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

ii
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

iii
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

iv
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

viii
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

ix
Table of Figures
2. CONTROLS
Figure 2–1 Front Panel ............................................................................................................................................10
Figure 2–2 Secondary Function Menu......................................................................................................................11
Figure 2–3 Saving Function Menu............................................................................................................................11
Figure 2–4 DSP7001 Rear Panel..............................................................................................................................15
Figure 2–5 DSP7002 Rear Panel..............................................................................................................................15
Figure 2–6 Dynamometer Brake Output...................................................................................................................15
Figure 2–7 TSC1/TSC2 Connector ...........................................................................................................................16
Figure 2–8 Supply 1/Supply 2 Connector .................................................................................................................16
Figure 2–9 USB Connector.......................................................................................................................................16
Figure 2–10 I/O Interface Card 1 and Card 2 ..........................................................................................................17
Figure 2–11 GPIB Interface .....................................................................................................................................18
Figure 2–12 RS-232 Interface...................................................................................................................................18
3. INSTALLATION/CONFIGURATION
Figure 3–1 Program Download Display...................................................................................................................19
Figure 3–2 Revision Display.....................................................................................................................................19
Figure 3-3 Alarm Warning Display...........................................................................................................................19
Figure 3–4 Main Menu .............................................................................................................................................20
Figure 3–5 Setup Menu ............................................................................................................................................21
Figure 3-6 Dyno Setup Menu....................................................................................................................................21
Figure 3–7 Dynamometer Configuration Menu.........................................................................................................21
Figure 3–8 Hysteresis Dynamometer Setup..............................................................................................................22
Figure 3–9 Hysteresis Setup Menu ...........................................................................................................................22
Figure 3–10 Hysteresis Dynamometer with Torque Transducer Setup.....................................................................23
Figure 3–11 Torque Transducer Setup Menu............................................................................................................23
Figure 3–12 Hysteresis Dynamometer with Eddy-Current or Powder Brake Setup.................................................24
Figure 3–13 TSC2 Eddy-Current Setup Menu ..........................................................................................................24
Figure 3–14 TSC2 Powder Brake Setup Menu..........................................................................................................25
Figure 3–15 Eddy-Current or Powder Brake Dynamometer Setup ..........................................................................25
Figure 3–16 TSC1 Eddy-Current Setup Menu ..........................................................................................................26
Figure 3-17 TSC1 Powder Brake Setup Menu ..........................................................................................................26
Figure 3–18 Eddy-Current or Powder Brake Dynamometer with Torque Transducer Setup ...................................27
Figure 3-19 TSC2 torque transducer setup menu .....................................................................................................27
Figure 3–20 Two Eddy-Current/Powder Brake Dynamometers (Independent Setup) ..............................................28
Figure 3-21 Tandem Setup Menu ..............................................................................................................................28
Figure 3–22 Tandem Configuration Menu ................................................................................................................29
Figure 3–22 Two Eddy-Current/Powder Brake Dynamometers (Tandem Setup) .....................................................29
Figure 3–23 Eddy-Current Dynamometer with Powder Brake Dynamometer (Tandem Setup) ...............................31
Figure 3–24 Maximum Speed Excited Menu ............................................................................................................32
Figure 3-25 In-Line Torque Transducer with Brake .................................................................................................32
Figure 3–26 TSC1 Setup Menu .................................................................................................................................33
Figure 3–27 RPM vs PPR Chart...............................................................................................................................34
Figure 3–28 Encoder Menu ......................................................................................................................................35
Figure 3–29 QUAD DEG Menu................................................................................................................................35
Figure 3–30 AI 1 Menu .............................................................................................................................................36
Figure 3–31 System Setup Menu................................................................................................................................36

