement amp Automation Explorer MAX provides access to your National Instruments GPIB and FieldPoint devices With MAX you can Configure your National Instruments hardware and software Create and edit channels tasks interfaces scales and virtual instruments Execute system diagnostics Vi
29. and path is now displayed in test result 11 0 12 0 13 0 windows 11 23 05 First Edition Changed PID setting options values 9 1 11 23 05 First Edition Added PID scaling commands 9 1 11 23 05 First Edition New PID adjustment procedures 9 2 9 3 08 10 05 Preliminary Correction Step 7 of software and driver installation procedure 2 2 Manual Rev A Table of Contents SAFETY dre iijje q c REVISIONS TO THIS MANUAL 2 e asso nnmnnn nnmnnn nnmnnn Il REVISION DATE II TABLE QF REVISION PO NRI RM HET CENE UTE ORE REO II TABLE OF lee gil qcee I TABLE OF UILGIBI dc VII IX PURPOSE OF THIS MANUAL tiene tre Ent reete SEDAN CIERRE eei E CEDE D IX WHO SHOULD USE THIS MANUAL ccceetun toi ro thea Ye e Ro Yo c v eee a eee EXE Te eR n e Tav EAE EVERY TR IX MANUAL ORGANEZALPDIQN s eire POTE eren a REOR tenes SIRE VIR PREX ENERO pev Rn IX CONVENTIONS USED IN THIS MAIN UAT a a a oa E Pe ER EE E XI 1 upiesrheje m
30. for each testing instrument are set up for each channel Alarms are also enabled or disabled at this time Control Function Options Values Model Selects the controller model being 5240 4629B DSP6000 and DSP6001 used NOTE The DSP6000 5240 and 4629B are only compatible with Magtrol Hysteresis Dynamometers The DSP6001 is compatible with Magtrol Hysteresis Eddy Current and Powder Brake Dynamometers Magtrol In Line Torque Transducers and auxiliary instrumentation Display Torque Selects the torque units oz in oz ft Ib in Ib ft g cm kg cm NOTE This may be the same as the N m cN m and N m dynamometer units or converted to other units Interface Type Selects the method of interfacing GPIB and Serial RS 232 between the controller and the computer GPIB Address Sets the GPIB address for the controller NOTE It must match the address that has been set up through the controller DSP6000 6001 front panel COM SETUP menu 5240 and 4629B rear panel next to the GPIB connector 1 to 32 NOTE Click Find Devices to display the controllers GPIB address in the Device Address table located in the upper left corner of the Configure Hardware window See Section 5 1 GPIB Device Address Detection Serial Port Selects the computer port number when using serial communication 1to4 Baud Rate Sets the baud rate for serial communications Applies only to DSP6000 6001 NOTE This valu
31. settings will be based on your local printer s default settings On the following page is an example of a customized report printed from M TEST 5 0 77 4 m o d 2 m o E o Chopter 15 Reports Magtrol M TEST 5 0 Motor Testing Software Starter Motor Test Report Test Date 3 8 2005 Test Time 12 03 05 PM Serial Number 1 Operator Code Maximum Current 1 409 Maximum Efficiency 0 627 Maximum Horsepower 0 081 Starter Motor from outboard boat engine HS 5482 Amps 1 Watts IN 1 36 140 1943 000 0 389 37 112 0 102 1896 000 0 391 37 409 0114 1860 000 0 92 37 876 0 131 1822000 0 394 38 534 0 159 1792000 0 403 40 788 0229 1764 000 0 423 45 109 0 340 1245 000 0473 53811 0 483 1714 000 0 542 63 596 0 573 1675 000 0 623 74311 0 618 1633 000 184 662 1582 000 93 278 1537 000 0 849 101 375 10 585 1486 000 0 913 108 703 0 552 1436 000 0 965 114 581 10 521 1390 000 1014 119 978 0488 1342 000 1 058 124739 0 454 1291 000 1 100 129 092 0 421 1244 000 1199 000 1 137 132 959 0391 1149 000 1 169 136288 0361 1 204 139 857 0 328 1094 000 B 1046 000 55 600 5 958 0 945 998 000 s310 o054 629 092 E m o I 2 m o E o 1 232 142 634 0 301
32. to the data to be acquired and displayed From the Display window move the desired parameters into the Selected column While running a curve test the dwell period that was set caused the program to lock up when the test was started The software uses a timing function to determine how long data can be acquired If a large number is entered e g 99 999 minutes the program is unable to read it and will crash To run a test for a long period of time use a reasonable time scale For example 6 hours 360 min If you additional assistance is required please contact Magtrol Customer Service at 1 716 668 5555 in the United States or 41 26 407 30 35 in Switzerland 82 z m gt Z 9 m Appendix A Graph Tools A 1 This chapter explains the graph tools common to the following windows Adjust PID Test 5 Axis Graph 1 Axis Graph and Compare J M TEST 5 0 Motor Test Software E zii xj y KAAGSTROL M TEST 5 0 Revision 1 02 Current Setup C Magtrol Setup Files Ramp Start Configure Hardware Display Configure Test AdjustPID TEST ViewData 5 Graph 1 Graph Compare Reports Security Torque 1 1 x 1 Horsepower xi Efficiency 1 Watts OUT 1 Auto Scale Torque oz in Curve Fit 0 Hide 9 Polynomial Order 0 00 0 00 13 em 1 1 1 1 0 1 1 1 1 1 1 1 1 1 Q 110 200 300 4
33. to three separate 1 axis graphs one for each tested parameter in the same window Refer to Chapter 13 1 Axis Graph for more information Compare Overlay data from two separate tests on the same graph with option to print Refer to Chapter 14 Compare for more information 10 5 CONFIGURE REPORT Click Report tab to produce a one page motor test summary Refer to Chapter 15 Reports for more information 68 E m o d 2 2 Magtrol M TEST 5 0 Motor Testing Software Chapter 10 Test 10 6 SAVE TEST DATA If data logging is enabled test data is automatically saved as a Microsoft Excel file using the motor s serial number as the file name Refer to Section 5 2 Data Logging for more information To save test data as a file that can be recalled later by M TEST 5 0 click Save Data in any of the following windows Test View Data 5 Axis Graph and 1 Axis Graph The Save As dialog box will open to prompt for a file name with an mdf file extension The data is then saved as a tab delimited file that can be imported into any spreadsheet program 69 E m o d 2 2 11 View Data After the test has been completed click View Data to see test results in a tabular format J M TEST 5 0 Motor Test Software J MAGSTROE Current Setup C Magtrol Setup Files Ramp msf Revision 1 02 Configure Hardware Display Configure Test Adjust PID TEST Yiew Data 5 Axis Graph 1 Axis Graph Repor
34. 0 003 1 988 120 775 31 399 0 069 1785 000 1 648 0 003 2 175 120 751 31 800 0 089 1782 000 2 166 0 004 2 854 120 746 32 386 0 117 1778 000 2 902 0 005 3 816 120 792 33 005 0 145 1774 000 3 688 0 006 4 838 120 725 33 611 0 173 1771 000 4 503 0 008 5 897 120 770 34 356 0 205 1766 000 5 468 0 010 7 140 Select Desired Data Columns 120 606 1674 000 120 565 1667 000 120 569 1660 000 120 546 1650 000 120 553 1644 000 120 544 1636 000 120 549 1634 000 120 577 1631 000 120 541 1627 000 120 497 1614 000 120 502 1610 000 Current Data Bye tore int Figure 11 2 Configure Print Window 2 Choose up to 9 different parameters by clicking on the down arrow and selecting desired parameter from the drop down list 3 Click OK to save settings 4 Click Print Print settings will be based on your local printer s default settings SE Note M TEST 5 0 only has the capability to print 9 columns at a time If printing more than 9 columns it is suggested that the file be saved and then printed from another program See Section 11 1 Save Test Data 7 m o d 2 m o c o 12 5 Axis Graph After the test has been completed click 5 Axis Graph tab to view test results in a multiplot graph J M TEST 5 0 Motor Test Software eT KAAGTROL M TEST 5 0 Cur
35. 00 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1892 Speed RPM remet uxo fos elll Comments Current Data C Temp 88888 mdF Figure A 1 M TEST Graph PLOT LEGEND Defines the color and style of the plots in order to distinguish one from the other The top 5 plots represent the raw data plots The bottom 5 plots represent curve fit data and are indicated by a double dash after the Y axis parameter name 83 gt 0 0 2 gt lt Appendix A Graph Tools Magtrol M TEST 5 0 Motor Testing Software Note 8 To select curve fitting options see Section 3 Fit The graph uses a default style for each new plot Each plot can be customized by clicking on it in the plot legend and then selecting the following format options from the shortcut menu Menu Item Function Options Values Common Plots Provides options for the plot type NOTE Point Line Bar Plot and Fill Baseline settings are preconfigured depending on the type of plot selected but can be changed manually Line plot e Scatter plot Line plot with points Fill to zero baseline Fill to next plot Bar plot Color Displays the color picker for selecting the plot color Select from three different color spectrums user defined colors recently selected colors system colors or create custom colors Line Style Provides solid and
36. 1500 Low Value 0 00 Dwell y 2 Figure 9 5 Matched Curve 61 Chopter 9 Adjust PID Magtrol M TEST 5 0 Motor Testing Software 9 3 ADJUSTING THE CONTROLLER FOR A RAMP TEST 1 In the Configure Test window under Ramp Test Parameters make sure the Dynamic PID Scaling is set to On 2 Click Adjust PID tab to return to the Adjust PID window 3 Set PandIto 35 4 SetD to Q 5 Set PS IS and DS to A 6 Set DPL and DIL to 1 7 Set Motor Voltage to appropriate value if a motor power supply was selected in the Configure Hardware window 8 Click Run The result will appear similar to the following example J M TEST 5 0 Motor Test Software F close J MASTROE Current Setup C Maatrol Setup Files Ramp msf Revision 1 02 Start Configure Hardware Display Configure Test Adjust PID TEST ViewData S AxisGraph 1 AxisGraph Compare Reports Security Exit E m o d o m c U 1 PS A sija osia DPL 1000 DIL 1 000 0 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 437 Save Setup 1 Run Figure 9 6 Ramp with bump and offset 9 Set IS to B For more information on ideal and actual response see Appendix Scaling 62 Magftrol M TEST 5 0 Motor Testing Software Chapter 9 Adjust PID 10 Click Run The result will appear similar to the following example J M TEST 5 0 Motor Test Software
37. 70 5 011 6 559 3 84 0 31 347 1746 9 992 12 901 5 82 0 349 38 47 1718 15 19 057 7 8 0 394 44 726 1685 20 24 921 9 83 2 8 02 9 14 57 1025 0 255 26 467 1791 0 467 0 619 1 86 2 8 02 9 15 10 1026 0 255 26 467 1791 0 475 0 629 1 81 28002 91521 1027 0255 26467 1791 0475 0629 187 E m o o m 4 0 9 15 33 1028 Figure 7 12 Microsoft Excel Data File The data file contains the date and time of the test the serial number of the motors and the acquired data The order in which the data is displayed from left to right is determined by the order of parameter selection in the Display window during initial setup See Chapter 6 Display 44 8 Configure Test Once the hardware configuration is complete and the test parameters have been selected the actual test must now be set up Click the Configure Test tab to open the Configure Test window J M TEST 5 0 Motor Test Software BE 5 x Bao Current Setup C Magtrol Setup Files Startup msf Revision 1 03 Configure Hardware Display Configure Test 5 Axis Graph 1 Axis Graph Control Parameter oz in 1 Pass Fail 2 Pass Fail 3 Pass Fail4 Pass Fail 5 Select Test 1 Pass Fail 9 Torque 9 None Jj None 9 None 9 Wout J None To Time Min Min Min Max Min Min 4 import From Spreadsheet Timebase Seconds Ma
38. 900 0 1000 0 1100 0 1200 0 1300 0 1400 0 1500 0 1600 0 1700 0 1792 0 mas Speed RPM wout 3 8296 1 Speed Autox axis3 Save Data Current Data 4 Figure 13 1 1 Graph Window S Note For detailed information on formatting and navigating graphs refer to Appendix A Graph Tools 4 m o 2 m o o 13 1 SELECT PLOTTED PARAMETERS 1 Select the Y axis parameter for each graph from the drop down list located to the left of the corresponding graph 2 Select the X axis parameter for each graph from the drop down list located below the corresponding graph 13 2 SAVE DATA If data logging is enabled test data is automatically saved as a Microsoft Excel file using the motor s serial number as the file name Refer to Section 8 2 Logging for more information To save test data as a file that can be recalled later by M TEST 5 0 click Save Data The Save As dialog box will open to prompt for a file name with an mdf file extension The data is then saved as a tab delimited file that can be imported into any spreadsheet program 73 14 Compare 857 14 1 14 2 Click Compare to overlay data from two separate tests the same graph M TEST 5 0 Motor Test Software ei g avene Current Setup C Magtrol Setup Files Ramp msf Revision 1 02 Start Configure Hardware Display Configure Test Adjust PID TE
39. E Hide Graph gt Clear Graph Figure 7 1 Average D U Motor Curve Before Inertial Cancellation 34 dNLas LSAL Magftrol M TEST 5 0 Motor Testing Software Chapter 7 Test Selection If locked rotor is specified as a minimum speed the controller will run a separate procedure immediately after the acceleration ramp that will quickly take the motor to stall and record the data The amount of time to wait at stall before taking data is defined by the Locked Rotor Dwell control found under Ramp Test Parameters in the Configure Test window See Section 8 4 Test Parameters Several seconds at locked rotor may be necessary for the system to stabilize With stored energy and the load cell acting as a spring there may be some bounce After acquiring the locked rotor data the motor will accelerate to its free run speed The inertially corrected curve is produced by matching a speed from the deceleration curve with the same speed from the acceleration curve and averaging the associated torque data This continues for every point on the curve If no exact matching speed is found on the acceleration curve the data will be interpolated to create a match If requested the locked rotor point will be added to the end of the data array to construct the complete curve f M TEST 5 0 Motor Test Software T MASIRON Current Setup C Magtr Revision 1 02 Configure Hardware Display Configure Test Adjust
40. E Under most circumstances it is a good idea to use inertia cancellation Once a Dynamic Corrected test has been run with inertia cancellation subsequent tests on the same motor or same type of motor may be run using the coefficients obtained from the first run Select Previous Value to use those coefficients without actually performing the inertia cancellation routine The Average Down Up routine inherently has inertia cancellation every time it is run For more information refer to Section 7 1 Ramp Testing Ramp Method Selects the ramp method used to test the Average Down Up An motor average of the deceleration and acceleration curves Typically produces the most accurate results and is somewhat dependent on the controller ramp tuning Inertia cancellation is automatic Dynamic Corrected Determines correction factor based on deceleration curve and stabilized point The correction factor is then applied to the entire data set In order for this to work properly the system tuning is highly critical Ramp Rate Sets the deceleration rate of the ramp in rpm Any m o o m 4 U per second Maximum Sets the upper limit or start of the ramp O to 100 000 Speed NOTE This may be helpful in cases where the motor spins at a very high speed possibly faster than the dynamometer is rated for A speed stabilized command is sent to the controller to hold the motor at this value before the ra
41. ECTION Figure 7 1 Average D U Motor Curve Before Inertial Cancellation eese 34 Figure 7 2 Average D U Motor Curve Figure 7 3 Correction Factor Calculation as Figure 7 4 Dynamic CF Test Before Inertial Cancellation esee 37 Figure 7 5 Dynamic CF Test seed etre casesesssosasessvesvesvtevseubsadinecasiesta FLESH RR EET eee b a on 37 Figure 7 6 Torque Curve Setu EXAMPLE E OI FOR EIA RE 39 Figure 7 7 Torque Curve Test Example etre eee a a deae e ence n Eee 39 Figure 7 8 Pass Fail Test Example us Figure 7 9 Pass Fail Test WindoW eee nime e tette f IC Ra E HU 42 Figure 7 I0 Pass Fail Test Results WindoW ate nire t EP Er re HE ORE HERR 42 Figure 7 1I Failed Test Example cie tote ed etii de nad dede poet e EH Ped 43 Figure 7 12 Microsoft Excel Data File ec roto ase se tie Re e RR ERR EXT SA ERE YN XR ta ER 44 8 CONFIGURE TEST Figure 6 1 Configure Test Window caseo coi pionero Coto n HX SEXE TE XY el ge Ecol s ehe ke ek epe Figure 8 2 Curve Test Setup Window p Figure 6 3 Manual Test Setup Windows iiiter ia EI REM GERE RH EUER ERR ERR S CEA nae 47 Figure 4 Ramp Test Setup eria dera en D dede ore 51 Figure 6 5 Pass Fail Test Setup Window eec tia tato ic dli een ea ERE HS 55 9 ADJUST PID Figure 9 1 Adjust PID Window Jia esa
