Magtrol 6510e User manual

User’s Manual
Model 6510e
Single-Phase
Power Analyzer
Via Paolo Uccello 4 - 20148 Milano
Tel [phone] Fax [phone] [email protected] www.dspmindustria.it

Preliminary Manual, Rev. F – November 2005
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 ©2001-2005 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.
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: _____________________________

i
1. Make sure that all Magtrol dynamometers and electronic products are earth-grounded, to ensure
personal safety and proper operation.
2. Securely ground the 6510ePowerAnalyzer case by connecting a good earth ground at the ground
stud located on the rear panel of the unit. Use a number 12 AWG, or larger wire.
3. Check line voltage before operating.
4. 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
Preliminary Manual, Revision F – November 2005
TABLE OF REVISIONS
Revisions To This Manual
Date Edition Change Section(s)
11/03/05 Preliminary Manual,
Rev. F
Corrected time it takes for a new input to fully average
(0.07323388 ms –> 73.23388 ms).
4.2.1.2 &
4.2.2.2
11/03/05 Preliminary Manual,
Rev. F
Updated crest factor and display range ratings. 1.3
08/10/05 Preliminary Manual,
Rev. E
External sensor input maximum voltage from ±10 V to ±1 V AC/
DC
1.3, 2.5
09/30/03 Preliminary Manual,
Rev. D
Correction: Line voltage - no setup required. 3.1.1
06/19/03 Preliminary Manual,
Rev. C
Added conguration commands IS and IC to start/clear average
mode.
5.6.1
06/19/03 Preliminary Manual,
Rev. C
Added data output command OAVE to retrieve displayed
values.
5.6.2
06/19/02 Preliminary Manual,
Rev. B
Added analog output option information to data sheet. 1.3
05/20/02 Preliminary Manual,
Rev. A
Changed mV/A to A/mV in External Sensor Scale Factor Setup
Menu graphic
3.3.3.2
05/20/02 Preliminary Manual,
Rev. A
Updated units and value range of SE1m2<terminator>
command code
5.6.1

iii
Table of Contents
SAFETY PRECAUTIONS .........................................................................................................................I
REVISIONS TO THIS MANUAL ...............................................................................................................II
REVISION DATE.................................................................................................................................................................II
TABLE OF REVISIONS......................................................................................................................................................II
TABLE OF CONTENTS ..........................................................................................................................III
TABLE OF FIGURES........................................................................................................................................................VI
PREFACE.............................................................................................................................................. VII
PURPOSE OF THIS MANUAL .......................................................................................................................................VII
WHO SHOULD USE THIS MANUAL............................................................................................................................VII
MANUAL ORGANIZATION...........................................................................................................................................VII
CONVENTIONS USED IN THIS MANUAL ................................................................................................................ VIII
1. INTRODUCTION ................................................................................................................................1
1.1 UNPACKING YOUR 6510ePOWER ANALYZER..................................................................................................... 1
1.2 NEW FEATURES OF THE 6510ePOWER ANALYZER ........................................................................................... 1
1.3 DATA SHEET................................................................................................................................................................ 2
2. CONTROLS.........................................................................................................................................5
2.1 FRONT PANEL............................................................................................................................................................. 5
2.2 FRONT PANEL CONTROLS AND BUTTONS.......................................................................................................... 5
2.2.1 ENABLING SECONDARY FUNCTIONS.................................................................................................... 6
2.2.2 USING FRONT PANEL CONTROLS AND BUTTONS .............................................................................. 6
2.3 VACUUM FLUORESCENT DISPLAY (VFD)............................................................................................................ 8
2.3.1 CONTRAST SETTINGS................................................................................................................................ 8
2.3.2 DISPLAY GUIDE........................................................................................................................................... 9
2.4 REAR PANEL............................................................................................................................................................. 10
2.5 REAR PANEL INPUTS AND OUTPUTS.................................................................................................................. 10
3. INSTALLATION/CONFIGURATION..................................................................................................13
3.1 POWERING UP THE 6510e....................................................................................................................................... 13
3.1.1 LINE VOLTAGE ........................................................................................................................................... 13
3.1.2 SELF-TEST................................................................................................................................................... 13
3.1.3 MAIN MENU ............................................................................................................................................... 14
3.2 PROTECTING YOUR 6510e...................................................................................................................................... 15
3.2.1 TRANSIENT OVERLOADS........................................................................................................................ 15
3.2.2 CURRENT OVERLOAD ............................................................................................................................. 15
3.2.3 SURGE PROTECTION ................................................................................................................................ 15
3.2.4 CIRCUIT BREAKERS................................................................................................................................. 16
3.3 TESTING INSTRUMENTATION SETUP ................................................................................................................. 17
3.3.1 WIRING MODE ........................................................................................................................................... 17
3.3.2 MEASUREMENT FILTER .......................................................................................................................... 18
3.3.3 EXTERNAL SENSOR ................................................................................................................................. 19
3.3.4 AMP SCALING............................................................................................................................................ 21
3.3.5 VOLTS SCALING ........................................................................................................................................ 23

