Magtrol 6200 User manual

MODEL 6200
Open Loop
Dynamometer Controller
User’s Manual
Via Paolo Uccello 4 - 20148 Milano
Tel [phone] Fax [phone] [email protected] www.dspmindustria.it

1st Edition rev. A – March 2014
While every precaution has been exercised in the compilation of this document to
ensure the accuracy of its contents, Magtrol, Inc. assumes no responsibility 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 ©2002- 2014 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
LabVIEW™ is a trademark of National Instruments Corporation.
Microsoft® is a registered trademark of Microsoft Corporation.
National Instruments™ is a trademark of National Instruments Corporation.
Windows® is a registered trademark of Microsoft Corporation.
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: _____________________________

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1. Make sure that all Magtrol dynamometers and electronic products are earth-grounded, to ensure
personal safety and proper operation.
2. Check line voltage before operating the 6200.
3. Make sure that dynamometers and motors under test are equipped with appropriate safety guards.
Safety Precautions

iv
The contents of this manual are subject to change without prior notice.
REVISION DATE
1st Edition rev. A – March 2014
TABLE OF REVISIONS
Revisions To This Manual
Date Edition Change Section(s)
03/03/14 1st Edition - rev. A Torque Offset and Gain procedure updated. 6.3.2
03/03/14 1st Edition - rev. A Basic Calibration Process updated. 6.3
03/03/14 1st Edition - rev. A Accessory Torque/Speed Output diagram updated. 2.2.1

v
Table of Contents
SAFETY PRECAUTIONS ....................................................................................................................... III
REVISIONS TO THIS MANUAL .............................................................................................................. IV
REVISION DATE................................................................................................................................................................IV
TABLE OF REVISIONS.....................................................................................................................................................IV
PREFACE............................................................................................................................................... VII
PURPOSE OF THIS MANUAL ........................................................................................................................................VII
WHO SHOULD USE THIS MANUAL.............................................................................................................................VII
MANUAL ORGANIZATION ............................................................................................................................................VII
CONVENTIONS USED IN THIS MANUAL ................................................................................................................. VIII
1. INTRODUCTION ................................................................................................................................ 9
1.1 UNPACKING YOUR 6200 ............................................................................................................................................ 9
1.2 FEATURES OF THE 6200............................................................................................................................................. 9
1.3 DATA SHEET............................................................................................................................................................... 10
2. CONTROLS....................................................................................................................................... 12
2.1 FRONT PANEL............................................................................................................................................................ 12
2.1.1 Front Panel Controls and Buttons .................................................................................................................. 12
2.1.2 How to Use Front Panel Controls and Buttons .............................................................................................. 13
2.2 REAR PANEL .............................................................................................................................................................. 14
2.2.1 Rear Panel Functions...................................................................................................................................... 14
2.3 VACUUM FLUORESCENT DISPLAY (VFD)........................................................................................................... 16
2.3.1 Contrast Settings ............................................................................................................................................ 16
2.3.2 Displaying Desired Information..................................................................................................................... 16
3. INSTALLATION ................................................................................................................................... 9
3.1 POWERING UP THE 6200 ........................................................................................................................................... 9
3.1.1 Setting Unit for Line Voltage ........................................................................................................................... 9
3.1.2 Hardware Connection..................................................................................................................................... 10
3.1.3 Self-Test ......................................................................................................................................................... 10
3.2 BASIC TEST SETUP................................................................................................................................................... 10
4. MANUALLY CONTROLLED OPERATION ....................................................................................... 11
4.1 SETTING DESIRED OPERATING PARAMETERS ................................................................................................. 11
4.1.1 Set Power Display to Desired Units (Watts, Hp or Aux.) .............................................................................. 11
4.1.2 Set Display to Desired Torque Units.............................................................................................................. 11
4.1.3 Set up System Parameters .............................................................................................................................. 11
4.1.4 Set Up Pass/Fail Parameters........................................................................................................................... 11
4.1.5 Set Up I/O Parameters.................................................................................................................................... 12
4.2 SETTING DYNAMOMETER LOAD ......................................................................................................................... 12
4.3 USING INTERNAL MEMORY .................................................................................................................................. 13
4.3.1 Storing Data Points ........................................................................................................................................ 13
4.3.2 Recalling Data Points..................................................................................................................................... 13
4.3.3 Exiting the Memory Mode............................................................................................................................. 13
4.3.4 Clearing the Memory ..................................................................................................................................... 13
5. COMPUTER CONTROLLED OPERATION ...................................................................................... 14
5.1 ABOUT THE GPIB INTERFACE............................................................................................................................... 14