x
4. PID SETTINGS
Figure 4–1 Open Loop Control Menu.......................................................................................................................38
Figure 4–2 Initial P Setting for Torque Control at 25% ...........................................................................................39
Figure 4–3 High Initial P Setting for Torque Control .............................................................................................39
Figure 4–4 Initial I Setting for Torque Control.........................................................................................................40
Figure 4–5 Initial D Setting for Torque Control .......................................................................................................40
Figure 4–6 Initial P Setting for Speed Control at 25%..............................................................................................41
Figure 4–7 Initial I Setting for Speed Control ..........................................................................................................42
Figure 4–8 Initial D Setting for Speed Control.........................................................................................................42
Figure 4–9 Ramp Down Low I..................................................................................................................................43
Figure 4–10 Ramp Down High I...............................................................................................................................44
Figure 4–11 Ramp Down Dynamic I ........................................................................................................................44
5. ALARM SYSTEM
Figure 5–1 Normal Condition “Energized Relay” ...................................................................................................45
Figure 5–2 Alarm Condition “De-Energized Relay” ...............................................................................................45
Figure 5–3 Typical Application.................................................................................................................................46
Figure 5–4 Alarm Enable/Disable Menu ..................................................................................................................46
Figure 5–5 Max Power Menu....................................................................................................................................47
Figure 5–6 Power -OL- Display................................................................................................................................48
Figure 5–7 Power Alarm Display .............................................................................................................................48
Figure 5–8 Global Power Alarm Setup.....................................................................................................................48
Figure 5–9 Global Power Alarm Disply ...................................................................................................................49
Figure 5–10 Speed Alarm Setup Menu......................................................................................................................49
Figure 5–11 -OL- Speed Alarm Display ...................................................................................................................50
Figure 5–12 Over Speed Alarm Message Display ....................................................................................................50
Figure 5–13 Torque Alarm Setup Menu ....................................................................................................................51
Figure 5–14 -OL- Torque Alarm Display..................................................................................................................51
Figure 5–15 Over Torque Alarm Message Display...................................................................................................51
Figure 5 –16 Global Torque Alarm Setup .................................................................................................................52
Figure 5–17 Air Flow Alarm Setup Display .............................................................................................................53
Figure 5–18 Air Flow Alarm Message Display ........................................................................................................53
Figure 5–19 Water Flow Alarm Setup Display .........................................................................................................54
Figure 5–20 Water Flow Alarm Message Display ....................................................................................................54
Figure 5–21 External Alarm Setup Display ..............................................................................................................55
Figure 5–22 External Alarm Message Display.........................................................................................................55
Figure 5–23 Temperature Alarm Message Display...................................................................................................56
Figure 5–24 Electrical Alarm Message Display.......................................................................................................57
Figure 5–25 Clutch Alarm Message Display ............................................................................................................57
6. MANUALLY CONTROLLED OPERATION
Figure 6–1 Power Units Menu ..................................................................................................................................58
Figure 6–2 Torque Units Menu .................................................................................................................................58
Figure 6–3 Torque Control Menu..............................................................................................................................59
Figure 6–4 Max Speed Menu ....................................................................................................................................60
Figure 6–5 Preload Function enabled ......................................................................................................................61
Figure 6–6 Tare function enabled ............................................................................................................................62
Figure 6–7 Torque Invert Flag Screen ......................................................................................................................63
7. COMPUTER CONTROLLED OPERATION
Figure 7–1 Setup Menu.............................................................................................................................................84
Figure 7–2 System Setup Menu.................................................................................................................................84

