Magtrol DSP7000 User manual

Model DSP7000
High Speed Programmable
Dynamometer Controller
User’s Manual

2nd Edition rev. L – January 2017
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 ©2011-2017 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 DSP7000.
3. Make sure that dynamometers and motors under test are equipped with appropriate safety
guards.
Safety Precautions

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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 been made since this edition.
REVISION DATE
2nd Edition revision L– January 2017
TABLE OF REVISIONS
Revisions To This Manual
Date Edition Change Section(s)
01/05/17 2 nd Edition rev. L I/O Card specications updated. 8.1
04/05/16 2 nd Edition rev. K Torque Commands updated. 7.4.6
08/10/15 2 nd Edition rev. J USB driver setup for Windows operating system updated. 7.1.1
07/07/15 2 nd Edition rev. H Installation instructions and commands updated
throughout chapter.
Chapter 7
07/07/15 2 nd Edition rev. H Setting tare function instructions updated. 6.7.1
07/07/15 2 nd Edition rev. H Alarm instuctions and commands updated throughout
chapter.
Chapter 5
06-09-15 2 nd Edition rev. G Figure 2-12 RS-232 Interface drawing updated. 2.4.4
06/19/14 2 nd Edition rev. F A/D Sample Rate changed from 7812.5 KHz to 7812.5 Hz. 10.3
03/27/14 2 nd Edition rev. E Miscellaneous Commands updated. 7.4.7
10/28/13 2 nd Edition rev. D Speed commands table updated.
Figure 4-1 updated for new rmware.
Section updated for new rmware.
7.4.5
4.3.1
6.6
07/11/13 2 nd Edition rev. C Note added to Calibration Frequency procedure. 9.3.4
07/03/13 2 nd Edition rev. B Step number 5 updated in Calibration Procedure of Digital
to Analog Converters.
9.3.3
07/03/13 2 nd Edition rev. B Step number 4 updated in Calibration Prodedure of
Analog to Digital Converters.
9.3.2
05/23/13 2 nd Edition rev. A Calibration procedure of Analog to Digital Converters
updated.
9.3.2
05/23/13 2 nd Edition rev. A Digital input and output added to specications. 8.1
03/09/13 2 nd Edition Torque invert signal added. B.3.4
03/09/13 2 nd Edition Prcedure for setting the scale factor updated. 10.2.1.1, 10.2.1.2,
10.2.1.3
03/09/13 2 nd Edition Calibration Procedure updated. 9.3, 9.3.3
03/09/13 2 nd Edition New drawing added. 8.2.3, 8.2.4
03/09/13 2 nd Edition Pin 25 updated to Alarm Relay 2 Common. 8.1.2
03/09/13 2 nd Edition QDS1,xx.xx, QDS2,xx.xx; QIS1,xx.xx, QIS2,xx.xx;
QPS1,xx.xx, QPS2,xx.xx commands updated.
7.4.6
03/09/13 2 nd Edition NDSI1,#, NDSI2,#; NISI1,#, NISI2,#; NPSI1,#, NPSI2,#
commands updated.
7.4.5