42. J 10 Hz 7p Apply Settings External Alarm Jj Disable Nominal Speed 0 m n Y IPre Load Jj 0 00 Max Speed J 25000 Save Setup Max Power kw J 10 000 Sc Max Torque a ibani 100 000 To Scale Factor 55 000 Sp Torque Ratio 9 1000 Lond Defaults Speed Ratio J 1000 Device J 6510e Device J Sorensen DHP D Figure 5 1 Configure Hardware Window The Configure Hardware window is where testing instrument dynamometer controller power analyzer power supply and sensor input device settings are entered into the program IESE Note For specific instructions on how to enter information into M TEST 5 0 see Section 3 3 Navigating M TEST 5 0 5 1 GPIB DEVICE ADDRESS DETECTION To search for GPIB devices connected to the motor test system and available to M TEST 5 0 click Find Devices The GPIB address of each device will be displayed in the table located in the upper left corner of the Configure Hardware window This eliminates the need to open a separate program in order to view communication settings 21 Chapter 5 Configure Hardware Magtrol M TEST 5 0 Motor Testing Software 5 2 DYNAMOMETER CONTROLLER Used with a Magtrol DSP6000 6001 5240 or 4629B Programmable Dynamometer Controller M TEST 5 0 provides the control of any Magtrol Dynamometer or Torque Transducer and runs test sequences in a manner best suited to the overall accuracy and efficiency of the Magtrol Motor Test System In this section specifications
43. Load Force Weight 2 MAGTROL INC 70 Gardenville Parkway Buffalo New York 14224 USA Phone 1 716 668 5555 Fax 1 716 668 8705 E mail magtrol 9 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 9 magtrol ch www mMmagtirol com Subsidiaries in Germany France China India Worldwide Network of Sales Agents BUREAU VERITAS Certification
44. M Readdress Figure 2 6 GPIB Configuration 2 Under Device Name select DEV9 3 Set DEV9 Attributes to the following SE Note The only DEV attributes that need to be changed are those that are outlined below All other settings should remain in their original format a Under Termination Methods 1 Select the Terminate Read on EOS check box 2 Change EOS Byte to 10 b Select the Readdress check box Select DEV12 Set DEV 12 Attributes by repeating steps 3a 3b Select DEV14 Set DEV 12 Attributes by repeating steps 3a 3b Click OK The GPIB device configuration is complete O PANNA 2 4 3 RS 232 SERIAL INTERFACE M TEST 5 0 will communicate with the DSP6000 6001 Dynamometer Controller using an RS 232 Serial Interface Connection diagrams and instructions can be found in the following User s Manuals e DSP6000 Section 5 7 Select the Baud Rate for the RS 232 Interface e DSP6001 Section 8 2 the RS 232 Interface 10 s gt 2 m 5 ONILI39 Magtrol M TEST 5 0 Motor Testing Software Chapter 2 Installation 2 5 SENSOR INPUT TEMPERATURE MEASUREMENT M TEST 5 0 allows the user to perform temperature measurement testing The feature provides complete dynamometer control allowing for temperature measurement while performing load simulation for duty cycle and life testing The options which may be purchased from either Magtrol or National Instru
45. M TEST files Chapter 5 CONFIGURE HARDWARE Contains the information needed to set up M TEST 5 0 software with details pertaining to the testing instruments controller power analyzer power supply and temperature measurement hardware being utilized in the test configuration Chapter 6 DISPLAY Provides instruction for selecting motor parameters to be tested Chapter 7 TEST SELECTION Describes the different testing methods available in M TEST 5 0 and provides all the information needed to make a test selection Preface Magtrol M TEST 5 0 Motor Testing Software Chapter 8 Chapter 9 Chapter 10 Chapter 11 Chapter 12 Chapter 13 Chapter 14 Chapter 15 Chapter 16 Chapter 17 Chapter 18 Appendix A Appendix B Appendix C CONFIGURE TEST Provides information required to set up M TEST 5 0 for the type of test to be performed ADJUST PID Contains instruction for adjusting proportional gain integral and derivative PID values of the dynamometer controller for a ramp curve or pass fail test TEST Provides step by step instructions for setting up and running a basic curve ramp manual and pass fail test from beginning to end VIEW DATA Provides instructions for viewing saving and printing test data in tabular format 5 AXIS GRAPH Contains general information for viewing test data in a multiplot graph 1 AXIS GRAPH Contains general information for viewing test data i
46. MAGTROL M TEST 5 0 Motor Testing Software J M TEST 5 0 Motor Test Software Start Configure Hardware Display Configure Test ViewData S AxisGraph Channel 1 pees DL Instrument Type Display Torque Brake Type WB Interface DsPeo01 Model HD 715 6 Acquire Aux TSC2 Tandem Disable Active Channel M TEST 5 0 Motor Test Software henon nom MAGTROL Waterflow Alarm Current Setup Apply Settings Depiry Cenfgee Test Adjest PID TEST WewData S Aits Graph 1 Ais Graph 0408 save setup 45 000 40 om FX p00 u NM ai som as d Nm watts our qp Mito ale 003 NL 10 0 030 9 omo 0 0 000 Eum Moyin Comments Current Data CiTemcif0000 mf 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 assumes no respo
47. NSTALLATION PROCEDURE The general installation order is as follows 1 Install M TEST 5 0 product software and drivers 2 Install National Instruments NI DAQ Mmx Data Acquisition Software 3 Install PCI GPIB interface board If only using a DSP6000 6001 the RS 232 serial interface may be used 4 Install National Instruments FieldPoint or USB 9211A if using temperature measurement sensor input function 4 gt 2 m 5 SNILLAD 5 Install optional National Instruments NI 6521 relay actuator card to control motor power via M TEST 5 0 The remainder of this chapter will provide specific installation instructions for each component of the system 2 2 INSTALLING M TEST 5 0 PRODUCT SOFTWARE AND DRIVERS 1 Exit all other programs before installing M TEST 5 0 2 Insert the M TEST 5 0 CD in your CD ROM drive The M Test 5 0 Installation Wizard will begin automatically Note If AutoRun is disabled on your computer the installation process must be started manually On the taskbar click the Start button and then click Run Click Browse to locate the CD Rom drive where the M TEST 5 0 installation CD 15 inserted From the M TEST CD root directory select setup exe then click Open 3 Click Next 2819 Destination Folder Select folder where the application will be installed 5 192 The installation wizard will install the files for M Test 5 0 in the following folder To install into
48. P or USB options DSP6001 PC Programmable Controller network interface amp FP TC Serial Cable 4 channel isolated Thermocouples FP 1000 8 per module 32 max to motor M TEST 5 0 e Motor Shaft Direction Indicator Indicates if the motor is turning clockwise or counterclockwise e EEE 488 and RS 232 Interface Computer interface with National Instruments M RS 232 available with DSP6001 and DSP6000 only Automatic Load Defaults Option Downloads testing instrument parameters based on model number e Dynamic PID Scaling Provides consistent control loop results throughout motor speed range during ramp test for DSP6001 only e PID Adjustment Routines Helps adjust the system for ramp and step functions Graphing Capabilities Display up to 5 test curves ina single graph or view as up to 3 separate 1 axis graphs easy to read colored and labeled plots with several graph formatting options manual or auto scaling e Curve Fitting A curve fitting routine can be applied to most motor test curves Raw data and curve fit data can also be displayed simultaneously e Customized Reports Allows user to produce a one page motor test summary which can include the motor s serial number maximum torque speed power and current values operator name time and date of test motor direction 32 data points and an X Y plot e Save Load Setup Function Test procedure configurations may be
49. PID TEST View Data 5 Axis Graph 1 Axis Graph Compare E m o o m E U Amps 1 volts 1 Watts IN 1 Speed RPM Torque oz in T Horsepower Watts OUT Time e e RM g EM p ml 1 1 1 1 1 1 200 0 300 0 400 0 500 0 600 0 700 0 8000 900 0 1000 0 1100 0 1200 0 1300 0 1400 0 1500 0 1600 0 1700 0 1800 RPM Ploto Hide Graph Y Axis X Axis le Graph E Torque S Start Test Stop Test save ote Data autovaxis auto x Axis Co Clear Graph Figure 7 2 Average D U Motor Curve 35 Chopter 7 Test Selection Magtrol M TEST 5 0 Motor Testing Software 7 1 3 Dynamic CF Since inertial effect is only a factor as speed is changing and inertial torque is proportional to the rate of change inertial value may be expressed as a unit of torque per change in rpm in a given period of time The DSP6000 and DSP6001 accumulate data at intervals of approximately 10 milliseconds With data rates this fast the amount of speed change from reading to reading is too small to be used accurately in the correction Therefore M TEST 5 0 inserts a wait state of 100 ms between each reading in order to allow a reasonable speed change In order to create a torque correction factor CF a torque value equal to the inertial torque and the difference in rpm per 100 ms that created that value is needed In the fo
50. R INPUT MEASUREMENT Temperature measurement previously an add on feature that had to be purchased separately is now included in M TEST 5 0 Up to 32 thermocouples or analog sensors can be read and monitored during a motor test Heat rise curves on the bearings windings and housing of a motor can be performed and air flow exhaust efficiencies can be measured with an air tool or internal combustion engine M TEST 5 0 with its complete dynamometer control even allows for sensor measurement while performing load simulation for duty cycle and life testing APPLICATIONS M TEST 5 0 besides being well suited for simulating loads cycling the unit under test and motor ramping is also ideal for production line and inspection applications due to its pass fail test function Another time saving feature that engineering labs will benefit from is the ability to duplicate tests and run them automatically This versatile program is extremely valuable to anyone involved in motor testing Chapter 1 Introduction Magtrol M TEST 5 0 Motor Testing Software F4 Specifications STANDARD FEATURES Multiple Testing Options Ramp Select from average ramp down up or ramp down with inertia correction factor Also allows extrapolation of free run and locked rotor data plus interpolation of specific speed or torque data points Curve Test speed torque amps watts input watts output and open loop parameters Capable of adjusting
51. R saben seve 11 2 9 National Instruments FieldPoint io eoe Ree hen ER ER EROR EVER E FESTE YER THREE HERE ERE SERRE 11 292 National Instruments USB 921 lA cs oes terrere 12 2 6 NATIONAL INSTRUMENTS NI 6521 RELAY ACTUATOR CARD 13 2 61 Installing the Relay eie texte Herodi gra 13 3 M TEST 5 0 INTERFACE 14 31 STARTING M TESEI O ceci re te IRE FERE RUF Ee X EE uae dee eese ire ee ce iei Ce ise 14 32 WINDOWS ws C 14 SU MER ME 15 322 ijConhpure Hardware sette RE URN t a S 15 323 15 3 2 4 Configure Testeresi RR 15 Dede ANG JUST 15 SD WES c S 15 3 2 1 Mew etum ttes hte 15 3 2 8 JAKIS ER 15 SUA MA KAS Grapes ss T M 15 Table of Contents Magtrol M TEST 5 0 Motor Testing Software 9 2 10 Compare vous ete REUS hb pe m e Pel Ee 15 352 1 REPOS iie rhe OE Det EO E 15 SADDAM vp 16 Eu Iq EC TET N 16 3 3 NAVIGATING M TEST 5 0 c
52. S DETECTION ccsciccesssaveresestedsoecdcendsesetccssroosesecsecssouecteessavevoebecodudvaceoseedrdensctsdecsensetne 21 5 4 DYNAMOMETER CONTROLLER lt ieee enira re aE NEEN ETANTE Re TEE rE ENN AS E 22 5 2 1 23 522 Defaults eoi ER RUE EO HII REMO HRS 23 5 2 3 etm iei etm dedu M 24 53 POWER MEASUREMENT cccccssssssceccssssssecccessseseeccesssneeececssseaeeeccesssseseeceenseaaeeeceesssseeececenseuaeeesensneaseceeeesenea 26 54 POWBRSUPPLY 5 eei ERES TUE TEE EDEN RE EE PESE Shs caus cae Vue cha 27 II SSBNSORSJINDPUE eio an a d 28 5 5 1 D yce Selectioti ensibus 28 9 927 SB ODA nensem M MIU NR TUE 28 3 a rate E Lor EE e I 29 5 06 SAVING THE HARDWARE CONFIGURATION irre tbt sixes cece eive kar aee o e ERE HER 30 DOs Apply uu T 30 2 62 NIME EE 30 6 DISPLAY RUE NER ERO 31 Gell DISPLAY SETUP 31 6 1 1 Motor 1 5 ern errem e dc E NM M M ET 31 62 NAVAS AU OM 32 6 2 T dol dA e 32 reizcwzEIen e
53. ST ViewData 5 Axis Graph 1 Axis Graph Compare Reports Security Control Parameter oz in Pass Fail 1 Pass Fail 2 Pass Fail 3 Pass Fail4 Pass Fail 5 Select Test Pass Fail J J a 9 9 RPM 9 wout 9 None From Min Max Min Min Max Min Hp LESEN Max 4 32 0 1800 2 0 36 0 1800 2 0 4 0 1800 E m o o m E 0 Im Import From Spreadsheet Timebase 1j Seconds Max Temp 100 00 Number of Cycles Jj 1 Max Current 50 00 Max Brake Current 9 50 00 Speed Range 99999 00 Save Data Include Equipment List Print Report Save Report Operator Code Data Folder Report Folder Auto Increment Pass Filename Serial Number Fail Filename Figure 7 8 Pass Fail Test Example This example demonstrates a motor test that collects data from 5 different torque points a typical test that might be run during incoming inspection or at the end of a production line At each of the load points information on amps input watts speed and output watts is gathered A minimum and maximum value is given for each load point A data directory C test data has been created containing two files where the data will be sent depending on whether the motor passes pass xls or fails fail xls A serial number is also assigned to each motor with an automatic increment which makes the information easy to track 41 Chopter 7 Test Selectio
54. ST ViewData 5 AxisGraph 1 Axis Graph Compare Reports Security Exit Torque 37 Torque Torque m Torque Y Axis Torque 1 X Axis Speed xi 18 Auto Scale i 0 1 0 1 D i 1 D D D 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 179 Speed Load Data 1 T CATemp 88888 mdf 0000000000000 rome eo oss 08418 0 amp Load Data 2 BONY Print Figure 14 1 Compare Window Note For detailed information on formatting and navigating graphs refer to Appendix A Graph Tools LOAD DATA 1 To view data from the current test the data must first be saved as an mdf file M Test Data File To save go to any of the following windows Start View Data 5 Axis Graph or 1 Axis Graph and click Save Data The Save As dialog box will open to prompt for a file name with an mdf file extension 2 Click Load Data 1 Load Data 2 The Open File dialog box will appear Select the desired M Test data mdf files and click OK 4 m o d 2 m o o SELECT PLOTTED PARAMETERS 1 Select the X and Y axis parameters to be compared from the corresponding drop down lists located to the left of the graph Parameters and plots for Test Data 1 are shown in red Parameters and plots for Test Data 2 are shown in green 74 15 Reports Click the Reports tab to open the Reports window J M TEST 5 0 Motor T
55. Software 3 2 12 SECURITY e Enable disable password protection e Set up multiple users e Assign user access rights for specific windows 3 2 13 Exit e Exit M TEST 5 0 3 3 NAVIGATING M TEST 5 0 4 gt 2 m 5 ONILI39 The following details will assist in navigating through M TEST 5 0 Note A mouse must be used to maneuver through the program 3 3 1 HELP For help with any item right click the control button text box indicator list etc A drop down menu will appear Click Description and Tip and a message box will appear with useful information about the item in question 3 3 2 Tass Navigate from window to window by clicking the tabs at the top of the screen 3 3 3 Text Boxes For text boxes there are two ways to make a selection 1 Click inside the box and scroll down to the item of choice 2 Click the up and down arrows to the left of the box until the desired option is reached 7 pevice y None 3 3 3 1 Numeric Entries For text boxes requiring a numeric value simply click inside the box and type the desired value To overwrite an existing entry click and drag the pointer across the field and then type the new value S Note When using the up and down arrows the program will not allow the numbers to leave the specified range If typing a value any number can be used but those out of range will be ignored Magtrol M TEST 5 0 Motor Testing Software Chapter 3 M
56. THE MATERIAL BEING USED THE ASSOCIATED TEXT DESCRIBES THE NECESSARY PRECAUTIONS TO TAKE AND THE CONSEQUENCES THAT MAY ARISE IF THE PRECAUTIONS ARE IGNORED 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 PUT AT RISK THE READER MUST ABSOLUTELY TAKE NOTE OF THE ACCOMPANYING TEXT AND ACT UPON IT BEFORE PROCEEDING FURTHER Xi 1 Introduction 1 1 1 2 ABOUT M TEST 5 0 Magtrol s M TEST 5 0 is a state of the art motor testing program designed for use with Windows 2000 XP operating systems for PC based data acquisition Used in conjunction with Magtrol s Motor Testing Equipment M TEST 5 0 is equipped with ramp curve and manual testing capabilities to help determine the performance characteristics of a motor under test The software also performs pass fail testing for production line and inspection applications The data generated can be stored displayed and printed in tabular or graphic formats and is easily imported into a spreadsheet M TEST 5 0 is ideal for simulating loads cycling the unit under test and motor ramping Magtrol can also make custom modifications to the software to meet your specific motor testing needs M TEST 5 0 is equipped to work in conjunction with any of the following Magtrol motor testing instruments e Dynamometer Con