xi
8. OPTIONAL EQUIPMENT
Figure 8–1 DSP7000 Top Cover ...............................................................................................................................86
Figure 8–2 IO Card Installation ...............................................................................................................................86
Figure 8–3 I/O Card Interface ..................................................................................................................................87
Figure 8–4 Filter Channel Setup Menu.....................................................................................................................90
Figure 8-5 Offset and Gain Setup Menu ...................................................................................................................90
Figure 8–6 External Alarm Setup .............................................................................................................................90
Figure 8–7 Alarm Contact Setup...............................................................................................................................90
Figure 8–8 Torque/Speed Setup ................................................................................................................................91
Figure 8–9 Torque/Speed DAC Setup Menu..............................................................................................................91
Figure 8–10 GPIB Card Installation ........................................................................................................................94
Figure 8–11 GPIB Installation ................................................................................................................................95
Figure 8–12 Setup Menu Display...............................................................................................................................95
Figure 8–13 RS-232 Interface...................................................................................................................................96
Figure 8–15 Straight Through Pin-to-Pin Cable Connection...................................................................................97
Figure 8–18 Connected Instruments Window .........................................................................................................100
Figure 8–19 Communication with Instrument Window ..........................................................................................100
Figure 8–20 Query Window ....................................................................................................................................101
Figrue 8–21 Tera Term Setup Window ....................................................................................................................101
Figure 8–22 Tera Term Licence Agreement Window...............................................................................................102
Figure 8–23 Tera Term Destination Location Window ...........................................................................................102
Figure 8–24 Tera Term Select Components Window...............................................................................................103
Figure 8–25 Tera Term Language Selection Window..............................................................................................103
Figure 8–26 Tera Term Start Menu Folder Window................................................................................................104
Figure 8–27 Tera Term Additional Tasks Window...................................................................................................104
Figure 8–28 Tera Term Window ..............................................................................................................................105
Figure 8–29 Terminal Setup Window ......................................................................................................................105
Figure 8–30 Serial Port Setup Window ...................................................................................................................106
Figure 8–31 Tera Term Window with a Command..................................................................................................106
10. THEORY
Figure 10–1 System Block Diagram........................................................................................................................112
Figure 10–2 Transposed Direct Form II Architecture.............................................................................................114

xii
Preface
PURPOSE OF THIS MANUAL
This manual contains all the information required for the installation and general use of the Model
DSP7000 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 DSP7000
Dynamometer Controller in conjunction with any Magtrol Hysteresis, Eddy-Current or Powder
Brake Dynamometer, Magtrol In-Line Torque Transducer 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 DSP7000 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/CONFIGURATION - Provides setup options available with the
DSP7000 Dynamometer Controller. Illustrates and outlines the hardware connection
setup and software configurations for each option.
Chapter 4: PID SETTINGS - Describes the Proportional Integral Derivative (PID) Loop and
provides information on theory, setup and use.
Chapter 5: ALARM SYSTEM - Describes the new built-in alarm feature providing the user
with information on how each different alarm operates along with instructions for
setup and use.
Chapter 6: MANUALLY CONTROLLED OPERATION - How to run a test when the DSP7000
is used as a stand-alone unit. Includes information on setting power and torque
units, torque and speed control and open loop control.
Chapter 7: COMPUTER CONTROLLED OPERATION - How to run a test when the DSP7000
is used with a PC. Includes information on data format, programming and command
set.
Chapter 8: OPTIONAL EQUIPMENT - Information on the optional I/O cards, GPIB Interface,
RS-232 Interface,
Chapter 9: CALIBRATION - Provides recommended calibration schedules along with step-
by-step instructions for the calibration procedure.

xiii
Magtrol Model DSP7000 Dynamometer Controller Preface
Chapter 10: THEORY
Chapter 11: TROUBLESHOOTING - Solutions to common problems encountered during setup
and testing.
Appendix A: INERTIA CORRECTION - Describes the inertial effect on motor test data providing
solutions for correction.
Appendix B: FRONT PANEL/DISPLAY MENU FLOW CHARTS - A visual display of various
setup procedures.
Appendix C: SCHEMATICS - For Encoder/Switch Board, Power Supply, DSP & Memory and
Analog I/O.
Appendix D: ADDITIONAL SCALE FACTOR TABLE - Provides additional scale factor values
based on test instrument selection.
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 PARTIES MAY BE PUT
AT RISK. THE READER MUST ABSOLUTELY TAKE NOTE
OF THE ACCOMPANYING TEXT, AND ACT UPON IT,
BEFORE PROCEEDING FURTHER.