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Date Edition Change Section(s)
03/09/13 2 nd Edition Din1,#, Din2,# command updated.
TAC1,#, TAC2,# command updated.
7.4.4
03/09/13 2 nd Edition Drawing updated 3.2.4.1, 3.2.5.1,
3.2.7.1, 3.2.8.1,
3.2.9.1, 3.2.10.1
03/09/13 2 nd Edition Note updated with correct section number for the Torque
Filter information.
3.2.1
03/09/13 2 nd Edition New features updated. 1.2
02/20/13 1st Edition - rev. Q One “x” added to the OD1, OD2 command to show a
return of 6 speed digits.
7.4.2
02/13/13 1st Edition - rev. P Section 6.8 How to Set the TM/TF Invert Flag added.
DINØ, DIN1 changed to DIRØ, DIR1 in the note section.
6.8
7.5
01/31/13 1st Edition - rev. O Step added to the setup instructions. 4.3.1
01/25/13 1st Edition - rev. N TMV1,# and TMV2,# command added.
A note was added to the DSP6001 Mode instructions.
7.4.7
7.5
01/04/13 1st Edition - rev. M F1,xx.xx and F2,xx.xx command function and denition
updated.
7.4.5
11/14/12 1st Edition - rev. L OS,# miscellaneous command added.
Calibration of Frequency added to the calibration
procedures.
7.4.7
9.3.4
10/26/12 1st Edition - rev. K The Supply 1/Supply 2 pin descriptions updated. 2.4.1
05/29/12 1st Edition - rev. J Power Supply connector description changed to include
HD 825 dynamometers.
1.3
04/25/12 1st Edition - rev. I Brake fuse changed to 1.25 Amps.
Congure Output Binary table descriptions updated.
1.3
7.2.2
03/14/12 1st Edition - rev. H OV,# command updated for both channels. 7.4.7
01/12/12 1st Edition - rev. G Section 6.6 How to Set Preload Control and section 6.7
How to Set and Reset Tare Function was added.
The ALC,# Alarm Command was added to section 7.4.1.
The TS1, TS2, TR1 and TR2 Commands were added to
section 7.4.7.
6.6, 6.7
7.4.1, 7.4.7
01/09/12 1st Edition - rev. F Driver and Tera Term location changed to Magtrol Manual
CD
7.1.1, 7.1.2, 8.4.2
12/27/11 1st Edition - rev. E USB Driver setup updated. 7.1.1, 7.1.2
12/13/11 1st Edition - rev D “Open or 8 Volts” was changed to “Open collector” for pin
9 in section 8.1.2. Function was changed for ALR1,# and
ALR2,# in section 7.4.1.
8.1.2, 7.4.1
12/06/11 1st Edition - rev C RPM vs PPR Chart added 3.4
12/02/11/ 1st Edition - rev B STAT command was updated in section 7.4.7 to include
ramp down, ramp up, and mode input. The OP command
was added in section 7.4.8.
7.4.7, 7.4.8
11/14/11 1st Edition - rev A Contact Rating changed from 1 amp, 24 VDC to 24 VDC,
1 amp max.
5.1.1, 8.1.2

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Table of Contents
SAFETY PRECAUTIONS ......................................................................................................................... I
REVISIONS TO THIS MANUAL ............................................................................................................... II
REVISION DATE................................................................................................................................................................. II
TABLE OF REVISIONS...................................................................................................................................................... II
TABLE OF CONTENTS ..........................................................................................................................IV
TABLE OF FIGURES..............................................................................................................................IX
PREFACE............................................................................................................................................... XII
PURPOSE OF THIS MANUAL ........................................................................................................................................XII
WHO SHOULD USE THIS MANUAL.............................................................................................................................XII
MANUAL ORGANIZATION ............................................................................................................................................XII
CONVENTIONS USED IN THIS MANUAL ................................................................................................................. XIII
1. INTRODUCTION ................................................................................................................................ 1
1.1 UNPACKING YOUR DSP7000..................................................................................................................................... 1
1.2 NEW FEATURES OF THE DSP7000 ........................................................................................................................... 1
1.3 DATA SHEET................................................................................................................................................................. 2
2. CONTROLS....................................................................................................................................... 10
2.1 FRONT PANEL............................................................................................................................................................ 10
2.2 FRONT PANEL CONTROLS AND BUTTONS......................................................................................................... 10
2.2.1 Enabling Secondary Functions....................................................................................................................... 11
2.2.2 Enabling Saving Function.............................................................................................................................. 11
2.2.3 How to Use Front Panel Controls and Buttons .............................................................................................. 12
2.3 VACUUM FLUORESCENT DISPLAY (VFD)........................................................................................................... 13
2.3.1 Contrast Settings ............................................................................................................................................ 14
2.3.2 Status Display Messages................................................................................................................................ 14
2.4 REAR PANEL .............................................................................................................................................................. 15
2.4.1 Rear Panel Inputs and Outputs....................................................................................................................... 15
2.4.2 Optional IO..................................................................................................................................................... 17
2.4.3 Optional GPIB................................................................................................................................................ 18
2.4.4 Optional RS-232............................................................................................................................................. 18
3. INSTALLATION/CONFIGURATION.................................................................................................. 19
3.1 POWERING UP THE DSP7000 .................................................................................................................................. 19
3.1.1 Self-Test ......................................................................................................................................................... 19
3.1.2 Main Menu..................................................................................................................................................... 20
3.2 INSTRUMENTATION SETUP (TORQUE) ................................................................................................................ 20
3.2.1 Dynamometer Configuration Menu ............................................................................................................... 21
3.2.2 Hysteresis Dynamometer Setup ..................................................................................................................... 22
3.2.3 Hysteresis Dynamometer with Transducer Setup .......................................................................................... 23
3.2.4 Hysteresis Dynamometer with Eddy-Current or Powder Brake Setup.......................................................... 24
3.2.5 Eddy-Current or Powder Brake Dynamometer Setup.................................................................................... 25
3.2.6 Eddy-Current or Powder Brake Dynamometer with Torque Transducer Setup............................................. 27
3.2.7 Two Eddy-Current/Powder Brake Dynamometers (Independent Setup) ....................................................... 28
3.2.8 Two Eddy-Current/Powder Brake Dynamometers (Tandem Setup) .............................................................. 29
3.2.9 Eddy-Current Dynamometer with Powder Brake Dynamometer (Tandem Setup)........................................ 31
3.2.10 In-Line Torque Transducer with Brake .......................................................................................................... 32