iv
Magtrol Model 6510eSingle-Phase Power Analyzer
Table of Contents
3.3.6 PHASE SETUP............................................................................................................................................. 24
3.3.7 SPECIAL FUNCTIONS ............................................................................................................................... 25
4. OPERATING PRINCIPLES ...............................................................................................................27
4.1 ANALOG PROCESSING ........................................................................................................................................... 27
4.1.1 VOLTS .......................................................................................................................................................... 27
4.1.2 AMPS............................................................................................................................................................ 28
4.1.3 EXTERNAL SHUNT ................................................................................................................................... 29
4.2 DIGITAL PROCESSING ............................................................................................................................................ 29
4.2.1 AC DETAILS ................................................................................................................................................ 30
4.2.2 DC DETAILS................................................................................................................................................ 32
4.2.3 ROUND-OFF ERROR ................................................................................................................................. 34
4.3 MEASUREMENT MODES........................................................................................................................................ 34
4.3.1 PEAK ........................................................................................................................................................... 34
4.3.2 PEAK HOLD / INRUSH CURRENT........................................................................................................... 35
4.3.3 DC ................................................................................................................................................................. 35
4.3.4 RMS .............................................................................................................................................................. 36
4.3.5 CREST FACTOR .......................................................................................................................................... 36
4.4 MEASUREMENT METHODS .................................................................................................................................. 36
4.4.1 CYCLE-BY-CYCLE MODE ........................................................................................................................ 36
4.4.2 CONTINUOUS MODE................................................................................................................................ 36
5. COMPUTER CONTROLLED OPERATION ......................................................................................37
5.1 ABOUT THE GPIB INTERFACE .............................................................................................................................. 37
5.1.1 INSTALLING THE GPIB/IEEE-488 CONNECTOR CABLE.................................................................... 37
5.1.2 CHANGING THE GPIB PRIMARY ADDRESS......................................................................................... 37
5.2 ABOUT THE RS-232 INTERFACE........................................................................................................................... 38
5.2.1 CONNECTION............................................................................................................................................. 38
5.2.2 COMMUNICATION PARAMETERS ......................................................................................................... 39
5.2.3 BAUD RATE................................................................................................................................................. 39
5.3 CHECKING THE 6510e-TO-PC CONNECTION ..................................................................................................... 39
5.4 DATA FORMAT.......................................................................................................................................................... 40
5.4.1 OT EXAMPLE ............................................................................................................................................. 40
5.4.2 OE EXAMPLE ............................................................................................................................................. 41
5.4.3 OA/OV/OW/OF EXAMPLE......................................................................................................................... 41
5.5 PROGRAMMING....................................................................................................................................................... 41
5.5.1 DATA TERMINATION CHARACTERS ..................................................................................................... 41
5.6 6510eCOMMUNICATION COMMANDS ............................................................................................................... 42
5.6.1 CONFIGURATION COMMANDS.............................................................................................................. 42
5.6.2 DATA OUTPUT COMMANDS ................................................................................................................... 44
6. CALIBRATION ..................................................................................................................................45
6.1 CLOSED-BOX CALIBRATION ................................................................................................................................ 45
6.2 CALIBRATION SCHEDULE..................................................................................................................................... 45
6.3 CALIBRATION COMMANDS.................................................................................................................................. 45
6.4 BASIC CALIBRATION PROCESS............................................................................................................................ 46
7. OPTIONAL FEATURES ....................................................................................................................48