1
GENERAL
INFORMATION
Calibration Certificate
1. Introduction
1.2 NEW FEATURES OF THE DSP7000
Magtrol’s new Model DSP7000 Dynamometer Controller is an upgraded version of the DSP6001,
providing superior motor testing capabilities by using state-of-the-art digital signal processing
technology. Designed for use with any Magtrol Hysteresis, Eddy-Current or Powder Brake
Dynamometer, Magtrol In-Line Torque Transducer or auxiliary instrumentation, the DSP7000 both
controls the dynamometer and provides digital readouts on the front panel. The features that make
the DSP7000 unique include:
• TwoChannels-Enablesunittosupportacombinationofuptotwotestinginstrumentswith
independent or tandem configurations.
• Built-InAlarm System - To caution the user when problems occur, there are automatic
electrical and temperature alarms programmed into the unit. Also inherent to the unit are
optional power, speed, torque, air flow, water flow and external input alarms that become
active when enabled by the user.
• Torque/SpeedAnalogOutputs-Abletointerfacewithadataacquisitionsystem
• DigitalFilter-Removesundesirednoisefromtorquesignals.
• Saving-Allowsusertosaveprogrammedvalueswithintheircongurations.
1.1 UNPACKING YOUR DSP7000
Your DSP7000 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 DSP7000.
2. Inspect the DSP7000 for any evidence of damage in shipping.
3. Make sure the carton contains the following:
DSP7000 Dynamometer Controller
Line cord
Magtrol User Manual CD-Rom
USB Cord