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Magtrol Model 6200 Open Loop Dynamometer ControllerTable of Contents
5.1.1 Installing the GPIB (IEEE-488) Connector Cable......................................................................................... 14
5.1.2 Changing the GPIB Primary Address ............................................................................................................ 15
5.2 CHECKING THE 6200-TO-PC CONNECTION ........................................................................................................ 15
5.3 PROGRAMMING........................................................................................................................................................ 16
5.4 6200 COMMAND SET................................................................................................................................................ 16
5.4.1 Command Set for 6200 .................................................................................................................................. 16
5.5 ACQUIRING SPEED-TORQUE DATA ...................................................................................................................... 18
5.6 SELECTING THE BAUD RATE FOR THE RS-232 INTERFACE ........................................................................... 19
6. CALIBRATION .................................................................................................................................. 21
6.1 CLOSED-BOX CALIBRATION ................................................................................................................................. 21
6.2 CALIBRATION SCHEDULE...................................................................................................................................... 21
6.3 BASIC CALIBRATION PROCESS............................................................................................................................. 21
6.3.1 Initial Calibration Procedure.......................................................................................................................... 21
6.3.2 Torque Offset and Gain.................................................................................................................................. 22
6.3.3 Accessory Torque Offset and Gain ................................................................................................................ 23
6.3.4 Auxiliary Input Offset and Gain..................................................................................................................... 23
6.4 ALTERNATE CALIBRATION PROCEDURE ........................................................................................................... 23
7. TROUBLESHOOTING....................................................................................................................... 26
APPENDIX A: LABVIEW PROGRAMMING EXAMPLES ..................................................................... 27
A.1 SIMPLE READ ............................................................................................................................................................ 27
A.2 CURRENT STABILIZED............................................................................................................................................ 28
APPENDIX B: FRONT PANEL/DISPLAY MENU FLOW CHARTS ....................................................... 29
B.1 SETUP MENU ............................................................................................................................................................. 29
B.2 POWER UNITS MENU............................................................................................................................................... 30
B.3 AUX SETUP MENU.................................................................................................................................................... 30
B.4 TORQUE UNITS MENU ............................................................................................................................................ 31
APPENDIX C: SCHEMATICS ................................................................................................................ 32
C.1 ENCODER/SWITCH BOARD.................................................................................................................................... 32
C.2 POWER SUPPLY......................................................................................................................................................... 32
C.3 DSP & MEMORY........................................................................................................................................................ 33
C.4 ANALOG I/O ............................................................................................................................................................... 34

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Magtrol Model 6200 Open Loop Dynamometer Controller Table of Contents
TABLE OF FIGURES
2. CONTROLS....................................................................................................................................... 12
Figure 2–1 Front Panel ............................................................................................................................................... 12
Figure 2–2 Secondary Function Menu ........................................................................................................................ 12
Figure 2–3 Rear Panel ................................................................................................................................................. 14
Figure 2–4 Dynamometer Brake Output ..................................................................................................................... 14
Figure 2–5 Accessory Torque-Speed Output............................................................................................................... 14
Figure 2–6 Dynamometer/TSC1 Connector................................................................................................................ 15
Figure 2–7 RS-232C Interface..................................................................................................................................... 15
Figure 2–8 GPIB/IEEE-488 Interface ......................................................................................................................... 15
3. INSTALLATION ................................................................................................................................... 9
Figure 3–1 Cover for Voltage Selector, Fuses ............................................................................................................... 9
5. COMPUTER CONTROLLED OPERATION ...................................................................................... 14
Figure 5–1 GPIB (IEEE-488) Interface....................................................................................................................... 15
Figure 5–2 Connector Pin-Out .................................................................................................................................... 19
6. CALIBRATION .................................................................................................................................. 21
Figure 6–1 Alternative Calibration .............................................................................................................................. 24