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3.3 TORQUE FILTER SETUP........................................................................................................................................... 33
3.4 INSTRUMENTATION SETUP (SPEED).................................................................................................................... 33
3.4.1 TACH A.......................................................................................................................................................... 35
3.4.2 QUAD DEG ................................................................................................................................................... 35
3.4.3 AI 1................................................................................................................................................................. 35
3.5 CONFIGURE COMMUNICATION............................................................................................................................ 36
3.5.1 GPIB Address................................................................................................................................................. 36
3.5.2 RS-232 Interface ............................................................................................................................................ 36
4. PID SETTINGS.................................................................................................................................. 37
4.1 ABOUT THE PID LOOP............................................................................................................................................. 37
4.1.1 P (Proportional Gain) ..................................................................................................................................... 37
4.1.2 I (Integral) ...................................................................................................................................................... 37
4.1.3 D (Derivative)................................................................................................................................................. 37
4.2 SETTING PID VALUES .............................................................................................................................................. 37
4.2.1 How To Set P (Proportional Gain) Value ....................................................................................................... 37
4.2.2 How to Set I (Integral) Value.......................................................................................................................... 37
4.2.3 How to Set D (Derivative) Value.................................................................................................................... 37
4.3 SETTING THE CORRECT PID’S FOR YOUR MOTOR .......................................................................................... 38
4.3.1 Setting the PID with an Unknown Motor or System ..................................................................................... 38
4.3.2 Setting the PID for Torque Control ................................................................................................................ 38
4.3.3 Setting the PID for Speed Control ................................................................................................................. 41
4.3.4 Setting the PID for Ramp Down .................................................................................................................... 43
5. ALARM SYSTEM.............................................................................................................................. 45
5.1 GENERAL INFORMATION ....................................................................................................................................... 45
5.1.1 Alarm Relay (IO Card Option) ...................................................................................................................... 45
5.1.2 Alarm Operation............................................................................................................................................. 46
5.1.3 Alarm Priority ................................................................................................................................................ 47
5.2 POWER ALARM ......................................................................................................................................................... 47
5.2.1 Instructions for Power Alarm Setup ............................................................................................................... 47
5.2.2 Power Alarm Action....................................................................................................................................... 47
5.2.3 To Reset Power Alarm.................................................................................................................................... 48
5.3 GLOBAL POWER ALARM........................................................................................................................................ 48
5.3.1 Instructions for Global Power Alarm Setup ................................................................................................... 48
5.3.2 Global Power Action ...................................................................................................................................... 49
5.3.3 to reset global power alarm ............................................................................................................................ 49
5.4 MAXIMUM SPEED ALARM .................................................................................................................................... 49
5.4.1 Instructions for Maximum Speed Alarm Setup.............................................................................................. 49
5.4.2 Maximum Speed Alarm Action...................................................................................................................... 50
5.4.3 To Reset Maximum Speed Alarm .................................................................................................................. 50
5.5 MAXIMUM TORQUE ALARM ................................................................................................................................ 50
5.5.1 Instructions for Maximum Torque Alarm Setup ............................................................................................ 50
5.5.2 Maximum Torque Alarm Action .................................................................................................................... 51
5.5.3 To Reset Maximum Torque Alarm................................................................................................................. 51
5.6 GLOBAL TORQUE ALARM...................................................................................................................................... 52
5.6.1 Instructions for Global Torque Alarm Setup .................................................................................................. 52
5.6.2 Global Torque Action ..................................................................................................................................... 52
5.6.3 To Reset Global Torque Alarm....................................................................................................................... 52