2
Magtrol Model DSP7000 Dynamometer ControllerChapter 1 – Introduction
GENERAL
INFORMATION
1.3 DATA SHEET
DSP7000
Data Sheet
DSP7000SeriesHigh-SpeedProgrammable
Dynamometer Controllers
1
www.magtrol.com
MAGTROL
FEATURES
• DSP7001 Single Channel:Lowcostandeasytouse
• DSP7002 Dual Channel:Enablesthesupportof
twotestinginstrumentswithindependentortandem
configurationsandtwofullyindependentcontrolloops
• Built-in Alarm System: Forpower,speed,torque,
temperature,airflow,waterflow,electricaloverload
andexternalinputs
• High Speed Data Acquisition:Upto500torqueand
speedpointspersecondofbothchannelswithtime
stamp
• High Quality, Easy-to-Read Vacuum Fluorescent
Readout: Displaystorque,speed,power,auxiliaryand
PID(proportionalgain,integralandderivative)values
• Fast Full-Curve Data Acquisition:Free-runto
lockedrotorinseconds
• Speed & Torque Operating Modes:PIDsettingsfor
exceptionaldynamometercontrol
• Programmable Digital PID Values:Controlledand
storedviaM-TestSoftwareorcontrolledmanually
• Built-in Current-Regulated Supply: Forusewith
HysteresisDynamometerorbrakesupto1amp
• Adjustable Torque Units:English,MetricandSIare
standard
• Digital Filter: Removesundesirednoisefromtorque
signals
• Saving:Currentlyusedconfigurationcanbesavedand
recalledatpowerup
• Single or Multi-point Torque and Speed Stabilized
Testing: ViaM-TEST7.0Software
• ClosedBoxCalibration
• Rack Mounting:19"(482.6mm)withhandles
• Backwards Compatible:Compatiblewiththe
DSP6001(inDSP6001mode)
• HD5 dynamometers: Supported
• USB: Standard
• Low RPM:calculationfromangle(quadraturesignal)
andtimedesignedtocaptureRPM’saslowas.001
RPM
• Position Measurement:Twoquadraturedecoders
OPTIONS
• Interfaces:RS-232andIEEE-488
• I/Ocardaccessibleprogrammatically(LabVIEW™,
VisualC)
DESCRIPTION
Magtrol’sModelDSP7000HighSpeedProgrammable
DynamometerControlleremploysstate-of-the-artDigital
SignalProcessingTechnologytoprovidesuperiormotortesting
capabilities.DesignedforusewithanyMagtrolHysteresis,
Eddy-CurrentorPowderDynamometer,MagtrolIn-Line
TorqueTransducerorauxiliaryinstrumentation,theDSP7000
canprovidecompletePCcontrolviatheUSBoroptional
IEEE-488orRS-232interface.Withupto500readingsper
second,theDSP7000isideallysuitedforboththetestlaband
theproductionline.
APPLICATIONS
Inthelaboratory,theDSP7000’shighsamplerateprovides
superior resolution for data acquisition and curve plotting.
Thisallowsforcapturingmoreusablemotortestdataduring
switching,breakdownandothertransitionalareasofthe
motor test curve. For production and incoming inspection,
theDSP7000displaystorque,speedandpoweratalltimes,
allowingtheControllertobeusedasamanualstandalone
unitoraspartofacompletePCsystem.
MOTOR TESTING SOFTWARE
Magtrol’sM-TEST7Software(sold separately)isastate-
of-the-artmotortestingprogramforWindows®-baseddata
acquisition.UsedwiththeMagtrolDSP7000Controller,
MagtrolM-TEST 7 Softwareprovidesthecontrolofany
MagtrolDynamometerandrunstestsequencesinamanner
bestsuitedtotheoverallaccuracyandefficiencyoftheMagtrol
MotorTestSystem.ThedatathatisgeneratedbyMagtrol’s
MotorTestingSoftwarecanbestored,displayedandprinted
intabularorgraphicformats,andcanbeeasilyimportedinto
aspreadsheet.
WritteninLabVIEW™,M-TEST7hastheflexibilitytotest
amajorityofmotortypesinavarietyofways.Becauseof
LabVIEW’sversatility,obtainingdatafromothersources(e.g.
thermocouples),controllingmotorpowerandprovidingaudio/
visualindicatorsisrelativelyeasy.
Magtrol’sM-TEST7Softwareisidealforsimulatingloads,
cyclingtheunitundertestandmotorramping.Becauseitis
easytogatherdataandduplicatetests,thesoftwareisideal
foruseinengineeringlabs,productiontestingandincoming/
outgoinginspection.
DSP7001 - single channel
DSP7002 - dual channel

3
Magtrol Model DSP7000 Dynamometer Controller Chapter 1 – Introduction
GENERAL
INFORMATION
2
DSP7000
MAGTROL
Specifications
MEASUREMENT CHARACTERISTICS
Maximum Torque 99,999 units
Maximum Speed 199,999 rpm
Accuracy
Speed: 0.01% of reading from 5 rpm to 200,000 rpm
Torque: 2 volt range ± 0.05% of range (±1 mV)
(used on all HD Series other than HD5 Series)
10 volt range ± 0.05% of range (±5 mV)
(used on all except HD Series)
ELECTRICAL CHARACTERISTICS
Voltage Requirements 85-264 VAC 50/60 Hz
Power Requirements 210 VA
Fuses (5 × 20 mm) Brake: IEC 1.25 A 250 V T
Main Power: IEC 2.5 A 250 V T
Max. Compliance Voltage 48 V DC, Brake Output
Max. Brake Output
Current 1 Amp, Calibrated that 100% OL = 1 Amp
TSC1 and TSC2 User
Power Supplies
24 Volt DC 450 mA (power supply fault protected)
5 Volt DC 200 mA (internal fuse at 500 mA)
ENVIRONMENT
Operating Temperature 5 ºC to 40 ºC
Relative Humidity < 80%
Temperature Coefficient 0.004% of range/°C of 5 V DC for both channels
DIMENSIONS
Width 19.0 in 483 mm
Height 3.5 in 89 mm
Depth
with handles
12.4 in
13.8 in
315 mm
351 mm
Weight 15.2 lb 6.9 kg
sPecIFIcatIONs
OPtIONal equIPMeNt
COMMUNICATIONS
RS-232 Interface
TheRS-232Interfaceprovidesbackwardscompatibilityfor
oldersystems.300,600,1200,2400,4800,9600,19200and
115200Baudratesaresupported.
GPIB IEEE-488 Interface
TheGPIBIEEE-488InterfaceprovidesstandardGPIB
communications.
Optionalequipmentmaybefactoryinstalledorpurchasedseparatelyanduserinstalled.
I/O CARD
• Torque/SpeedAnalogOutputs:Forinterfacewitha
dataacquistionsystem
• AnalogSignalsuchastachometercanberoutedtoPID
loop
• Externalalarminput
• Alarmrelaycontacts
• 2Relays
• 3Digitalinputs
• 2Digitaloutputs
• 2Analoginputs
• 2Analogoutputs
• 5Voltsavailabletouserfusedat500mA.Nominal200
mA
• AllI/OdatacanbeaccessedbyLabVIEW™