57. TION OPTIONS VALUES Device Selects the device used to read power None data EMI NOTE The DC power supply may be used HP603xA to read back amps and volts if absolutely HP66xxA necessary However doing so will result in Lambda Genesys reduced accuracy and slower data transfer Power Ten rates which subsequently affects the Sorensen DCS number of data points acquired Sorensen DHP P 3 Xantrex XFR Xantrex 5100 5300 1 and 3 phase 6510 6510e 6530 1 ph 2 1 ph 3 w 3 ph 3 w 3 ph 4 w 3ph 3v 3a 6550 1 ph 2 w 1 ph 3 3 ph 3 w 3 ph 4 w 3ph 3v 3a e LMG310 1 ph 2 3 ph 4 w 3 2 ph 3 w 2 m 3 ph 3 w 3 m star 3 ph 3 w 3 m delta E m o o m 4 U e WT1600 1 ph 2 w 1 ph 3 w 3 ph 3 w 3 ph 4 w 3 ph 3v 3a GPIB Address Selects the corresponding GPIB address 1 to 32 for the power measurement device NOTE Click Find Devices to display the device s GPIB address in the Device Address table located in the upper left corner of the Configure Hardware window See Section 5 1 GPIB Device Address Detection Units Sets the power units that the 5100 is Watts and kW displaying NOTE This control only needs to be set if a Magtrol 5100 Power Analyzer with external shunt is being used This is because some current ranges cause the 5100 to read consumed power in kilowatts M TEST 5 0 is configured to automatica
58. Zoom magnifying glass e Panning Tool hand HEA A 4 1 Cursor Movement Moves the cursor on the graph 1 Click the Cursor Movement Tool crosshairs button 2 Click on the graph s cursor close up shown below and drag to any point on any plot Amps 1 2 Pl wee i 1 1 1 0 5 0 0 1 0 2 0 The corresponding X and Y coordinates are displayed in the Cursor Legend Amps 1 0 00 0 39 S Note For more cursor tools and options see Section A 5 Cursor Legend 4 2 Zoom Zooms in and out of the graph S Note Before using the Zoom tool Auto Scale must be disabled See Section 2 Scale 1 Click the Zoom magnifying glass button 86 gt 0 0 m z gt lt Magtrol M TEST 5 0 Motor Testing Software Appendix A Graph Tools 2 Select from the following options to zoom in and out of the graph The top row of Zoom options from left to right are e Zoom to Rectangle With this option click a point on the display to be the corner of the zoom area and drag the tool until the rectangle covers the zoom area e X zoom Use this option to zoom in on an area of the graph along the X axis e Y zoom Use this option to zoom in on an area of the graph along the Y axis The bottom row of Zoom options from left to right are e Zoom to Fit Use this option to autoscale all X and Y scales on the graph or chart e Zoom In about Point With this option
59. allation Complete dialog box will appear Click Next When prompted to restart shut down or restart later select Shut Down in preparation for interface board installation Note If you choose to restart later please note that you must restart your computer before running any National Instruments software 4 gt 2 4 m 5 SNILLAD Magtrol M TEST 5 0 Motor Testing Software Chapter 2 Installation 2 4 INTERFACE SETUP The GPIB interface board National Instruments M PCI GPIB purchased through Magtrol or directly from National Instruments must be installed at this time The National Instruments PCI GPIB 15 a high performance plug and play IEEE 488 interface for PCs and workstations equipped with PCI expansion slots ICS Note If only using a DSP6001 or DSP 6001 Dynamometer Controller in the test configuration the RS 232 serial interface may be used 4 gt 2 4 m 5 SNILLAD 2 4 1 INSTALLING THE GPIB 1 Shut down your computer 2 Install the PCI GPIB controller board in an available PCI expansion slot according to National Instruments user documentation 3 Turnon your computer The new hardware will automatically be installed and the NI 488 2 Getting Started Wizard will appear NI 488 2 Getting Started Wizard lgl xl Click on the following steps to use the NI 488 2 Software for Windows with your GPIB instruments gt Verify your hardware and software instal
60. ating A Shortcut double click the desktop icon and the program will automatically start The Start window will appear J M TEST 5 0 Motor Test Software J MAGTROL pp O O ATEST 5 0 Current Setup C Magtrol Setup Files Ramp msf Revision 1 02 Start Configure Hardware Display Configure Test Adjust PID TEST View Data 5 Axis Graph 1 AxisGraph Compare Reports Security Exit Current User ton Select Language English Current Setup Filename 4 C Magtrol Setup Files Ramp msf Load Setup 1 Save Setup 1 Current Data Filename 3 CA Temp 88888 mdf Load Data 1 Current Report Filename 4 C Temp 88888 rpt LoadReport Figure 3 1 Start Window 3 2 M TEST WINDOWS The following outline is a representation of how M TEST 5 0 is organized and shows at a quick glance where all the main features are located within the program The 12 navigation tabs displayed at the top of the M TEST 5 0 screen are purposely in the same order sequentially from left to right as a standard motor test procedure Following is a brief description of the functions of each area Sg Note For detailed explanations of every button and control of each window program area please refer that window s corresponding chapter in this manual 4 gt 2 4 m 5 SNILLAD Magtrol M TEST 5 0 Motor Testing Software Chapter 3 M TEST 5 0 Interface 3 2 1 START e Log in and log out if password protection enabled
61. ave As dialog box will open to prompt for a file name with an mdf file extension The data is then saved as a tab delimited file that can be imported into any spreadsheet program 72 13 1 Axis Graph After the test has been completed click 1 Axis Graph tab to view test results in up to three separate 1 axis graphs one for each tested parameter in the same window J M TEST 5 0 Motor Test Software E 15 T MASIRON Current Setup C MagtrolSetup Files Ramp Revision 1 02 Start Configure Hardware Display Configure Test Adjust PID TEST ViewData 5 Axis Graph 1 Graph Torque Torque 1 auto Y Axis 0 07 1 1 1 1 1 1 i 1 1 1 1 1 1 i i 1 i 210 0 300 0 400 0 500 0 600 0 700 0 800 0 900 0 1000 0 1100 0 1200 0 1300 0 1400 0 1500 0 1600 0 1700 0 1792 0 EFORIE Speed RPM Torque 0 00100 0 E lad speed autox axis 09 0 8 07 P Ampsi xj Bos auto v tos Axis 2 0 4 1 i 1 1 1 1 1 1 1 1 1 0 1 06 20 4 0 6 0 8 0 10 0 120 140 160 180 200 220 240 260 280 300 320 34 mew Torque oz in mooo ead Torque Autox axis 2 Wout 40 0 30 0 Watts OUT xi 2 20 0 auto v Axis 3 e 0 07 1 1 1 T T 1 1 D D D D D T T T 1 210 0 300 0 4000 5000 600 0 700 0 800 0
62. aved as a tab delimited file that can be imported into any spreadsheet program The Save Data button is also conveniently located in the following windows View Data 5 Axis Graph and 1 Axis Graph CURRENT REPORT FILENAME To load a previously saved report click Load Report and select the appropriate file in the Load Report File dialog box Save REPORT The current report can be saved by clicking Save Report The Save As dialog box will appear Select the desired folder and type the desired file name which will be saved with an rpt file extension The Save Report button is also located in the Reports window 20 4 gt 2 4 m 5 SNILLAD 5 Configure Hardware Before beginning any test the connected motor test equipment must first be set up within M TEST 5 0 Click the Configure Hardware tab to open the Configure Hardware window J M TEST 5 0 Motor Test Software 7 hKAACS TROL Current Setup Setup Files Ramp msf Start Configure Hardware Configure Test Adjust PID 5 Axis Graph 1 Axis Graph Address Device X Channel 1 5n 9 05 6001 Instrument 5 In Display Torque J Ib in Brake Type WB Mt Interface mM Ej Model J HD 715 6 En rt 7 Aux TSC2 7 TAIN PE Disable To 3 4 Active Channel Jj 1 Encoder J 60 bit No m Find Devices Airflow Alarm Jj Disable Quadrature Input J Disable Me Waterflow Alarm Disable Torque Filter
63. cccssscccccesssseccesesssensceccesseaaeeecessnsaeeecesessseeecesensneaaeeceesnsaeeeccesssaaeeeesenseuseeesesseaaeees 16 3 3 1 sj X 16 SMELL PUERUM 16 3 3 3 Text 16 3 3 4 IndiCatOE Sion esos ente Ec REPE ERIS ra Ee Te CO Pre EC EGO EE RERO Uie Ho CHR RE ER Dye 17 335 Tnaccessible Contfols 17 D MET LUPMTEEREPMECEER M 18 OG RR EE 18 4 1 1 Ti SOU 19 42 SELECT LANGUAGE reenn Ee O Mr Reo tr evite ER HERE 19 4 2 1 Additional Languages UE IEEE E UEM ee ERE EE CE MER RESERVAS NEUES NET ets alates 19 43 CURRENT SETUP FILENAME dde ee ov eT US EE 20 4 3 1 SAVE Setup oer e CHEN ROS Ge Ut tu erat Dette ONG RU MO AE IRR RORIS 20 44 CURRENT DATA FILENAME hoen siese E epe Fee are ES EEUU EE aisi 20 4 4 1 Save Dat ose Ye EU Ed 20 4 5 CURRENT REPORT FILENAME esee eterna 20 45 1 Save NRE POC E 20 5 CONFIGURE 21 5 1 GPIB DEVICE ADDRES
64. ce FP 1000 240 V Power Supply and Serial Cable HW TTESTFP A HARDWARE Additional FieldPoint 8 Channel Thermocouple Module includes mounting base 004968 USB 4 Channel Isolated Input Module USB 9211A and USB Cable 1 m HW TTEST USB CONTROLLERS High Speed Programmable Dynamometer Controller DSP6001 Hysteresis Dynamometers HD series TESTING Eddy Current Dynamometers WB series INSTRUMENTS Powder Brake Dynamometers PB series In Line Torque Transducers TM TMHS TMB series POWER High Speed Single Phase Power Analyzer 6510e ANALYZERS High Speed Three Phase Power Analyzer 6530 Closed Loop Speed Control and Power Supply 6100 POWER Power Supply for WB amp PB Dynamometers series 2 7 and 43 DES 310 SUPPLIES Power Supply for WB amp PB Dynamometer series 65 115 and 15 DES 311 Power Amplifier required for all HD 825 Dynamometers 5241 MISC Torque Speed Conditioner TSC 401 CASES GPIB Interface Card PCI 73 M023 Relay Actuator Card for controlling motor power via M TEST 5 0 73 M052 GPIB Cable 1 meter 88M047 CABLES GPIB Cable 2 meters 88M048 Torque Transducer Connector Cable ER 113 01 www magtrol com motortesting mtest htm For information on the most current software release available refer to Magtrol s Web site at Due to the continual development of our products we reserve the right to modify specifications without forewarning z T o X gt 2 10 m 2 m 2 gt 2 Installation 2 1 I
65. click a point to zoom in on e Zoom Out about Point With this option click a point to zoom out from Note Press and hold the SHIFT key to switch between Zoom In about Point and Zoom Out about Point A 4 3 PANNING TOOL Moves entire plot area within the graph window Note Before using the Panning tool Auto Scale must be disabled See Section 2 Scale 1 Click the Panning Tool hand button 2 Click on the graph and hold then drag to the desired position A 5 CURSOR LEGEND The first three text boxes display the plot name and X and Y coordinates respectively of the cursor s location on the graph The buttons on the cursor legend from left to right are e Cursor Movement Selector multidirectional arrows e Formatting Button crosshairs e Lock Button padlock msi fow jos 1081 18348 87 gt 0 0 2 gt lt Appendix A Graph Tools Magftrol M TEST 5 0 Motor Testing Software A 5 1 A 5 2 A 5 3 A 5 4 Cursor Movement SELECTOR Click this button to move the cursor using the Cursor Mover If enabled a green indicator will appear in the upper left corner of the button as shown on the previous page See Section A 5 4 Cursor Mover FORMATTING BUTTON The graph uses a default style for each new cursor The graph s cursor can be customized by clicking on the Formatting button in the Cursor Legend and then selecting the following format options from the
66. com Note The NI DAQ 8 x installer should open automatically If not select Start gt gt Run Enter x autorun exe where x is the letter of the CD drive Install NI DAQmx VI Logger NATIONAL J ON NSrRUMENTS View Software Documentation Install Device Documentation View Device Documentation Exit NI DAQmx Data Acquisition Driver Software ni com daq Figure 2 3 NI DAQmx Data Acquisition Driver Software Installer Click Install NI DAQmx VI Logger The Welcome message will appear and the installer will begin initializing This will take a few moments When this step is complete the Product Information dialog box will appear After reading the displayed information click Next Select the Destination Folder then click Next The default is C Program Files National Instruments To install into a different folder click the Browse button and select another folder The Features dialog box will appear of the features required to install run M TEST 5 0 should be selected by default It is recommended to keep the default settings Click Next The License Agreement will appear In order to proceed the displayed license s must be accepted by selecting the corresponding option button Click Next The Start Installation dialog box will appear Review the displayed summary then click Next The installer has been configured Click Next to begin installation After several minutes the Inst
67. contactor with PCL 1760 relay card Removed Rated Voltage and Rated Current power supply controls since no longer necessary In compiled program pressing the X did not execute shutdown code Added Exit tab and dialog for Replaced Advantech PCI 1760 Relay actuator card with National Instruments NI 6521 relay actuator Added Pre Load option to dynamometer configuration Added Magtrol Free Run Speed Sensor FR 10 as instrument type option for Channel 2 TSC2 Added 1 2 and 6 bit Encoder options to Channel 1 configuration Added Include Equipment List field to Data Logging Added Locked Rotor parameter under Ramp Test configuration Release Date Revisions Corrections 1 00 05 06 2005 Initial release 1 01 05 11 2005 1 02 10 21 2005 Added PID scaling commands shutdown 1 03 04 24 2006 card Bug fixes contact factory for details 1 04 06 08 2006 Added Cycle Count indicator for Curve and Pass Fail tests Bug fixes contact factory for details 95 gt 0 0 m z gt lt Index Symbols Dynamic CF 36 l Axis Graph 15 73 Dynamic PI Scaling 92 5 Axis Graph 15 72 Dynamometer Controller 22 A E Adjust PID 15 57 Exit 81 Alarms 23 F Apply Settings 30 Auto Scale 85 FieldPoint 11 29 Average D U Down Up 34 FieldPoint Explorer 11 Find Devices 21 Formatting Button 88 8 Channels 24 G Compare 15 74 Configure Display Window 31 GPIB Configure Hardware 15 21 Addresses 21 Configure Test 15 45 Board 9
68. dashed line styles Select from either a solid line or 4 different dashed line styles Line Width Provides line widths Hairline width to 5 pixels NOTE Top selection in menu with two intersecting vertical lines represents hairline width This has no effect on the screen display but will print a very thin line if the printer and print mode support hairline printing Anti Aliased Smooths the appearance of lines Enable checked and Disabled unchecked NOTE Using anti aliased line plots can slow performance Bar Plots Provides bar plot options Line plot no bars Vertical bars or Horizontal bars with varying options for thickness and spacing Fill Baseline Interpolation Provides options for filling in the space below the plot with the same color as the plot Provides interpolation options determining how lines are plotted between data points Zero Fills from the plot to a baseline generated at O e Infinity Fills from the plot to the positive edge of the graph Infinity Fills from the plot to the negative edge of the graph For multiplot graphs At the bottom of the shortcut menu select another plot to fill the space below the plot to the next selected plot Plot only data points scatter plot Curved or straight line between plotted points Link points with right angled elbow plot from left or right of data points Useful for creating histogram l
69. ding the current setup file that is loaded If you do not wish to override the current setup file after pressing Save Setup click Cancel when prompted and read the note below Note To save current test configuration as a new setup file click Apply Settings then return to the Start window Create a new setup file by clicking Save Setup under Current Setup Filename See Section 4 3 1 Save Setup 30 E m o o m U 6 Display 6 1 6 1 1 Click the Display tab to open the Display Setup window TT T MASIR Current Setup C Magtrol Setup Files Ramp msf Revision 1 02 Start Configure Hardware Display Configure Test Adjust PID TEST ViewData 5 AxisGraph 1 AxisGraph Compare Reports Security Available Selected Watts IN 1 Speed RPM Torque oz in Horsepower Watts OUT Time Watts IN Sum PF1 PF2 PF3 dNLas 1531 Figure 6 1 Display Setup Window The Display Setup window is used to select the parameters that will be measured displayed and graphed during a test DISPLAY SETUP PARAMETERS Torque Amps 1 Volts 1 Input Watts 1 Power Factor 1 Output Watts Speed Amps 2 Volts 2 Input Watts 2 Power Factor 2 Output Kilowatts Time Amps 3 Volts 3 Input Watts 3 Power Factor 3 Horsepower Auxiliary Input Amps Sum Volts Sum Input Watts Sum Power Factor Sum Efficiency Direction of Rotation The numbers refer to the phase o
70. djustment to see results When optimal setting is reached the result will appear similar to the following example Jf M TEST 5 0 Motor Test Software J MASTROE Revision 1 02 RE Psi A 3 psi 1 000 00 0 010 Figure 9 10 Final Ramp 64 m o o m E U 1O Test This chapter includes step by step instructions for setting up and running a basic curve ramp manual and pass fail test from beginning to end Follow these steps in order which are purposely in the same order sequentially from left to right as the navigation tabs at the top of the M TEST 5 0 screen 1 Configure Hardware 2 Configure Display 3 Configure and Run Test 4 View Test Results e Tabular display View Data e Graphical display e 5 Axis Graph e 1 Axis Graph e Compare 5 Configure Report 10 1 CONFIGURE HARDWARE The following hardware configuration is common for each test For a detailed procedure refer to Chapter 5 Configure Hardware 1 Click Configure Hardware tab to open the Configure Hardware window E m o d 2 2 Select Dynamometer Controller and corresponding settings Select Instrument Type and Model for Channel 1 TSC1 If applicable select Instrument Type and Model for Channel 2 TSC2 Click Load Defaults Make any changes to default settings if necessary Select Power Measurement device and corresponding settings Select Power Supply and corresponding