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5.7 AIR FLOW ALARM.................................................................................................................................................... 52
5.7.1 Instructions for Air Flow Alarm Setup........................................................................................................... 52
5.7.2 Air Flow Alarm Action................................................................................................................................... 53
5.7.3 To Reset Air Flow Alarm ............................................................................................................................... 53
5.8 WATER FLOW ALARM ............................................................................................................................................. 54
5.8.1 Instructions for Water Flow Alarm Setup....................................................................................................... 54
5.8.2 Water Flow Alarm Action .............................................................................................................................. 54
5.8.3 To Reset Water Flow Alarm ........................................................................................................................... 54
5.9 EXTERNAL ALARM (I/O CARD OPTION) ............................................................................................................. 55
5.9.1 Instructions for External Alarm Setup............................................................................................................ 55
5.9.2 External Alarm Action.................................................................................................................................... 55
5.9.3 To Reset External Alarm ................................................................................................................................ 55
5.10TEMPERATURE ALARM (WB/PB ONLY) .............................................................................................................. 56
5.10.1 Instructions for Temperature Alarm Setup..................................................................................................... 56
5.10.2 Temperature Alarm Action............................................................................................................................. 56
5.10.3 To Reset Temperature Alarm.......................................................................................................................... 56
5.11ELECTRICAL ALARM .............................................................................................................................................. 56
5.11.1 Instructions for Electrical Alarm Setup.......................................................................................................... 56
5.11.2 Electrical Alarm Action.................................................................................................................................. 56
5.11.3 To Reset Electrical Alarm .............................................................................................................................. 57
5.12CLUTCH ALARM (WB/PB ONLY) ........................................................................................................................... 57
5.12.1 Clutch Alarm Action ...................................................................................................................................... 57
5.12.2 To Reset Clutch alarm.................................................................................................................................... 57
6. MANUALLY CONTROLLED OPERATION ....................................................................................... 58
6.1 HOW TO SET DESIRED POWER UNITS ................................................................................................................ 58
6.2 HOW TO SET DESIRED TORQUE UNITS .............................................................................................................. 58
6.3 HOW TO SET TORQUE CONTROL.......................................................................................................................... 59
6.4 HOW TO SET SPEED CONTROL ............................................................................................................................. 60
6.5 HOW TO SET OPEN LOOP CONTROL.................................................................................................................... 61
6.6 HOW TO SET PRELOAD CONTROL ....................................................................................................................... 61
6.7 HOW TO SET AND RESET TARE FUNCTION........................................................................................................ 62
6.7.1 Setting the Tare Function ............................................................................................................................... 62
6.7.2 Resetting the Tare Function............................................................................................................................ 62
6.8 HOW TO SET THE TM/TF INVERT FLAG .............................................................................................................. 63
7. COMPUTER CONTROLLED OPERATION ...................................................................................... 64
7.1 ABOUT THE USB INTERFACE ................................................................................................................................ 64
7.1.1 USB Driver Setup for Windows Operation System ....................................................................................... 64
7.1.2 Checking the DSP7000-To-PC Connection for GPIB Setup ......................................................................... 70
7.2 DATA FORMAT........................................................................................................................................................... 71
7.2.1 Output Data (OD)........................................................................................................................................... 71
7.2.2 Output Binary Command (OB)...................................................................................................................... 72
7.3 PROGRAMMING ....................................................................................................................................................... 73
7.3.1 Data Termination Characters.......................................................................................................................... 73
7.3.2 Timeout .......................................................................................................................................................... 74
7.4 DSP7000 COMMAND SET ........................................................................................................................................ 74
7.4.1 Alarm Commands .......................................................................................................................................... 75
7.4.2 Communication Commands........................................................................................................................... 76
7.4.3 Ramp Commands........................................................................................................................................... 77