4
Magtrol Model DSP7000 Dynamometer ControllerChapter 1 – Introduction
GENERAL
INFORMATION
3
DSP7000
MAGTROL
rear PaNels
Specifications
FrONt PaNel
DSP7001 Rear Panel
For use with any Magtrol Dynamometer
(Hysteresis, Eddy-Current, Powder Brake),
Magtrol Torque Transducer
••
Connector for Model
DES Power Supplies
(for WB/PB and HD 825 Dynamometers only)
USB (standard) and Optional
GPIB/IEEE-488 Interface
or RS-232 Interface for
Connection to PC
(GPIB Shown)
•
•
•
Optional I/O Card
DSP7002 Rear Panel
For use with any Magtrol Dynamometer
(Hysteresis, Eddy-Current, Powder Brake),
Magtrol Torque Transducer
•
•
Connectors for Models
DES Power Supplies
(for WB/PB and HD 825 Dynamometers only)
•
•
Optional I/O Card 1 and I/O Card 2
• •
USB (standard) and Optional
GPIB/IEEE-488 Interface
or RS-232 Interface for
Connection to PC
(GPIB Shown)
•
•
Ready for Rack Mounting
•
Displays Torque, Speed, Power
and PID Values
•
• • • • • • •
Setup Menu/Open Loop Mode
Set Desired Power
Units/Brake on/off
Set Desired Torque Units/Set Point Torque
Speed Control/
Set Point Speed PID Scale/Adjustable PID
(Proportional Gain,
Integral and Derivative)
•
Select Display Format
• •
Tare
Reset Tare

5
Magtrol Model DSP7000 Dynamometer Controller Chapter 1 – Introduction
GENERAL
INFORMATION
4
DSP7000
MAGTROL
System Configurations
DSP7002 Connected to Hysteresis Dynamometer with In-Line Torque Transducer
Motor
Under
Test
TM Torque Transducer
AC Mains
Hysteresis Dynamometer (HD)
DSP 7002
DYNAMOMETER
CONTROLLER
No Connection
USB
PC
M-TEST
AC Mains
Motor
Under
Test
Hysteresis Dynamometer (HD)
DSP 7001
DYNAMOMETER
CONTROLLER
USB
PC
M-TEST
No Connection
DSP7001 Connected to Hysteresis Dynamometer
Torque Transducer
(TM)
DES Power Supply
Hysteresis
Brake
(<1 Amp)
Hysteresis Brake
(<5 Amp)/
Eddy-Current/
Powder Brake
OR
DSP 7001
DYNAMOMETER
CONTROLLER
USB
M-TEST
PC
DSP7001 Connected to a Hysteresis or Eddy-Current/Powder Brake with In-Line Torque Transducer