71. e Seconds 100 00 Number of Cycles Jj 1 e 50 00 Brake Current 50 00 99999 00 E m o o m E 0 Save Data Include Equipment List Print Report Save Report Data Folder Report Folder Pass Filename Fail Filename Figure 8 5 Pass Fail Test Setup Window The following parameters may be used when setting up a Pass Fail Test Control Function Options Values Import from Imports desired load points dwell times and N A Spreadsheet limits from an external tab delimited text file and displays the values in the table above Control Selects the parameter that will be used to Amps 1 Amps 2 Amps 3 Parameter control the loading process Amps Sum Input Watts 1 Input Watts 2 Input Watts 3 Input Watts Sum Speed Torque Output Watts Auxiliary Input Direction of Rotation and Output Kilowatts Pass Fail 1 5 Selects up to 5 parameters that will be used for Amps 1 Amps 2 Amps pass fail checking Amps Sum Input Watts 1 Input Watts 2 Input Watts 3 Input Watts Sum Speed Torque Output Watts and Output Kilowatts Timebase Sets the timebase for all the Time values in the Seconds and Minutes Pass Fail Control table 55 Chapter 8 Configure Test Magtrol M TEST 5 0 Motor Testing Software 8 5 1 8 Control Function Options Values Number of Selects the number of times to repeat the 1 to 32 767 Cycles cycling of a load profile
72. e EMI mentioned DC power supplies be sure that its HP603xA GPIB address corresponds to what you have HP66xxA set in the GPIB Address control Lambda Genesys Power Ten Sorensen DCS Sorensen DHP Xantrex XFR Xantrex GPIB Address Sets the GPIB address for the DC power 1 to 32 supply NOTE Click Find Devices to display the power supply s GPIB address in the Device Address table located in the upper left corner of the Configure Hardware window See Section 5 1 GPIB Device Address Detection Voltage Set Sets desired DC voltage Any Current Set Sets to the maximum current that the DC Any power supply needs to deliver Relay Control Accessible when optional National Instruments Enabled and Disabled NI 6521 relay actuator card is installed Automatically switches on the motor at the beginning of a test and conversely turns motor power off at test completion See Section 2 6 Instruments NI 6521 Relay Actuator Card for more information 27 Chopter 5 Configure Hardware Magtrol M TEST 5 0 Motor Testing Software 5 5 SENSOR INPUT Up to 32 thermocouples or analog sensors can be read and monitored during a motor test Heat rise curves on the bearings windings and housing of a motor can be performed and air flow exhaust efficiencies can be measured with an air tool or internal combustion engine M TEST 5 0 with its complete dynamometer contr
73. e Manual and Pass Fail e Displays 22 Tested and Calculated Parameters e Three Phase Power Analyzer Data Acquisition Motor Shaft Direction Indicator e JEEE 488 and RS 232 Interface e Automatically Loads Dynamometer Default Values e Dynamic PID Scaling e PID Adjustment Routines e Miultiplot or Single Plot Graphical Display e Curve Fitting e Customized Reports e Save Load Setup Function Magtrol M TEST 5 0 Motor Testing Software Chapter 1 Introduction 1 4 DATA SHEET M TEST 5 0 Motor Testing Software T ZZ s D gt or 2 NEW FEATURES WITH 5 0 e New Graphical User Interface Tabbed pages for quick navigation e Temperature Sensor Measurement Temperature testing capabilities are now included in standard program e Multiple Language Support Switch to from English French German or Spanish at any point during the program Additional language dictionaries can be created edited by the user e Graphing Options Display up to three different 1 axis graphs one for each tested parameter in the same window Compare Test Data Overlay data from two separate tests on the same graph e Rapid Graph Plotting Change both the X and Y axis to display additional test curves without having to exit the graph e Cursor Tools Obtain the X and Y coordinates of any point on acurve Magnify any section of the graph e Simplified PID Scaling New slider controls set both coarse and fine gain ad
74. e 4 1 Start Window LOGIN If password protection is enabled see Chapter 16 Security each user must log in to access M TEST 5 0 program windows 1 Click Login The password prompt will appear Current User Load Data 1 Save Data 1 Current Report Filename Load Report 1 Save Report 1 Figure 4 2 Password Prompt 18 03149 15 SNILLAD Magtrol M TEST 5 0 Motor Testing Software Chapter 4 Start 2 Type your designated user name and password 3 Click Login button inside password prompt dialog box After providing this information you will have access to the program windows assigned to you in the current security setup 4 1 1 Locour To change users the current user must first log out Return to the Start window and click Login 2 When the password prompt appears click Logout Sg Note When M TEST 5 0 is closed the current user is automatically logged out 4 2 SELECT LANGUAGE Select the language you would like to work with while using M TEST 5 0 Click inside the Select Language box then click on the desired language Standard options include English German Spanish and French S Note The language can be changed at any time while running the program by simply returning to the Start window and selecting a new language 4 2 1 ADDITIONAL LANGUAGES Additional language dictionaries can be created by the user by editing the Language File csv file located
75. e c rax toco E XY Ce Eo ERE FE VR ORENSE Figure 9 2 C rve no Figure 9 3 CCurpe e rn ier Figure 9 A Curve Figure 9 5 Matched CUrVessasco in coenae o as to ien EEA EERE ANENE EUREN UY Ce EE NEAR E DIR SHE Figure 9 6 Ramp with bump and offset PT Figure9 7 ROMP wuh bump eis arenei xD Ortu cats AU Figure 9 8 Ramp no bump but unstable eive ete tei t nds e eb t nite lege 63 Figure 9 9 Ramp no bump and stable esses ttti eter eret eoa donet dee ae de erae dba dokn Ned 64 Figure 9 10 Final ROMP RN 64 10 TEST Pigure 10 1 Test Window Examples eee te a e D re esee keep Eee Dev bent aaepe uiuo 66 vii Table of Contents Magtrol M TEST 5 0 Motor Testing Software 11 VIEW DATA Figure 11 I View Data WInOW cec e eme xe er n eis ed a UXOR ER RE HERE HUM 70 Figure 11 2 Configure Print Window cation o testi oia Ore ect i dr Eel Een Fa de 71 12 5 AXIS GRAPH Figure 12 I 5 Axis Graph Wind OW iis iniit a EON 72 13 1 AXIS GRAPH Figure 13 I 1 Axis Graphi Window eie emet tem Rt RH e Hd RE RU ERE 73 14 COMPARE Figure 14 I Compare Window 2 ee aei re Re Ee RT cass Feci ee X DRE ERES E ER oT ggg 74 15 REPORTS Figure 15 I R
76. e must match the baud rate set up through the front panel COM SETUP menu on the DSP controller 300 600 1200 2400 4800 9600 and 19200 Acquire Aux TSC2 If using the auxiliary input on the DSP6000 6001 to read an additional parameter set this control to Yes to have the data displayed and stored with other acquired data NOTE Proper scaling must be set up from the front panel AUX SETUP menu on the DSP controller Yes and No 22 m o o m 4 U Magtrol M TEST 5 0 Motor Testing Software Chopter 5 Configure Hardware Control Function Options Values Active Selects the channel on which the Channel 1 or Channel 2 Channel control loop is closed when using a NOTE Certain load device DSP6001 dynamometer combinations will not permit changing channels See Section 5 2 3 Channels Pre Load Writes an open loop value of current to 0 00 to 99 99 the dynamometer brake NOTE Acts to preload the brake limiting motor speed without interfering with the PID loop 5 2 1 ALARMS Only for use with the DSP6001 Dynamometer Controller Control Function Options Values al Airflow Alarm Enables the airflow alarm function for HD Enable and Disable Hysteresis Dynamometers indicating a lack of o air flow m Waterflow Enables the waterflow alarm function for Enable and Disable Alarm WB Eddy current and PB Powder Brake dynamometers indicati
77. e time is in seconds PS Adjusts the proportional gain scaling on the A B C D E F G H AND I Proportional DSP6001 Gain Scaling IS Integral Adjusts the integral scaling on the DSP6001 A B C D E F G H AND Scaling DS Derivative Adjusts the derivative scaling on the DSP6001 A B C D E F G H AND I Scaling DPL Adjusts the dynamic proportional gain scaling Any Dynamic on the DSP6001 Proportional NOTE Only applicable during a ramp test Gain Scaling when Dynamic PID Scaling is turned On under Ramp Test Parameters in the Configure Test window DIL Dynamic Adjusts the dynamic integral scaling on the Any Integral DSP6001 Scaling NOTE Only applicable during a ramp test when Dynamic PID Scaling is turned On under Ramp Test Parameters in the Configure Test window High Value Sets the maximum value for the desired system Any repsonse adjustment The program will cycle between the low value and this value Low Value Sets the minimum value for the desired system Any repsonse adjustment The program will cycle between this value and the high value Dwell When performing curve tests this control sets 0 to 32767 58 Magtrol M TEST 5 0 Motor Testing Software Chapter 9 Adjust PID Control Function Options Values Run When the controls are configured click Run to begin the adjustment procedure NOTE Curve tests allow adjusment of the PID values on the fly After the ram
78. ect a PID value that optimizes the control loop over a wide range of speed With Magtrol s experience in motor testing our engineers have developed a dynamic PI algorithm The PI values change with the speed set point In most cases the PI values are high when the motor is lightly loaded and tend to decrease at higher loads M TEST 5 0 provides a Dynamic PI Scaling control under the Ramp Test Parameters of the Configure Test window Here the dynamic scaling can be enabled or disabled and the span of the scaling can also be selected See Section 8 4 Ramp Test parameters 3500 39x 3400 3406 E IDEAL RAMP AUN ACTUAL RAMP 3200 3200 300 2000 200 2000 NS T 2600 2000 BW 2400 200 2200 2 s 5 3 200 AL ACTUAL ROMP 1000 1600 1806 1400 1 N 8 1200 1200 N 1000 1020 NS 800 806 600 bw 400 004 T Y T T 0 T 0 T T 0 5x 100 1560 260 2500 500 4000 4500 55900 7000 7 0 BOO Time ins Figure B 2 Ramp Down Low I Ramp shows low value for I term Note bump at beginning of ramp and good results toward end of ramp 3500 3500 3400 3400 NO IDEAL RAMP ACTUAL RAMP 79 47 17 3200 3200 3000 3000 2800 2800 IDEAL RAMP I 8 2 8 T ACTUAL RAMP 1000 1000 800 800 600 600 400 400 7 1 7000
79. el being used NOTE To label another thermocouple channel use the up and down arrows to select another channel Select thermocouple channel in box to left 0 through 7 Type desired label any string of alphanumeric characters in box to right Gain Adjusts any error that may occur between the M TEST 5 0 reading and the reference temperature This control may also be used to compensate for filter loss if low pass filters are installed at all thermocouple inputs NOTE To set gain for another thermocouple channel use the up and down arrows to select another channel Select thermocouple channel in box to left 0 through 7 Enter desired gain in box to right Offset Adjusts any offset that may occur between the M TEST 5 0 reading and the reference temperature NOTE To set offset for another thermocouple channel use the up and down arrows to select another channel Select thermocouple channel in box to left 0 through 7 Enter desired offset in box to right 29 m o o m 4 U Chopter 5 Configure Hardware Magtrol M TEST 5 0 Motor Testing Software 5 6 SAVING THE HARDWARE CONFIGURATION 5 6 1 SETTINGS When finished configuring the hardware click Apply Settings Note This does not permanently save the current test configuration See Section 5 6 2 Save Setup 5 6 2 Save SETUP The current test configuration is saved overri
80. election RAMP TESTING MeasurRinGc METHODS Old Measuring Methods Years ago motor performance was determined by loading a motor to a specific speed and recording the torque data This procedure was repeated at a number of points until sufficient data was acquired to construct a curve The time to accomplish this was excessive causing the motors to heat up severely While the method produced accurate data at each point the drastic increases in temperature caused a shift in the curve and resulted in inaccurate data New Measuring Methods Methods were developed to quickly ramp a motor from free run to locked rotor negating the heating effects However along with the ramping came inertial effects on the data When a motor is accelerating or decelerating Measured Torque True Motor Torque Inertial Torque stored energy Unless inertial torque is excluded motor performance data will be in error since the measured torque will vary in proportion to the rate of acceleration or deceleration This type of error can produce startling results For example during rapid deceleration system inertia can produce apparent efficiency greater than 1 This may occur as output power is divided by input power without extracting the stored energy of the system M TEST 5 0 provides two methods of measuring inertially compensated data Average D U Down Up and Dynamic CF 33 E m o o m U Chopter 7 Test Selection Magtrol
81. ent Type selected Load Defaults at the bottom of the window to update the parameters for that model This step must be performed for the testing instrument torque units to be programmed properly in the controller If it is necessary once the defaults are set they can be m o o m U adjusted Tandem If a tandem dynamometer is being used Enable and Disable this function must be enabled Encoder Selects the encoder type being used 1 2 6 20 30 60 600 and NOTE Some models may have dual 6000 bit encoders for normal and low speed operation In this situation select the encoder currently in use Quadrature If the dynamometer has a low speed Enable or Disable Input quadrature encoder installed the speed signal may be smoothed substantially by enabling this feature NOTE This applies only to 600 and 6000 bit encoders that have both channels wired to the DSP6001 controller Torque Filter Applies digital filtering to the torque signal 3 10 25 and 50 Hz cutoff input frequencies Select Off to disable filtering 24 Magtrol M TEST 5 0 Motor Testing Software Chopter 5 Configure Hardware WB and PB dynamometers Control Function Options Values Nominal For WB and PB dynamometers this is the 0 99 999 Speed maximum speed at rated torque NOTE Exceeding the nominal speed will cause the dissipated power to be greater than the dyna
82. eports Windowsni eiie tei pd a Er v EE E ED D Lee Eo 75 Figure 15 2 Display Report adh Figure 15 3 Sample Motor Test Report entrent imn rr rrt bes cen cdensvass cena ERR eh 78 16 SECURITY Figure 16 1 Password Administration Window iiit 79 17 EXIT Figure 17 1 PH 81 APPENDIX A GRAPH TOOLS Figure A I M TEST Graphis tete ta eie aba poit dide d ng et dett 83 APPENDIX B PID SCALING Figure System Block Dido ram seca io code da euo e aret ree taret a Res Dac ect MN IR Geass 91 Figure 2 Ramp Down LOWA eerte teer EO RO KO Res RR RE EH ERROREM 93 Figure B 3 Ramp Down ax sotoso x o e I Rn ORE RE LL Ae CRY eV eco v XE D X SEXE VES 93 Figure B4 Ramp Dowrn Dynamic nibo E HERE TL TO EE REY EO II 94 viii Preface PURPOSE OF THIS MANUAL This manual contains information required for installation and general use of Magtrol s M TEST 5 0 Motor Testing Software To achieve maximum capability and ensure proper use 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 in need of a software program to complement their Magtrol test equipment setup The setup may include any of the follo
83. ers the National Instruments NI 6521 relay actuator card for controlling motor power via M TEST 5 0 The relay actuator used in conjunction with a contactor serves as an ON OFF switch for supplying power to the motor under test When the relay actuator is enabled see Section 5 4 Power Supply M TEST 5 0 automatically closes the relay at the beginning of each test Relay closure allows power to be applied to the contactor which in turn applies power to the motor When the test is completed the relay automatically opens and the contactor and motor are switched off The National Instruments NI 6521 relay actuator card is rated at 150 V AC DC 2 amps 60 VA max Please refer to the included manufacturer s specifications for additional ratings INSTALLING THE RELAY CARD Shut down your computer 2 Install the National Instruments NI 6521 card in an available PCI expansion slot according to National Instruments user documentation 3 Turnon your computer If installation was successful Windows will detect the device and display the Found New Hardware message 4 Connect the motor contactor to relay 0 RO of the NI 6521 connector following the pin diagram in the user documentation 4 gt 2 4 m 5 SNILLAD 3 M TEST 5 0 Interface 3 1 STARTING M TEST 5 0 From the taskbar click Start point to Programs gt gt M Test 5 0 then click M Test If you created a shortcut on your desktop see Section 2 1 1 Cre