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7.4.4 Setup Commands ........................................................................................................................................... 78
7.4.5 Speed Commands........................................................................................................................................... 79
7.4.6 Torque Commands ......................................................................................................................................... 81
7.4.7 Miscellaneous Commands ............................................................................................................................. 82
7.4.8 Quadrature Commands................................................................................................................................... 83
7.5 6001 MODE ................................................................................................................................................................. 84
8. OPTIONAL EQUIPMENT.................................................................................................................. 85
8.1 I/O CARD 1 AND I/O CARD 2................................................................................................................................... 85
8.1.1 I/O Card Installation....................................................................................................................................... 85
8.1.2 I/O Card Interface .......................................................................................................................................... 87
8.1.3 I/O Card Configuration .................................................................................................................................. 89
8.1.4 I/O Card 1/Card 2 Command Set................................................................................................................... 92
8.2 GPIB INTERFACE ...................................................................................................................................................... 93
8.2.1 GPIB Card Installation................................................................................................................................... 93
8.2.2 About the GPIB Interface............................................................................................................................... 94
8.2.3 Installing the GPIB (IEEE-488) Connector Cable......................................................................................... 95
8.2.4 Changing the GPIB Primary Address ............................................................................................................ 95
8.3 RS232 INTERFACE..................................................................................................................................................... 96
8.3.1 RS-232 Installation......................................................................................................................................... 96
8.3.2 Connection ..................................................................................................................................................... 97
8.3.3 Communication Parameters ........................................................................................................................... 98
8.3.4 Baud Rate....................................................................................................................................................... 98
8.4 CHECKING THE DSP7000-TO-PC CONNECTION................................................................................................. 98
8.4.1 GPIB Communication check.......................................................................................................................... 98
8.4.2 RS232 Communication Check..................................................................................................................... 101
9. CALIBRATION ................................................................................................................................ 107
9.1 CLOSED-BOX CALIBRATION ............................................................................................................................... 107
9.2 CALIBRATION SCHEDULE.................................................................................................................................... 107
9.3 BASIC CALIBRATION PROCESS........................................................................................................................... 107
9.3.1 Initial Calibration Procedure........................................................................................................................ 107
9.3.2 Calibration of Analog to Digital Converters ................................................................................................ 108
9.3.3 Calibration of Digital to Analog Converters ................................................................................................ 109
9.3.4 Calibration Frequency.................................................................................................................................. 111
10. THEORY ........................................................................................................................................ 112
10.1HOW THE PID LOOP WORKS................................................................................................................................ 112
10.1.1 Scale Factors for Hysteresis, Eddy-Current and Powder Brake Dynamometers ......................................... 112
10.1.2 Speed Correction for WB (Eddy-Current Brake) Dynamometer................................................................. 112
10.1.3 Equations...................................................................................................................................................... 113
10.2ADDITIONAL SCALE FACTOR ............................................................................................................................. 113
10.2.1 How To Set Additional Scale Factor ............................................................................................................ 113
10.3FILTER PARAMETERS ........................................................................................................................................... 114
11. TROUBLESHOOTING................................................................................................................... 115
APPENDIX A: INERTIA CORRECTION ............................................................................................. 116
A.1 INERTIAL EFFECT ON MOTOR TEST DATA....................................................................................................... 116
A.2 PROCEDURE FOR INERTIA CORRECTION ........................................................................................................ 116
A.2.1 Key Conditions............................................................................................................................................. 117

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APPENDIX B: FRONT PANEL/DISPLAY MENU FLOW CHARTS ..................................................... 118
B.1 PRIMARY KEY FUNCTIONS.................................................................................................................................. 118
B.2 SECONDARY KEY FUNCTIONS ........................................................................................................................... 119
B.2.1 Display Both................................................................................................................................................. 119
B.2.2 Setup............................................................................................................................................................. 119
B.2.3 Power Units .................................................................................................................................................. 124
B.2.4 Torque Units................................................................................................................................................. 125
B.2.5 Max Speed.................................................................................................................................................... 125
B.2.6 Scale P.......................................................................................................................................................... 126
B.2.7 Scale I........................................................................................................................................................... 127
B.2.8 Scale D ......................................................................................................................................................... 128
B.3 TEST INSTRUMENT SETUP................................................................................................................................... 129
B.3.1 Hysteresis Dynamometer Setup Menu......................................................................................................... 129
B.3.2 Eddy-Curennt Dynamometer Setup Menu................................................................................................... 130
B.3.3 Powder Brake Dynamometer Setup Menu................................................................................................... 131
B.3.4 Torque Transducer/Torque Flange Sensor Setup Menu ............................................................................... 132
B.3.5 HD5 Setup Menu.......................................................................................................................................... 133
B.3.6 Eddy-Current Dynamometer with Eddy-Current Dynamometer (Tandem Setup) ...................................... 134
B.3.6 Powder Brake Dynamometer with Powder Brake Dynamometer (Tandem Setup) ..................................... 135
B.3.7 Eddy-Current Dynamometer with Powder Brake Dynamometer (Tandem Setup)...................................... 136
APPENDIX C: SCHEMATICS .............................................................................................................. 137
C.1 DSP7000 CORE BLOCK........................................................................................................................................... 137
C.2 DSP7000 ANALOG INPUTS .................................................................................................................................... 138
C.3 DSP7000 DIGITAL INPUTS..................................................................................................................................... 139
C.4 DSP7000 ENCODER IN............................................................................................................................................ 140
C.5 DSP7000 ANALOG OUTPUT................................................................................................................................... 141
C.6 DSP7000 DIGITAL OUTPUT ................................................................................................................................... 142
APPENDIX D: ADDITIONAL SCALE FACTOR TABLE ...................................................................... 143
SERVICE INFORMATION.................................................................................................................... 144
RETURNING MAGTROL EQUIPMENT FOR REPAIR AND/OR CALIBRATION .................................................... 144
Returning Equipment to Magtrol, Inc. (United States) .............................................................................................. 144
Returning Equipment to Magtrol SA (Switzerland)................................................................................................... 144