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PURPOSE OF THIS MANUAL
This manual contains all the information required for the installation and general use of the Model
6200 Open Loop Dynamometer Controller. To ensure proper use of the instrument, please read
this manual thoroughly before operating it. Keep the manual in a safe place for quick reference
whenever a question arises.
WHO SHOULD USE THIS MANUAL
This manual is intended for bench test operators who are going to use the Model 6200 Dynamometer
Controller in conjunction with any Magtrol Hysteresis Dynamometer or auxiliary instrumentation.
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 the 6200 Dynamometer
Controller, which describes the unit and provides its technical characteristics.
Chapter 2: CONTROLS - Description of the elements located on the front and rear panels of
the unit.
Chapter 3: INSTALLATION - Provides setup options available with the 6200 Dynamometer
Controller. Illustrates and outlines the hardware connection setup and software
configurations for each option.
Chapter 4: MANUALLY CONTROLLED OPERATION - How to run a test when the 6200 is
used as a stand-alone unit. Includes information on setting power and torque units,
torque and speed control and open loop control.
Chapter 5: COMPUTER CONTROLLED OPERATION - How to run a test when the 6200 is
used with a PC. Includes information on GPIB Interface, RS-232 Interface, data
format, programming and command set.
Chapter 6: CALIBRATION - Provides recommended calibration schedules along with step-
by-step instructions for the calibration procedure.
Chapter 7: TROUBLESHOOTING - Solutions to common problems encountered during setup
and testing.
Appendix A: LABVIEW™ PROGRAMMING EXAMPLES - Magtrol’s comprehensive motor-
test software programs, made specifically to compliment the 6200 Dynamometer
Controller.
Appendix B: FRONT PANEL/DISPLAY MENU FLOW CHARTS - A visual display of various
setup procedures.
Preface

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Magtrol Model 6200 Open Loop Dynamometer ControllerPreface
Appendix C: SCHEMATICS - For Encoder/Switch Board, Power Supply, DSP & Memory and
Analog I/O.
CONVENTIONS USED IN THIS MANUAL
The following symbols and type styles may be used in this manual to highlight certain parts of the text:
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’sattention to information,
direCtives, proCedures, etC. whiCh, if ignored, may result
in damage being Caused to 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.

9
GENERAL
INFORMATION
Calibration Certificate
1. Introduction
1.2 FEATURES OF THE 6200
• Highquality,easytoreaddisplay-Vacuumuorescentreadoutwith0.36”(9.1mm)highdigits.
• High-speeddataacquisition-120torqueandspeedreadingspersecondviaIEEE(GPIB)bus.
• Pass/Failtesting-Upperandlowerlimitsareprogrammablefortorque,speed,andauxiliary
input.
• Currentregulatedsupply-Providesupto1ampoutput.
• Internaldatastorage-Nonvolatilememoryofupto100datapoints.
• Dynamometeroverloadprotection-Maximumpowerlimitcanbeprogrammedtoshutdownif
exceeded.
• Twostandardcomputerinterfaces-RS-232andIEEE-488.
• Additionalanaloginput-Acceptsany±5VDCtransducer.
• Manytorquemeasurementoptions-IncludesEnglish,metric,andSItorquereadingsasstandard.
• Closedboxcalibrationoftorqueandauxiliaryinput-Eliminatesneedtoopenboxforadjustments.
The 6200 is designed to work with any personal computer using an IEEE-488 or an RS-232 interface,
or as a stand-alone unit. In a computer-controlled environment, the 6200 provides the following
motor testing capabilities:
• Currentregulatedcontrolofdynamometerbrakeforopen-looptesting
• Torque(Q)andSpeed(N)dataacquisitionatarateofupto120readingspersecond.
• Saving-Allowsusertosaveprogrammedvalueswithintheircongurations.
1.1 UNPACKING YOUR 6200
Your 6200 was packaged carefully for shipping. Please notify your carrier and Magtrol Customer
Service if you believe your unit was damaged in shipping.
1. Save all shipping cartons and packaging material until you inspect the 6200.
2. Inspect the 6200 for any evidence of damage in shipping.
3. Make sure the carton contains the following:
MODEL 6200
CONTROLLER/DISPLAY
UP DOWNRECALL
SETUP SHIFT
STORE
CLR MENU
DISPLAY
AUX SETUP
TORQUE SET
TORQUE UNITS
BRAKE ON/OFF
POWER UNITS
POWER
POWER/AUX TORQUE SPEED
DECREASE INCREASE
6200 Dynamometer Controller/Readout
Line cord
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