84. est Software 3 l KAACSTROL M TEST 5 0 Current Setup C Magtrol iles Ramp msf Revision 1 02 Configure Hardware Display Configure Test Adjust PID TEST ViewData 5 Axis Graph 1 Axis Graph Compare Reports Security Test Title Test XY Graph Test Date Show Graph IV 10000 0 Y axis J Torque oz in 9000 0 Test Time axis Maximum Torque X axis Speed RPM Maximum Speed Curve Fit v Polynomial Order 2 7 Direction of Rotation Serial Number Operator Code Comments This is a test 0 07 0 1 0 0 0 20000 40000 60000 80000 10000 Select Desired Data Columns Watts IN 1 PF1 Efficiency Speed Torque Horsepower Watts OUT v v v wo RPM ozin v View Report 1 Print Report 1 Save Report 1 Figure 15 1 Reports Window The Reports window is where the desired parameters and overall layout for a custom printed report are selected SE Note For specific instructions on how to enter information into M TEST 5 0 see Section 3 3 Navigating M TEST 5 0 m o d 2 m o E o 75 Chapter 15 Reports Magtrol M TEST 5 0 Motor Testing Software 15 1 CONFIGURE REPORT The following parameters may be used when configuring a report Control Function Options Values Test Title Displays the title to be placed at the top Type desired title of the report Test Selects specific test information to be
85. ew devices and instruments connected to your system Update your National Instruments software 7 While these remaining two processes are running the Installer Information message box may appear notifying that You must restart your system for the configuration changes made to M TEST 5 0 to take effect If this message box appears click Cancel Your system will re boot later see step 8 8 Afterthe installation of the M TEST 5 0 drivers and NI Measurement amp Automation software is complete your computer will automatically re boot Please note that this may take several minutes 2 2 1 CnEArING A Desktop SHORTCUT For easy access to M TEST 5 0 a shortcut can be placed on your computer desktop 1 Start Windows Explorer and locate the directory where M TEST 5 0 is installed 2 Click the M Test exe file and drag it to your desktop 3 access M TEST 5 0 double click the shortcut and the program will automatically start E TERRE 4 gt 2 m 5 Chapter 2 Installation Magtrol M TEST 5 0 Motor Testing Software 2 3 INSTALLING NI DAQmx DATA ACQUISITION DRIVER SOFTWARE The National Instruments NI DAQ mx Data Acquisition Driver Software must be installed at this time 1 8 9 10 11 12 Insert the National Instruments NI DAQmx for Windows CD in your CD ROM drive The CD is supplied with M TEST 5 0 The software can also be downloaded from National Instruments Web site at www ni
86. f a three phase system If using a single phase source select an option with a 1 31 Chapter 6 Display Magftrol M TEST 5 0 Motor Testing Software 6 1 2 NAVIGATION Move parameters between the Available and Selected columns by either using the arrow buttons or double clicking an entry e Use the gt gt button to move all Available parameters to the Selected column e To reset clear all Selected parameters click lt lt button To select multiple items hold down the CTRL key while clicking on the desired parameters e To select multiple consecutive items hold down SHIFT key while clicking the uppermost and bottommost desired parameters 6 2 SAVE SETUP The current test display parameters are saved overriding the current setup file that is loaded If you do not wish to override the current setup file after clicking Save Setup click Cancel when prompted and read the note below S Note To save current test display parameters in a new setup file first return to the Start window Create a new setup file by clicking Save Setup under Current Setup Filename See Section 4 3 Save Setup 32 E m o o m E U 7 Test Selection 7 1 7 1 1 1 7 1 1 2 Before any further setup is completed a test type must be chosen M TEST 5 0 offers four methods of testing ramp curve manual and pass fail This chapter will provide all the information needed to make a test s
87. ide the shaded area Sg Note If 10 or more users click Page Down to access additional password setup fields 2 designated User Name and Password in the appropriate text boxes Passwords can include any alphanumeric character m z gt Z 9 m 3 Next to each name select which windows that user will be allowed to access by illuminating the green indicator underneath the window name Dimmed indicators disallowed windows are show in gray S Note View Graph encompasses all 3 graph windows 5 Axis Graph 1 Axis Graph and Compare 79 Chopter 16 Security Magtrol M TEST 5 0 Motor Testing Software 16 1 1 16 1 2 3 Click Save A message box will appear reading Security Data Successfully Saved 4 Click OK PasswoRD VISIBLE Passwords can be displayed or hidden e Click Password Visible to display passwords Click Hide Password to display passwords as a series of asterisks one for each character DisaBLE PASSWORD PROTECTION To completely disable password protection simply click the corresponding indicator e Password Protection ON Indicator is dimmed to gray e Password Protection OFF Indicator is illuminated in green 80 m gt Z 9 m 17 Exit Click the Exit tab to open the Exit window J KAAGTROL TEST 5 0 Figure 17 1 Exit Window e Click Yes to quit M TEST 5 0 e Click No to return to the Start window
88. ike plots Plot in the y direction first Plot in the x direction first Point Style Provides point styles for the data points Hide data points or select from a variety of open or filled shapes crosses and Xs 84 gt 0 0 m 2 gt lt Magftrol M TEST 5 0 Motor Testing Software Appendix A Graph Tools A 2 AUTO SCALE By default the horizontal and vertical scales of the graph will automatically adjust to reflect the range of plotted values When the Auto Scale indicator is illuminated in green autoscaling is enabled To disable autoscaling click on the indicator to dim it change from green to gray Auto Scale A 3 CURVE FIT If a smoother curve is preferred a polynomial curve fitting routine can be applied Options include Hide Displays only the raw data e Show Displays two plots one for raw data and one for curve fit data e Displays only the curve fit data Curve Fit 1 Hide y Polynomial Order A 3 1 PoLvNouiAL ORDER Create a smoother curve by increasing or decreasing the value until a desired curve fit is displayed The more complex the curvature of the data the higher the polynomial order required to fit it gt 0 0 m z gt lt 85 Appendix A Graph Tools Magftrol M TEST 5 0 Motor Testing Software A 4 GRAPH PALETTE The buttons on the graph palette from left to right are e Cursor Movement Tool crosshairs e
89. in the M TEST 5 0 program folder in any spreadsheet program To add a new language simply add a new column to the spreadsheet and manually enter translations for every term using the English column column B as a template SE Note If for any reason you need to obtain the default Language File that was installed with M TEST 5 0 you can download it from Magtrol s web site at http www magtrol com support downloads htm 4 gt 2 4 m 5 E TENERE Chopter 4 Start Magtrol M TEST 5 0 Motor Testing Software 4 3 4 3 1 4 4 4 4 1 4 5 4 5 1 CURRENT SETUP FILENAME By default M TEST 5 0 automatically loads the most recently saved Setup file upon startup To load another previously saved Setup file click Load Setup and select the appropriate file in the Load Setup File dialog box Save SETUP The current test configuration can be saved by clicking Save Setup The Save As dialog box will appear Select the desired folder and type the desired file name which will be saved with an msf file extension CURRENT DATA FILENAME To load previously saved test data click Load Data and select the appropriate file in the Load Data File dialog box Save Data To save test data as a file that can be recalled later by M TEST 5 0 click Save Data The Save As dialog box will appear Select the desired folder and type the desired file name which will be saved with an mdf file extension The data is then s
90. is an improved motor testing program that replaces M TEST 4 0 The program is comprised of many new features that make it unique New Graphical User Interface Tabbed pages for quick navigation e Temperature Sensor Measurement Temperature testing capabilities are now included in standard program e Multiple Language Support Switch to from English French German or Spanish at any point during the program Additional language dictionaries can be created edited by the user e More Graphing Options Display up to three different 1 axis graphs one for each tested parameter in the same window e Compare Test Data Overlay data from two separate tests on the same graph e Rapid Graph Plotting Change both the X and Y axis to display additional test curves without having to exit the graph e Cursor Tools Obtain the X and Y coordinates of any point on a curve Magnify any section of the graph Simplified PID Scaling New slider controls set both coarse and fine gain adjustment simultaneously e Single or Multi User Login Enable password protection and assign user access rights for specific windows and program functions e Loads Most Recently Saved Setup File Upon Startup Provides valuable time savings for users who repeatedly run only one type of test e Automatic GPIB Device Address Detection Displayed within program to easily check communication parameters 1 3 2 FEATURES e Multiple Testing Options Ramp Curv
91. justment simultaneously Single or Multi User Login Enable password protection and assign user access rights for specific program functions e Loads Most Recently Saved Setup File Upon Startup Provides valuable time savings for users who repeatedly run only one type of test Automatic GPIB Device Address Detection Displayed within program to easily check communication parameters M TEST 5 0 Graphical Data Output DESCRIPTION Magtrol s new M TEST 5 0 is a state of the art motor testing program for PC Windows 2000 XP based data acquisition Used with a Magtrol Programmable Dynamometer Controller M TEST 5 0 works with any Magtrol Dynamometer or In Line Torque Transducer to help determine the performance characteristics of a motor under test Up to 22 parameters are calculated and displayed utilizing M TEST 5 0 s feature rich testing and graphing capabilities An integral component of any Magtrol Motor Test System M TEST 5 0 performs ramp curve manual and pass fail tests in a manner best suited to the overall efficiency of the test rig Written in LabVIEW M TEST 5 0 has the flexibility to test a variety of motors in a multitude of configurations The data generated from this user friendly program can be stored displayed and printed in tabular or graphical formats and is easily imported into a spreadsheet Magtrol can also make custom modifications to the software to meet additional motor testing requirements SENSO
92. l tab delimited text file and displays it in the Control Data table above N A Control Parameter Selects the desired parameter to be used as the control NOTE When controlling by Speed or Torque the controller uses its internal circuitry to close the loop on the desired set point The PID controls are fully active for system response tuning However when using Amps Input Watts or Output Watts control the controller operates in an open loop mode and the loop is closed through the M TEST 5 0 program This means that the control loop will probably not be as tight as the Speed or Torque modes The only system tuning control available is proportional gain Amps 1 Amps 2 Amps 3 Amps Sum Input Watts 1 Input Watts 2 Input Watts 3 Input Watts Sum Speed Torque Output Watts and Open Loop NOTE Torque will be in the units previously selected in the Display Torque text box under Dynamometer Controller in the Configure Hardware window For Amps and Input Watts control the number refers to the phase of a three phase System If using a single phase source select an option with a 1 Speed Range Sets the speed range for the dynamometer controller NOTE The value entered should be slightly greater than the free run speed of the motor Adjusting the Speed Range properly will give the best dynamic range for the PID settings This parameter is only used with a tandem dynamometer setup 0 to 99999
93. lation Communicate with your instrument Do not show at Windows startup Figure 2 4 NI 488 2 Getting Started Wizard 4 Click Verify your hardware and software installation The NI 488 2 Troubleshooting Wizard will appear TJ NI 488 2 Troubleshooting Wizard x NI 488 2 Software Presence Verified v GPIB Hardware Presence Verified v GPIB Interfaces Sequentially Verified GPIB Name GPIBO PCI GPIB passed Help Retest Exit Figure 2 5 NI 488 2 Troubleshooting Wizard 5 When the software hardware and interfaces have been verified as shown in Figure 2 4 NI 488 2 Troubleshooting Wizard click Exit 6 Select the Do not show at Windows startup check box 7 Click Exit to close the NI 488 2 Getting Started Wizard Chopter 2 Installation Magtrol M TEST 5 0 Motor Testing Software 2 4 2 GPIB Devices 1 Run the GPIB Configuration utility in Measurement and Automation Explorer On the taskbar click the Start button and then click Run Click Browse to locate C Program Files National Instruments NI 488 2 Bin GpibC onf exe then click Open PI GPIB Configuration 2x N GPIB Device Templates Device Name DEVE 2 d DEVS DEVS Attributes Interface Termination Methods Timeouts aeo SendEDI at end of write GPIB Address M Terminate Read on EOS Primary Set EO with EDS on Write s z Compare Secondary NONE E 0 EOS Byte
94. llowing example a motor has been decelerated from free run FR to some minimum speed value A speed equal to approximately 75 of FR is selected from the curve One speed point on either side of that point is used to obtain an average speed change that produces that torque That value is now programmed as a static speed point We now have data from the deceleration curve at 75 of FR and data from a Static point at 75 of FR The difference in torque divided by the change in speed produces the torque correction factor DECELERATION SPEED vs TORQUE CURVE DYNAMIC TORQUE VALUE 0 75 OF FR _ gt STATIC TORQUE VALUE AVERAGE THE CHANGE DIFFERENCE IN SPEED BETWEEN IN TORQUE THESE POINTS D Q A 0 DIFFERENCE IN TORQUE CHANGE IN SPEED Figure 7 3 Correction Factor Calculation The test sequence is to ramp a motor down from its free run speed to a user specified minimum speed or maximum torque The ramp is then terminated and the motor is allowed to accelerate When the motor nears free run speed it is loaded to a static speed approximately 75 of free run When ten readings are acquired within 0 3 of the target speed loading is removed and the motor may be turned off The correction factor is then calculated 36 E m o o m E U Magtrol M TEST 5 0 Motor Testing Software Chapter 7 Test Selection J M TEST 5 0 Motor Test Software Y Nds X Anis Tee Sf seen E
95. lly record and display power in watts As a result if the 5100 is displaying power in kW this control must be set to kW External Shunt Enables the external shunt s connected to Yes and No the power analyzer if applicable 26 Magtrol M TEST 5 0 Motor Testing Software Chopter 5 Configure Hardware Shunt 1 Sets the scaling constant for the external 10 0001 to 99999 Scaling shunt on phase 1 NOTE The constant is determined by dividing the full scale amps of the shunt by 50 mV Shunt 2 Sets the scaling constant for the external 0 0001 to 99999 Scaling shunt on phase 2 NOTE The constant is determined by dividing the full scale amps of the shunt by 50 mV Shunt 3 Sets the scaling constant for the external 0 0001 to 99999 Scaling shunt on phase 3 NOTE The constant is determined by dividing the full scale amps of the shunt by 50 mV 5 4 POWER SUPPLY Tells the system which DC power source is being used and sets the corresponding attributes S Note None is defined as any AC or DC external power source not controlled by the system is defined as a DC power source that is controlled by the system E m o o m 4 U Control Function Options Values Device Selects the type of power supply being used e None NOTE If running from AC lines select None AC Regulated Staco MPA2 as your power supply If using one of th
96. ments include National Instruments FieldPoint National Instruments USB 9211A 2 5 1 NATIONAL INSTRUMENTS FIELDPoINT Features 8 thermocouple inputs per module x 4 modules 32 thermocouples maximum Built in voltage isolation on all channels Filtering reduces electrical noise associated with attaching thermocouples to motors Connects to computer through RS 232 serial port 2 5 1 1 Installing Hardware Shut down your computer 2 Connect the FP 1000 RS 232 RS 485 network interface to the FP TC 8 channel thermocouple input module s 3 Connect a power supply to the network interface with the positive lead to the V terminal and the negative lead to the C terminal 4 Connect the serial cable from the network interface to COMI serial port on the computer 2 5 1 2 Thermocouple Connections 1 Install thermocouples beginning at Channel 0 Following is a list of channels with the corresponding terminals Channels NEL A E positive terminal negative terminal 0 1 2 1 3 4 2 5 6 3 7 8 4 9 10 5 11 12 6 13 14 7 15 16 2 5 1 3 Thermocouple Type and Temperature Unit Changes 1 the taskbar click Start button and then click Explore to open Windows Explorer 2 Locate directory where M TEST 5 0 is installed default C ProgramFiles M Test 5 0 3 Double click MTSCFG iak to open FieldPoint Explorer 4 Expand Devices and Interfaces folder 5 Right click FP coml 6 Select Find Devices
97. mometer s rating Max Speed Maximum no load speed at which the 0 to 99 999 dynamometer can be run without physical damage Max Speed Maximum speed that may be used under O to 10 000 Excited any load condition Max Power Maximum rated power in kilowatts that 0 to 99 999 the dynamometer can dissipate without causing physical damage Max Torque Maximum torque rating of the 0 to 10 000 dynamometer Torque Aux This is the torque value at 5 volts output 0 to 99 999 Scale Factor for WB amp PB dynamometers and TM transducers and the scale factor for the auxiliary input Scale Factor This is the torque value at 5 volts output for O to 99 999 Gearbox Ratio If using a motor with a gearbox attached the gearbox ratio may be entered here to give the true motor speed and torque Otherwise the dynamometer speed and torque will be displayed NOTE All parameters throughout the program will reflect the motor performance only The value should be entered as the ratio from the motor shaft to the gearbox output shaft in an x 1 ratio For example f the motor shaft spins at 3600 rpm and the gearbox output shaft spins at 2 rpm the ratio entered should be 1800 25 E m o o m E U Chopter 5 Configure Hardware Magtrol M TEST 5 0 Motor Testing Software 5 3 POWER MEASUREMENT To read amps volts watts power factor and system efficiency data a separate device is needed CONTROL FUNC
98. mp begins In order to function properly the PIDs must be set to a reasonable value or no loading will occur 52 Magtrol M TEST 5 0 Motor Testing Software Chapter 8 Configure Test Control Function Options Values Minimum Speed Sets the lower limit of the ramp Any NOTE Zero 0 can be specified to run to locked rotor or any speed above that The System response is such that accurately controlled operation in the range of 1 to 100 rpm is not possible without the use of an optional speed encoder For that reason Magtrol does not recommend trying to obtain data at those speeds Maximum Torque Stops the ramp when a specific torque limit has been reached Any NOTE Torque will be in the units previously selected in the Display Torque control under Controller in the Configure Hardware window Locked Rotor Dwell sec When running the Average Down Up ramp test a Minimum Speed setting of zero locked rotor will cause the motor to be loaded to stall at a rate 10 times greater than what was specified for the test This may cause a bounce in the torque reading that must be removed by waiting a short period of time Adjust this control to set the settling time before taking a reading Any Locked Rotor Allows collection of locked rotor data When enabled motor will ramp down to Minimum Speed then obtain locked rotor data at zero 0 Enabled select check b
99. mpensate for a changing measurement Derivative takes action to inhibit more rapid changes of the measurement than proportional gain 90 gt 0 0 m z gt lt Magtrol M TEST 5 0 Motor Testing Software Appendix B PID Scaling B 2 HOW THE PID LOOP WORKS The following diagram demonstrates the correlation between the variables in the PID loop e t Yd t Yt t Set Point gt Proportional gt p M HD amp PB Integral Speed Reading ES Yi t Correction E we Yswb t IIR Filter A D Figure B 1 System Block Diagram B 2 1 PID Sca ina Hysteresis Eppy CURRENT AND PowpER BRAKE DYNAMOMETERS Yt t Scale Ys t Yt t 1 725 2 Yt t Ys t 22 75 1 725 2 1 6623 Yt t 5319 93 MAX SPEED TSCI amp TSC2 Ys 91 gt 0 0 2 gt lt Appendix B PID Scaling Magtrol M TEST 5 0 Motor Testing Software B 2 2 SPEED WB BRAKE DYNAMOMETERS Ys t gt Speed Correction Yswb t The WB Dynamometer follows same scaling as the HD and PB with addition of one calculation for both torque and speed This calculation is due to the fact that for a given current the torque changes with the speed This is referred to as speed correction Yswb t Ys t Ys t speed correction factor 2
100. mprise the Cursor Mover button How the cursor moves is determined by whether or not it is locked Refer to Section A 5 3 Lock Button The corresponding X and Y coordinates are displayed in the Cursor Legend e Click the diamond on the right to move the cursor incrementally to the right along the X axis 88 gt 0 0 2 gt lt Magtrol M TEST 5 0 Motor Testing Software Appendix A Graph Tools e If locked cursor moves to the next point on the plot e unlocked cursor moves to the next coordinate on the X axis e Click the diamond on the left to move the cursor incrementally to the left along the X axis e If locked cursor moves to the previous point on the plot e Jf unlocked cursor moves to the previous coordinate on the X axis e Click the diamond on top to move the cursor incrementally up the Y axis The X coordinate remains the same e If locked cursor moves to the next plot above e Tf unlocked cursor moves to the next coordinate above on the Y axis e Click the diamond on the bottom to move the cursor incrementally down the Y axis The X coordinate remains the same e If locked cursor moves to the next plot below e Tf unlocked cursor moves to the next coordinate below on the Y axis ee Note To move cursor make sure the finger of the pointer selection tool is on the desired diamond See example below LI L Correct Incorrect A 6 HIDE GRID When the Hide Grid indica
101. n Magtrol M TEST 5 0 Motor Testing Software When the test is running the data will appear as follows J M TEST 5 0 Motor Test Software MAGTROL Current Setup C Maatrof ramp msf Revision 1 00 Efficiency Speed RPM Torque o368 120 090 42 396 0 959 0 450 1719 000 15 000 Test running 16 0 15 0 14 0 13 0 12 0 Horsepower 0 026 Time 7 781 Hide Graph Single Graph gt Clear Graph 11 0 10 0 Torque oz in o 1 1 1 zer o o Index 4 Cycle Count 0 Y Axis Torque Auto Y Axis Auto X Axis EB Rl Save Data Figure 7 9 Pass Fail Test Run Window Once the test is completed a window will appear that indicates the results of the test J M TEST 5 0 Motor Test Software E 2 MAG Current Setup C p ROD agtrol Setup Files Ramp msf Volts 1 Configure Test Adjust PID Watts IN1 Speed RPM Torque oz in TEST Data Horsepower 5 Axis Graph 1 Axis Graph Watts OUT Revision 1 02 120 900 29 854 1792 000 0 632 0 001 0 838 120 850 33 248 1773 000 4 993 0 009 6 546 120 894 37 513 1749 000 9 986 0 017 12 916 120 875 42 276 1725 000 15 010 0 026 19 147 E m o d o m c U
102. n made since this edition REVISION DATE Second Edition revision A May 2006 Corresponds to Release 1 03 and later versions of M TEST 5 0 TABLE OF REVISIONS Date Edition Change Section s National Instruments NI DAQ mx Data Acquisition Driver Software is now required for ALL M TEST 5 0 installations Replaced Advantech PCI 1760 relay actuator card with National 1 4 2 1 2 3 05 16 06 2nd Edition rev A 2 1 2 3 04 28 06 Second Edition Instruments NI 6521 relay actuator card 2 6 5 4 04 28 06 Second Edition Added NI DAQ Driver Software installation instructions 2 3 04 28 06 Second Edition Added Pre Load option to dynamometer configuration 5 2 Added Magtrol Free Run Speed Sensor FR 10 as instrument type option for Channel 2 TSC2 04 28 06 Second Edition Added 1 2 and 6 bit Encoder options to Channel 1 configuration 5 2 3 04 28 06 Second Edition Added Include Equipment List field under Data Logging 8 2 04 28 06 Second Edition Added Locked Rotor parameter under Ramp Test configuration 8 4 04 28 06 Second Edition 5 2 3 04 28 06 Second Edition National Instruments USB 9211 changed to USB 9211A beh as Added optional Advantech PCI 1760 relay actuator card to control 1 4 2 1 2 2 First Eden motor power via M TEST 5 0 2 5 5 4 11 23 05 First Edition Exit tab added chapter 17 11 23 05 First Edition Current data filename
103. n up to 3 separate single plot graphs COMPARE Provides instructions for displaying two different sets of test data simultaneously REPORTS Provides instructions for creating viewing saving and printing test reports SECURITY Provides instructions for enabling and setting up optional password protection EXIT Provides instructions for quitting M TEST 5 0 TROUBLESHOOTING Provides solutions to common problems encountered during setup and testing GRAPH TOOLS Contains detailed information on formatting and navigating the graphs in M TEST 5 0 PID SCALING Describes the function of the PID loop and provides instructions for PID PI scaling and speed correction SOFTWARE REVISION HISTORY Displays timeline of all M TEST 5 0 releases including brief descriptions of changes involved with each revision Magtrol M TEST 5 0 Motor Testing Software 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 m 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 functioning of the product to be obtained CAUTION THIS IS USED TO DRAW THE OPERATOR S ATTENTION TO INFORMATION DIRECTIVES PROCEDURES ETC WHICH IF IGNORED MAY RESULT IN DAMAGE BEING CAUSED TO
104. ng a lack of water flow External Alarm Enables the external alarm function for any Enable and Disable dynamometer indicating a problem based on additional user input IS Note For more information on Alarms see Chapter 6 Alarm System in the DSP6001 Dynamometer Controller User s Manual 5 2 2 Loap DEFAULTS e Loads default values for all parameters from the M TEST Defaults txt file after the type and model of testing instrument s has been selected e Click Load Defaults and the values will automatically update SE Note This step must be completed for the testing instrument torque units to be programmed properly into the controller If necessary once the defaults are set they can be adjusted 5 2 2 1 Updated M TEST Defaults File The M TEST Defaults file is subject to change as ratings on Magtrol s Motor Test Equipment change If you have purchased any Magtrol Dynamometers or Torque Transducers since initially installing M TEST 5 0 visit www magtrol com support downloads htm on Magtrol s Web site to ensure that you have the most recent M TEST Defaults txt file available Simply click the link to connect you directly or type the Web address into your browser Please feel free to contact our sales department at 1 716 668 5555 if you should have any questions or concerns 23 Chopter 5 Configure Hardware Magtrol M TEST 5 0 Motor Testing Software 5 2 3 CHANNELS M TEST 5 0 channels are u
105. nsibility 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 2005 2006 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 National Instruments LabVIEW FieldPoint NI DAQ and NI 488 2 trademarks of National Instruments Corporation Microsoft and Windows are registered trademarks of Microsoft Corporation Pentium and Celeron are registered trademarks of Intel Corporation Second Edition revision A May 2006 FE MAGTROL Safety Precautions Make sure that all Magtrol dynamometers and electronic products are earth grounded to ensure personal safety and proper operation Check line voltage before operating electronic equipment Make sure that dynamometers and motors under test are equipped with appropriate safety guards Revisions To 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 revision date on the web site then refer to the manual s Table of Revisions for any changes updates that have bee
106. ol even allows for sensor measurement while performing load simulation for duty cycle or life testing 5 5 1 Devce SELECTION Control Function Options Values Device Selects the sensor input module None USB 9211 FieldPoint TC 5 5 2 USB 9211A m 77 Control Function Options Values Thermocouple Selects type of thermocouple J K N R S Units Selects desired temperature unit for acquired Deg displayed values Deg Kelvins Deg R From Custom Scale TCO Assigns a specific name label to each Select checkbox next to each thermocouple channel being used TCO TC1 thermocouple channel being TC2 used Type desired label any string of alphanumeric characters without spaces in box to right 28 Magtrol M TEST 5 0 Motor Testing Software Chapter 5 Configure Hardware 5 5 3 TC Control Function Options Values Module Number Selection Hardware Assigns a number to each Fieldpoint module that appropriate settings can be configured NOTE To configure another module use the up and down arrows to select another module number Selects installed Fieldpoint module s to be read during test 0 1 2 FP Module 1 FP Module 2 FP Module 3 FP Module 4 Labels Assigns a specific name label to each thermocouple chann
107. onds Sampling Rate sec 1 00 Number of Cycles 2 Brake Current 9o Max Temp Max Current ix Include Equipment List Print Report Save Data Save Report Operator Code Data Folder Report Folder Auto Increment Pass Filename Serial Number Fail Filename E m o o m E U Figure 7 6 Torque Curve Setup Example J M TEST 5 0 Motor Test Software MAGTROL Current Setup C Maatrof ramp msf Revision 1 00 Amps 1 2 Volts 1 Watts IN 1 1 Efficiency Speed RPM Torque Horsepower Time 120 224 129 995 0 826 0 026 1791 000 0 594 0 001 146 797 Torque oz in S 5 Index 0 Y Axis Hide Graph Single Graph GD Gear Graph CycleCount 0 Start Test Stop Test guru D AuoYAxis D Figure 7 7 Torque Curve Test Example 39 Chopter 7 Test Selection Magtrol M TEST 5 0 Motor Testing Software 7 3 7 4 MANUAL TESTING In this mode of operation the computer is being used only as a data acquisition device No control is performed by M TEST 5 0 PASS FAIL TESTING Pass Fail motor testing is well suited for production line and inspection applications Up to five parameters torque speed amps output watts and with optional power analyzer input watts can be tested simultaneously and checked against user defined values providing a quick pass or fail indication to the ope
108. ox and Disabled clear check box Maximum Brake Current Sets the maximum amount of current necessary that will still lock the rotor if desired during the test sequence Different size dynamometers require different amounts of DC current to produce full torque or enough torque to lock the rotor of a motor being tested The hysteresis dynamometer s rotor will become magnetized if current is applied while the shaft is not turning This produces residual magnetism also known as a bump If too much current is applied the bump may be sufficiently large as to not allow the motor to begin rotating again NOTE If locked rotor is not desired this control is irrelevant 0 to 99 99 Dynamic PI Allows scaling of the PI values from full value at Off and On Scaling the start of the ramp to a percentage at the end of the ramp Special Data Enables the user to select specific data points Yes and No Points throughout the performance curve of the motor For more information refer to Section 8 4 1 Special Data Points Table Import from Imports data from an external tab delimited text N A Spreadsheet and displays it in the Special Data Points table above 53 m o o m 4 U Chapter 8 Configure Test Magtrol M TEST 5 0 Motor Testing Software 8 4 1 SPEciAL Data Points TABLE When a ramp test is run there are typically many hundreds of data points only a few of
109. p test has run once the settings may be changed and then the test may be repeated N A Save Setup The current PID settings are saved overriding the current setup file that is loaded If you do not wish to overide the current setup file after pressing Save Setup click Cancel when prompted and read the note below NOTE To save current PID settings in a new setup file first return to the Start window Create a new setup file by clicking Save Setup under Current Setup Filename See Section 4 3 1 Save Setup N A ADJUSTING THE CONTROLLER FOR A CURVE OR PASS FAIL TEST Note When amps input watts output watts or output kW curve pass fail tests are being performed only the proportional gain P can be adjusted Set P to 35 Set I and D to 0 SOY des cod x Set PS IS and DS to A Set High Value to the highest load used on the motor during testing Set Dwell to 2 or 3 seconds Hardware window Set Low Value to the lowest load used on the motor during testing Set Motor Voltage to appropriate value if a motor power supply was selected in the Configure 59 E m o o m E U Chopter 9 Adjust PID Magtrol M TEST 5 0 Motor Testing Software 8 Click Run The result will appear similar to the following example J M TEST 5 0 Motor Test Software J MASIRON Current Setup C Magtral Setup Files Ramp msf Figure 9 2 Curve no I or D Revision 1 02
110. r the report XY Graph Displays a single plot using the Any of the parameters previously parameters selected for the X and selected in the Display window axis The axes are autoscaled for best resolution Select Desired Selects parameters to print in the Any of the parameters previously Data Columns tabular data columns of the report selected in the Display window Up to 9 different parameters can be selected byclicking on the down arrow and selecting desired parameter from the drop down menus 76 4 m o 2 m o o Magftrol M TEST 5 0 Motor Testing Software Chapter 15 Reports 15 2 15 3 15 4 VIEW REPORT Displays the report as it will look when printed J Display Report Starter Motor Test Report Test Date 3 8 2005 Maximum Horsepower 0 081 itarter Motor from outboard boat engine H5 5482 15 20 25 30 35 40 Torque Watts IN 1 Effciency 136 140 10 081 137 112 10 102 137 409 10 114 37 876 0 131 Figure 15 2 Display Report Print See Section 15 4 Print Report Return Closes the Display Report window and returns to the Reports window SAVE REPORT To save the report for future viewing or printing click Save Report The Save As dialog box will open to prompt for a file location and file name with an rpt file extension PRINT REPORT Click Print Report Print
111. rator With pass fail testing motors can be tested at specified load points The user determines the length of time to hold at each particular load point Loading can be accomplished by either stepping or ramping to the desired point If stepping to a load point is desired enter a time of 0 zero for that point If ramping to a load point is desired enter the number of seconds or minutes depending on the timebase setting for the controller to ramp from the starting point to the ending point To remain at a fixed load for a period of time use the same value for From and Testing at free run and locked rotor can also be performed obtain free run or locked rotor data use the following values Parameter Free Run Locked Rotor Amps 0 99999 Input Watts 0 99999 Speed 99999 0 Torque 0 99999 Output Watts 0 99999 40 E m o o m E U Magtrol M TEST 5 0 Motor Testing Software Chapter 7 Test Selection 7 4 1 Pass FAiL Test EXAMPLE In the example below a Pass Fail test will be performed that will 1 Dwell at 0 torque for 2 seconds Step to 5 oz in and dwell for 2 seconds Step to 10 oz in and dwell for 2 seconds Step to 15 oz in and dwell for 2 seconds wr WN Step to 20 oz in and dwell for 2 seconds not shown in example T MASTRS Current Setup Ci Startup msf Revision 1 03 Configure Hardware Display Configure Test Adjust PID TE
112. red folder and click Select Cur Dir Operator Code Records the operator s name initials or ID number for saving printing on the report Any Pass Filename For pass fail testing specifies the file name and location for passed motor data NOTE Pass data is save as a tab delimited file Click Pass File Folder to access Save As dialog box Select the desired folder and type the desired file name NOTE Save the file with a txt or xls extension for easy importing into a spreadsheet Fail Filename For pass fail testing specifies the file name and location for failed motor data NOTE Fail data is save as a tab delimited file Click Fail File Folder to access Save As dialog box Select the desired folder and type the desired file name NOTE Save the file with a txt or xls extension for easy importing into a spreadsheet Include Equipment List Inserts the Controller Dynamometer and Power Analyzer models into the comments field Enabled select check box and Disabled clear check box 46 m o o m U Magtrol M TEST 5 0 Motor Testing Software Chapter 8 Configure Test 8 3 CURVE MANUAL TEST PARAMETERS When Curve test is selected the window will appear as follows 7 M TEST 5 0 Motor Test Software Select Test Save Data Data Folder Serial Number Include Equipment List Auto Increment
113. rent Setup C Magtrol Setup Files Ramp msf Revision 1 02 Start Configure Hardware Display Configure Test Adjust PID TEST YiewData 5 Axis Graph 1 Axis Graph Compare Reports Security Torque xj Ampsi xj i i Horsepower Efficiency eue EX Watts OUT gt 0 030 15 0 30 0 30 9 Auto Scale Curve Fit 0 020 10 0 20 0 20 jj Hide 4 9 7 0010 5 0 10 010 Polynomial Order Torqug oz in 000 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 17000 0 00 ride Grid 110 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1892 Speed RPM EH Si Torque ozin 1792 00 10 63 8 4 amp Speed xi Comments Current Data C Temp 88888 mdF Figure 12 1 5 Axis Graph Window S Note For detailed information on formatting and navigating graphs refer m to Appendix A Graph Tools En 2 m 7 z 12 1 SELECT PLOTTED PARAMETERS Up to 5 Y axis test parameters are plotted against one common X axis parameter 1 Select each Y axis parameter from the drop down lists located to the left of the graph 2 Select the X axis parameter from the drop down list located below the graph 12 2 SAVE DATA If data logging is enabled test data is automatically saved as a Microsoft Excel file using the motor s serial number as the file name Refer to Section 5 2 Data Logging for more information To save test data as a file that can be recalled later by M TEST 5 0 click Save Data The S
114. rotor is generally not desirable 6 Click Test tab to open Test window 7 Select which parameters will be plotted from the X and Y axis drop down lists located in the lower right corner of the Test window 8 Click Start Test The Test data table to the left will appear based on the parameters selected in the Display window The Test graph will display the plot for the selected X and Y o parameters e To display additional test curves simply change the X and Y axis parameters and click Start z Test again S Note If results are unacceptable see Section 9 2 Adjusting the Controller for a Ramp Test 10 3 3 MANuAL TEST Manual testing is best used for a quick check of a parameter 1 Click the Configure Test tab to open the test configuration window Under Select Test select Manual Under Manual Test Parameters set Sampling Rate Click Test tab to open Test window pho quos Select which parameters will be plotted from the X and Y axis drop down lists located in the lower right corner of the Test window 6 Click Start Test The Test data table to the left will appear based on the parameters selected in the Display window The Test graph will display the plot for the selected X and Y parameters To display additional test curves simply change the X and Y axis parameters and click Start Test again 67 Chapter 10 Test Magtrol M TEST 5 0 Motor Testing Software 10 3 4 Pass FaiL TEST Pass Fail tes
115. rtment receives and analyzes your equipment 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 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 No 154033 Only ship ECONOMIC way 3 days max within Europe 3 Include the following documents with your equipment e Delivery note with Magtrol SA s address as listed above e Three pro forma invoices with e Your VAT number e Value for customs purposes only e 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 99 Testing Measurement and Control of Torque Speed Power
116. s based on the slope of the curve over the last 25 data points taken The following table provides information needed to create a specific data set based on desired data points Data to Obtain Speed Data Points Torque Data Points extrapolated free run data 99999 0 extrapolated locked rotor data 0 99999 full data set 88888 88888 extrapolated free run full data set and 99999 88888 and 0 0 88888 and 99999 extrapolated locked rotor data extrapolated values with special points 99999 special points 0 0 special points 99999 in between S Note When specifying speed or torque points other than free run and locked rotor place them first in the table The command for the full data set should be the last item 54 Magtrol M TEST 5 0 Motor Testing Software Chapter 8 Configure Test 8 5 PASS FAIL TEST PARAMETERS When Pass Fail test is selected the window will appear as follows Jf M TEST 5 0 Motor Test Software Bao im Current Setup C rtup msf Revision 1 03 Start Configure Hardware Control Parameter oz in Pass Fail 1 Pass Fail 2 Pass Fail 3 Pass Fail4 Pass Fail 5 Select Test Pass Fail Jj Torque Jj AL 9 Winl 9 RPM 9 Wout J None seve ser From To Time Min Max Min Min Max Min 4 d 4 Save Setup D z HL Max 4 5 2 2 z W Import From Spreadsheet Timebas
117. sampling rate and using step or ramp from one load point to the next Manual Runs test from front panel of the Dynamometer Controller while computer acquires data Allows adjustment of sampling rate Pass Fail Checks amps input watts with optional Power Analyzer speed torque and output watts against user defined values Displays 22 Tested and Calculated Parameters Torque speed and auxiliary input are displayed from the DSP6000 6001 5240 or 4629B Controller amps volts and watts from an optional power analyzer Calculated values including horsepower efficiency power factor output watts and time can also be displayed Three Phase Power Analyzer Data Acquisition Obtain data on each individual phase and or the sum used in the chosen parameters amps volts input watts and power factor SYSTEM CONFIGURATION A Magtrol Dynamometer provides motor loading with a Magtrol Programmable Dynamometer Controller acting as the interface between the PC running M TEST 5 0 and the dynamometer If motor electrical parameters are to be measured or used to determine load points a Magtrol Power Analyzer is also required Interfacing between the computer and electronic instrumentation is the National Instruments M card or RS 232 serial interface when using a DSP6000 or DSP6001 Shaded area represents additional components and setup required for GPIB Temperature Testing Select from F
118. sed for multiple testing instrument connections If using a DSP6001 Dynamometer Controller there can be up to 2 testing instrument connections Any Magtrol dynamometer or brake can be connected to Channel 1 TSC1 Channel 2 TSC2 can only support a Magtrol Eddy Current WB or Powder Brake PB Dynamometer Magtrol In Line Torque Transducer TM a Magtrol Free Run Speed Sensor FR 10 or auxiliary instrumentation If using a 5240 4629B or DSP6000 Dynamometer Controller default is set to Channel 1 TSC1 and only a Hysteresis HD Dynamometer may be used Control Function Options Values Instrument Selects the type of loading device or For Channel 1 TSC1 Type dynamometer connected to the channel s Hysteresis Dynamometer TSC1 and TSC2 of the controller Eddy Current Dynamometer WB Powder Brake Dynamometer PB Brake For Channel 2 TSC2 Auxiliary Eddy Current Dynamometer WB Powder Brake Dynamometer PB In Line Torque Transducer TM Free Run Speed Sensor 10 Brake Type If using a brake and Magtrol In Line Torque HB Hysteresis Brake Transducer in a cross loop function WB Edgy current Brake selects the type of brake connected to the PB Powder Brake Brake Output or Supply 1 of the controller Applies to TSC1 only Model Selects the specific model number of the The available model numbers will testing instrument be listed depending upon the NOTE Once the model is selected click nstrum
119. settings 90 Select Sensor Input device temperature testing hardware and corresponding settings if applicable 10 Click Apply Settings 10 2 CONFIGURE DISPLAY The following display configuration applies to curve manual and ramp tests For a detailed procedure refer to Chapter 6 Display 1 Click Display tab to open Display Setup window 2 Select parameters to record and or display during test 65 Chapter 10 Test Magtrol M TEST 5 0 Motor Testing Software 10 3 CONFIGURE AND RUN TEST Sg Note For detailed information on formatting and navigating graphs refer to Appendix A Graph Tools The software configuration for each test varies Following are step by step instructions for setting up and running a curve ramp manual and pass fail test For detailed procedures refer to Chapter 8 Configure Test J M TEST 5 0 Motor Test Software E J MASTROE Current Setup C Magtrof ramp msf Revision 1 00 m o d 2 2 Ramping down Amps 1 Volts 1 Watts IN 1 1 7 0 Efficiency 3 0 Speed RPM T Torque oz in Horsepower Time P d E 900 0 1000 0 1100 0 1200 0 1300 0 1400 0 1500 0 1600 0 1700 0 1800 Speed RPM Y Axis X Axis Torque Speed art Save Data AutoY Axis D Auto X Axis S Hide Graph qu Clear Graph
120. shortcut menu e Color Refer to table in Section A 1 Plot Legend e Cursor Style Provides various cursor styles Select from multiple crosshair styles and lengths e Point Style Refer to table in Section A 1 Plot Legend e Line Style Refer to table in Section A 1 Plot Legend e Line Width Refer to table in Section A 1 Plot Legend Show Name Displays the name of the cursor on the graph Bring to Center Centers the cursor on the graph without changing the X and Y scales e Go to Cursor Changes the X and Y scales to show the cursor at the center of the graph Lock BurroN Controls the cursor s movement when using either the Cursor Movement Tool or the Cursor Mover Options include e Free Move the cursor anywhere on the graph not limited to the plot or enter any X and Y value in the Cursor Legend to move the cursor to that coordinate e Snap to Point Cursor moves to the closest plot point The cursor can switch to another plot in this mode e Lock to Plot Applies to the Cursor Movement Tool in the Graph Palette only Locks the cursor to a particular plot The cursor cannot switch to another plot in this mode Cunson Moves the cursor mathematically S To enable the Cursor Mover do one of the following 1 Click on the Cursor Mover Selector in the Cursor Legend or 2 Click on the Cursor Movement Tool in the Graph Palette Move the cursor by clicking on one of the 4 diamonds that co
121. stored and recalled using standard Windows file structure M TEST 5 0 is equipped to work in conjunction with any of the following Magtrol motor testing instruments e Dynamometer Controller DSP6001 6000 5240 4629B e Hysteresis Eddy Current or Powder Dynamometer HD WB PB e In Line Torque Transducer TM TMB TMHS e Power Analyzer 6530 6510e 6510 6550 5100 5300 6510e or 6530 Power Analyzer Motor Under Test HD Hysteresis Dynamometer z T o X gt 2 10 m 2 m 2 gt Magtrol M TEST 5 0 Motor Testing Software Chapter 1 Introduction Ordering Information SYSTEM REQUIREMENTS e Personal computer with Intel Pentium IV processor or equivalent Magtrol e Microsoft Windows 2000 XP e e 1 GB of RAM e 1 6 GB of available hard drive space e color monitor with minimum screen resolution of 1024 x 768 DSP6001 Controllers input function will be used SYSTEM OPTIONS AND ACCESSORIES M TEST 5 0 National Instruments M card available from RS 232 serial interface can be used instead of GPIB card for interfacing with Magtrol DSP6000 or e National Instruments FieldPoint or USB 9211A hardware Required only if temperature testing sensor CATEGORY DESCRIPTION MODEL PART EN CU ERE awrrester TESTING Network interfa
122. ta Folder to access Save As dialog box Open the desired folder and click Select Cur Dir Serial Number Records the serial number for generating data log files and reports Enter the serial number for the first motor being tested Auto Increment Increments the serial number by one integer at the end of each test NOTE If the serial number is alphanumeric the software looks for the last alpha character in the string If it is followed by a number that number will be incremented by one at the end of the test If no number follows the last alpha character a number will be added and incremented after each test Enabled select check box and Disabled clear check box Print Report Generates a custom printed report after each curve ramp or manual test NOTE The report must be configured first Refer to Chapter 15 Reports Enabled select check box and Disabled clear check box Save Report Saves a custom report after each curve ramp or manual test to be viewed or printed at a later time NOTE The report must be configured first Refer to Chapter 15 Reports Enabled select check box and Disabled clear check box Report Folder If Save Report is enabled specifies the drive and directory for report files NOTE File names are automatically generated from the serial number and saved with an rpt file extension Click Data Folder to access Save As dialog box Open the desi
123. ting Software Chapter 8 Configure Test 8 4 RAMP TEST PARAMETERS When Ramp test is selected the window will appear as follows 7 M TEST 5 0 Motor Test Software EN T MASIRON Current Setup Revision 1 03 Configure Hardware Adjust PID TEST ViewData 5 AxisGraph 1 Reports Security Data Points Select Test Torque Speed Inertia Cancellation Yes Ramp Method Average Down Up Ramp Rate 200 00 Max Speed 1800 00 Min Speed 200 00 Max Torque oz in 1000 00 Dynamic PI Scaling Special Data Points Locked Rotor Locked Rotor Dwell sec No 4 Brake Current 96 Import From Spreadsheet Save Data Include Equipment List Print Report C sve Resort Operator Code Data Folder Report Folder Auto Increment Pass Filename Serial Number Fail Fil ail Filename Figure 8 4 Ramp Test Setup Window 51 E m o o m 0 Chopter 8 Configure Test Magtrol M TEST 5 0 Motor Testing Software The following parameters may be used when setting up a Ramp Test Control Function Options Values Inertia Provides accurate torque and power data Yes No and Previous Value Cancellation during a ramp test The stored energy of the rotating mass in the system tends to make the motor look stronger than it actually is during a deceleration ramp Inertia cancellation removes the inertial component and gives data as if a number of discrete stabilized points were taken NOT
124. ting is best used for checking a few data points at the end of a production line or at incoming inspection 1 Click the Configure Test tab to open the Configure Test window 2 Under Select Test select Pass Fail 3 Under Pass Fail Test Parameters select Control Parameter 4 Enter From To and Time values and Volts when using a DC or regulated AC power supply in pass fail control data table 5 Select Pass Fail Parameters up to 5 and enter minimum and maximum values for each of the load points 6 Click Test tab to open Test window 7 Select which parameters will be plotted from the X and Y axis drop down lists located in the lower right corner of the Test window 8 Click Start Test 9 Once the test has completed its sequence the test results will appear indicating whether the motor was PASS or FAIL 10 Select Next Test to run the same test for a new motor S Note If results are unacceptable see Section 9 Adjusting the Controller for a Curve or Pass Fail Test 10 4 VIEW TEST DATA When the test run is complete there are a few different options for viewing test results 10 4 1 TABULAR DISPLAY View Data Display test results in a data table with option to print Refer to Chapter 11 View Data for more information 10 4 2 GraPHICAL DISPLAY 5 Axis Graph Display up to 5 test curves in a single graph with option to print Refer to Chapter 12 5 Axis Graph for more information 1 Axis Graph Display up
125. tor is illuminated in green the grid will be visible Conversely when the Hide Grid indicator is dimmed grayed out the grid will be hidden Hide Grid gt 0 0 m z gt lt 89 Appendix B PID Scaling B 1 B 1 1 B 1 2 ABOUT THE PID LOOP The DSP6001 has PID adjustment capability for both the speed and torque modes to provide the best system response The PID loop comprises the following three variables P proportional gain I integral D derivative Other important variables include e Set point desired load or speed e Error difference between the set point and the actual measurement P PROPORTIONAL GAIN With proportional gain the controller output is either proportional to the error or to a change in measurement Deviation from the set point is usually present Increasing the proportional gain will make the PID loop unstable Increasing the integral value will eliminate this instability For best loop control set the proportional gain as high as possible without causing the loop to become unstable INTEGRAL With integral the controller output is proportional to the amount of time the error is present Increasing the integral value eliminates the offset from the set point If the response becomes oscillatory increase the derivative value D Derivative With derivative the controller output is proportional to the rate of change of measurement or error Derivative can co
126. tor to begin rotating again NOTE If locked rotor is not desired this control is irrelevant 0 to 99 99 Maximum Temperature Allows a maximum value to be set for temperature when using temperature acquisition hardware NOTE If any thermocouple exceeds the Maximum Temperature value the test in progress will abort Any NOTE The temperature units are the same as what was selected in the hardware setup For FieldPoint Units are configured within FieldPoint Explorer See Section 2 4 1 3 Thermocouple Type and Temperature Unit Changes For USB 9211 Units are set up in the Configure Hardware window under Sensor Input Maximum Current Allows a maximum value to be set for current NOTE If the measured current exceeds the value set up by this control the test in progress will abort Any 49 m o o m U Chopter 8 Configure Test Magtrol M TEST 5 0 Motor Testing Software 8 3 1 Data TABLE IE Used for entering a load profile for curve tests Table includes the following items From The starting load value To The ending load value Time The number of seconds or minutes to achieve the series Volts Sets the voltage for each step when using a DC or regulated AC power supply The power supply will be programmed to the voltage desired at the beginning of each step Note Volts are only applicable when using a DC or regulated AC po
127. troller DSP6001 6000 5240 4629B e Hysteresis Eddy Current or Powder Dynamometer HD WB PB e In Line Torque Transducer TM TMB TMHS e Power Analyzer 6530 6510e 6510 6550 5100 5300 Note A DC power supply may be used in place of a power analyzer for reading back amps and volts However this is not recommended because readings will be less accurate and data transfer rates will be substantially slower Written in LabVIEW M TEST 5 0 has the flexibility to test a variety of motors in a multitude of configurations If you have a specialized test that you wish to perform contact Magtrol Technical Assistance at 716 668 5555 SYSTEM REQUIREMENTS Recommended e Personal computer with Intel Pentium III or Celeron 600 MHz processor equivalent e Microsoft Windows 2000 XP 128 MB of RAM e 1 GB of available hard drive space VGA color monitor with minimum screen resolution of 1024 x 768 e National Instruments card e RS 232 serial interface can be used instead of GPIB card for interfacing with Magtrol DSP6000 or DSP6001 controllers e National Instruments FieldPoint or USB 9211A hardware Required only if temperature testing sensor input function will be used T 0 2 D gt or z Chapter 1 Introduction Magtrol M TEST 5 0 Motor Testing Software 1 3 SOFTWARE FEATURES z o S 1 3 1 New Features or M TEST 5 0 Magtrol s M TEST 5 0 Software
128. ts Security Volts 1 Watts IN1 Efficiency Speed RPM Torque ozin Horsepower Watts OUT 120 642 30 502 0 027 1792 000 0 632 0 001 0 838 120 800 31 309 0 064 1786 000 1 505 0 003 1 988 120 775 31 399 0 069 1785 000 1 648 0 003 2475 120 751 31 800 0 089 1782 000 2 166 0 004 2 854 120 746 32 386 0 117 1778 000 2 902 0 005 3 816 120 792 33 005 0 145 1774 000 3 688 0 006 4 838 120 725 33 611 0 173 1771 000 4 503 0 008 5 897 120 770 34 356 0 205 1766 000 5 468 0 010 1 140 120 687 35 877 0 261 1758 000 7 313 0 013 9 507 120 693 37 178 0 303 1750 000 8 856 0 015 11 461 120 694 38 119 0 324 1745 000 9 728 0 017 12 553 120 696 39 484 0 364 1736 000 11 334 0 019 14 550 120 689 41 141 0 403 1726 000 13 136 0 022 16 765 120 625 42 183 0 428 1719 000 14 323 0 024 18 207 120 632 43 862 0 455 1710 000 15 895 0 027 20 099 120 612 44 828 0 469 1704 000 16 786 0 029 21 152 120 630 45 625 0 481 1699 000 17 575 0 029 22 081 120 606 46 996 0 506 1689 000 19 087 0 032 23 839 120 579 48 303 0 519 1682 000 20 220 0 034 25 150 120 569 48 892 0 530 1677 000 20 955 0 035 25 987 120 606 49 527 0 533 1674 000 21 357 0 036 26 437 120 565 50 344 0 540 1667 000 22 120 0 036 27 267 120 569 51 324 0 552 1660 000 23 140 0 038 28 405 120 546 52 753 0 563 1650 000 24 377 0 040 29 743 120 553 53 710 0 566 1644 000 25 057 0 041 30 462 120 544 54 469 0 572 1636 000 25 790 0 042 31 201 120 549 54 736 0 577 1634 000 26 170 0 043 31 622 120 577 55 193 0 577 1631 000 26 395 0 043 31
129. uite satisfactory for most applications Loading can be accomplished by either stepping or ramping to the desired point If stepping to a load point is desired enter a time of 0 zero for that point If ramping to a load point is desired enter the number of seconds or minutes depending on the timebase setting for the controller to ramp from the starting point to the ending point To remain at a fixed load for a period of time use the same value for From and To obtain free run or locked rotor data use the following values Parameter Free Run Locked Rotor Amps 0 99999 Input Watts 0 99999 Speed 99999 0 Torque 0 99999 Output Watts 0 99999 In the example illustrated in Figures 7 6 and 7 7 a torque curve test will be performed that will 1 Ramp the torque from zero to 10 in 5 seconds Dwell at 10 for 5 seconds Step to 20 in zero seconds Dwell at 20 for 5 seconds Ramp to zero in 3 seconds Dwell at zero for 5 seconds LO OO A ROS Repeat the cycle steps 1 6 a second time 38 E m o o m U Magtrol M TEST 5 0 Motor Testing Software Chapter 7 Test Selection 7 M TEST 5 0 Motor Test Software T MASIKON turrent Seti Revision 1 03 Configure Hardware Display Configure Test Adjust PID TEST ViewData 5 Axis Graph Reports Security Select Test j Curve Control Parameter oz in Torque Speed Range 99999 00 Timebase Sec
130. utine The deceleration curve is shown against an ideal curve and PIDs are adjusted until the curves align with each other Adjustments made to the PID values during Curve Pass Fail Test and Ramp Test Setup Routines are automatically transferred to the controller when the test is executed S Note While PID adjustments can be made with any Magtrol programmable dynamometer controller only the DSP6000 and DSP6001 can receive PID values changed with M TEST 5 0 57 Chopter 9 Adjust PID Magtrol M TEST 5 0 Motor Testing Software 9 1 PID PARAMETERS The following parameters may be used when adjusting the DSP6000 6001 Dynamometer Controller Control Function Options Values Actual Indicates the plot in the graph that displays the N A actual system response to a test run Ideal Indicates the plot in the graph that displays the N A optimum result of a test run NOTE This plot is only displayed during a ramp test Control Indicates the plot in the graph that displays the N A value and dwell settings NOTE This plot is only displayed during a curve test P Adjusts the proportional gain setting on the 0 to 99 m Proportional 05 6000 6001 Gain o Integral Adjusts the integral setting on the 0 to 99 DSP6000 6001 v D Derivative Adjusts the derivative setting on the 0 to 99 DSP6000 6001 the dwell time at no load and at load for the adjustment procedure Th
131. wer supply and will not be visible to the user during line AC operation To set type values in the table and use the TAB key or mouse to move from cell to cell The time units are set by the Timebase control to the right and are applied to all time values in the table Any values entered in the From and To columns will be in the units specified by the Control Parameter To clear the table right click inside of it and select Empty Table Note If a certain profile is repetitive enter the basic sequence in the table once and use the Number of Cycles control on the right to repeat that sequence any number of times The following is an example of using the Control Data while running a torque curve with a line AC power supply Sequence From To Time Description 1 0 0 2 This will load the motor with zero torque for 2 seconds 2 0 10 10 This will ramp the load from 0 to 10 torque units in 10 seconds 3 10 10 5 will dwell at 10 torque units for 5 seconds 4 10 0 O This will finish by stepping from 10 to 0 in 0 seconds Note When loading by Amps Input Watts Torque or Output Watts a value of 0 zero will obtain free run data A value of 99999 will obtain locked rotor data Note When loading by Speed a value of 99999 will obtain free run data A value of 0 zero will obtain locked rotor data 50 E m o o m 4 0 Magtrol M TEST 5 0 Motor Tes
132. which may be of interest to the user If Special Data Points is set to Yes the user has the option of obtaining only those desired speed or torque points a combination of special points or the entire data set S Note display graphing and file saving selections will be based on these points only The graphing routine may be corrupted because of the unnatural order of special points e Speed and Torque Special Data Points are entered here e set type values in the table and use the TAB key to move from cell to cell S Note Data needs to be entered in decreasing order for Speed and increasing order for Torque If a matching value is not found within the measured data set the program will interpolate the value from data obtained one point above and one point below The process applies to all measured parameters E m o o m E U e Extrapolation of true free run and locked rotor values If a motor is coupled to a dynamometer there will be some amount of drag produced by bearing friction and windage This can cause some motors to reduce their uncoupled free run speed by hundreds or even thousands of rpm If desired the program will calculate the true free run parameters based on the slope of the curve over the first 25 data points taken To obtain locked rotor data without actually stalling the motor run the motor to the lowest speed possible The program calculates the locked rotor parameter
133. wing Magtrol products e Hysteresis Eddy Current or Powder Brake Dynamometer HD WB or PB e In Line Torque Transducer TM TMB or TMHS e Power Analyzer Model 5100 5300 6510 6510e 6530 or 6550 e Dynamometer Controller Model DSP6000 DSP6001 5240 or 4629B Optional auxiliary instrumentation can also be used A DC power supply may be used in place of a power analyzer for reading back amps and volts However this is not recommended because readings will be less accurate and data transfer rates will be substantially slower 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 INTRODUCTION Contains the technical data sheet for M TEST 5 0 and highlights the new features of the software Chapter 2 INSTALLATION Provides general installation instructions for M TEST 5 0 software GPIB interface board FieldPoint temperature measurement hardware and National Instruments relay actuator PCI card Chapter 3 M TEST 5 0 INTERFACE Provides instruction for M TEST 5 0 startup and navigation Includes a brief overview of the software capabilities Chapter 4 START Provides instruction for logging in out selecting language and loading saving
134. x Maximum allowable value for the Pass Fail parameter displayed directly above Note When checking for direction of rotation enter either CW or CCW in both the Min and Max columns 56 E m o o m 4 U 9 Adjust PID The PID can be adjusted either prior to a test being run or afterwards if the test results are unacceptable For more information on PID see Appendix B PID Scaling Click the Adjust PID tab to open the Adjust PID window 5 0 Motor Test Software q4 q aoi Current Setup C Magtrol lesiRamp msf Revision 1 02 Start Configure Hardware Display Configure Test Adjust PID TEST ViewData 5 Axis Graph 1 AxisGraph Compare Reports Security Exit Actual Control E m o o m E 0 o a Psi a ISS DSi A bet 1000 Dm jj 1000 High Value j 0 00 Low Value Jj 0 00 Dwell J 2 100 Save Setup Figure 9 1 Adjust PID Window The Adjust PID window is where PID setup routines are provided S Note For specific instructions on how to enter information into M TEST 5 0 see Section 3 3 Navigating M TEST 5 0 In order to assist the operator in adjusting the PID values there are two setup routines e Curve Pass Fail Test Setup Routine step function is sent to the controller and the system response is plotted against it Adjust PID values on the fly until desired response is obtained Ramp Test Setup Ro
135. x Temp 100 00 Number of Cycles 9 1 Max Current 9 50 00 E m o o m E U Max Brake Current j 50 00 Speed Range 99999 00 Save Data Include Equipment List Print Report eave R DUITE Operator Code Data Folder Report Folder Auto Increment Pass Filename Serial Number Fail Filename Figure 8 1 Configure Test Window The Configure Software window is where the software is programmed for the type of test to be performed S Note For specific instructions on how to enter information into M TEST 5 0 see Section 3 3 Navigating M TEST 5 0 8 1 SELECT TEST e Selects the type of test you wish to perform e Options include Ramp Curve Manual and Pass Fail tests As different tests are selected the required controls for that test will become active S Note For detailed information on each type of test see Chapter 7 Test Selection 45 Chapter 8 Configure Test Magtrol M TEST 5 0 Motor Testing Software 8 2 DATA LOGGING Data Logging allows M TEST 5 0 to automatically store acquired data at the end of each test Control Function Options Values Save Data Enables data logging function Enabled select check box and Disabled clear check box Data Folder Specifies the drive and directory for curve ramp and manual test data files NOTE File names are automatically generated from the serial number and saved with an xls file extension Click Da
136. ziii MAGTROL M TEST 5 0 Current Setup C Magtrol Setup Files Ramp mst Revision 1 02 Configure Hardware Configure Test Adjust PID TEST View Data Reports Security Exit 60 40 o Ps 150 A DS 1 1000 3 1 000 E m o d o m c U Figure 9 7 Ramp with bump 11 Increase IS value until bump diminishes Use the I slider for finer adjustment Click Run between each adjustment to see results When optimal setting is reached the result will appear similar to the following example f M TEST 5 0 Motor Test Software MAGTROL FilesiRamp msf Revision 1 02 Psi 15 055 DPL 1 000 3 1 000 100 120 140 160 180 200 220 240 250 280 300 Figure 9 8 Ramp no bump but unstable 63 Chopter 9 Adjust PID Magtrol M TEST 5 0 Motor Testing Software 12 Set D to 35 13 Increase DS until major instability diminishes Use the D slider for finer adjustment Click Run between each adjustment to see results When optimal setting is reached the result will appear similar to the following example J M TEST 5 0 Motor Test Software A MAGTROL Start Configure Hardware Display Configure Test Adjust PID TEST ViewData 5 Axis Graph Psi 151 DSi 3 1000 DIL 1 000 Figure 9 9 Ramp no bump and stable 14 Decrease DIL until minor instability diminishes While adjusting click Run between each a

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