v
Magtrol Model 6510eSingle-Phase Power Analyzer Table of Contents
7.1 ANALOG OUTPUTS ................................................................................................................................................. 48
7.1.1 SPECIFICATIONS ....................................................................................................................................... 48
7.1.2 CHANNEL ASSIGNMENTS....................................................................................................................... 48
7.1.3 HARDWARE CONNECTION ..................................................................................................................... 49
7.1.4 SOFTWARE CONFIGURATION ................................................................................................................ 49
7.1.5 CALIBRATION ............................................................................................................................................ 50
8. TROUBLESHOOTING.......................................................................................................................52
APPENDIX A: SCHEMATICS ...............................................................................................................53
A.1 MAIN BOARD - DSP, RAM, FLASH........................................................................................................................ 53
A.2 MAIN BOARD - INPUT/OUTPUT, GPIB, RS-232................................................................................................... 54
A.3 MAIN BOARD - FPGA.............................................................................................................................................. 55
A.4 INPUT MODULE - CURRENT ................................................................................................................................. 56
A.5 INPUT MODULE - VOLTAGE .................................................................................................................................. 57
A.6 KEY PAD .................................................................................................................................................................... 58
A.7 ANALOG OUTPUT.................................................................................................................................................... 59
GLOSSARY............................................................................................................................................63
INDEX.....................................................................................................................................................64
SERVICE INFORMATION......................................................................................................................66
RETURNING MAGTROL EQUIPMENT FOR REPAIR AND/OR CALIBRATION ..................................................... 66
RETURNING EQUIPMENT TO MAGTROL, INC. (UNITED STATES)................................................................ 66
RETURNING EQUIPMENT TO MAGTROL SA (SWITZERLAND) ..................................................................... 66

vi
Magtrol Model 6510eSingle-Phase Power Analyzer
Table of Contents
TABLE OF FIGURES
2. CONTROLS
Figure 2–1 Front Panel ..............................................................................................................................................5
Figure 2–2 Secondary Function Menu........................................................................................................................6
Figure 2–3 Device Setup Menu...................................................................................................................................9
Figure 2–4 Rear Panel ..............................................................................................................................................10
Figure 2–5 Input Module ..........................................................................................................................................10
Figure 2–6 RS-232C Interface ..................................................................................................................................11
Figure 2–7 GPIB/IEEE-488 Interface ......................................................................................................................11
3. INSTALLATION/CONFIGURATION
Figure 3–1 Program Download Display...................................................................................................................13
Figure 3–2 Title Display ...........................................................................................................................................13
Figure 3–3 Revision Display.....................................................................................................................................14
Figure 3–4 Phase Main Menu...................................................................................................................................14
Figure 3–5 Custom Main Menu ................................................................................................................................14
Figure 3–6 Transient Voltage Suppression................................................................................................................16
Figure 3–7 Single-Phase, Two-Wire Wiring Schematic.............................................................................................17
Figure 3–8 Single-Phase, Two-Wire Wiring Connection ..........................................................................................17
Figure 3–9 Sensor Substituton Wiring Schematic.....................................................................................................19
Figure 3–10 Sensor Substitution Wiring Connection................................................................................................19
Figure 3–11 External Sensor Scale Factor Setup Menu ...........................................................................................20
Figure 3–12 Current/Potential Transformer Connection..........................................................................................21
Figure 3–13 Amp Scaling Setup Menu......................................................................................................................21
Figure 3–14 Amp/Volt Scaling Activated ..................................................................................................................22
Figure 3–15 Volt Scaling Setup Menu.......................................................................................................................23
Figure 3–16 Cycle-by-Cycle Mode ...........................................................................................................................24
Figure 3–17 Hold Mode............................................................................................................................................25
Figure 3–18 Average Mode .......................................................................................................................................25
Figure 3–19 Peak Hold Clear Display......................................................................................................................26
Figure 3–20 Custom Display ....................................................................................................................................26
4. OPERATING PRINCIPLES
Figure 4-1 Peak Example..........................................................................................................................................34
Figure 4–2 Peak Hold/Inrush Current Example .......................................................................................................35
Figure 4–3 Crest Factor Example.............................................................................................................................36
5. COMPUTER CONTROLLED OPERATION
Figure 5–1 GPIB Installation ...................................................................................................................................37
Figure 5–2 GPIB Address Setup Menu .....................................................................................................................38
Figure 5–3 RS-232 Interface.....................................................................................................................................38
Figure 5–4 Cable Connection Using Null Modem....................................................................................................38
Figure 5–5 RS-232 Baud Rate Setup Menu ..............................................................................................................39
6. CALIBRATION
Figure 6–1 Calibration/Verification Test Setup.........................................................................................................46
Figure 6–2 Calibration Mode Enabled.....................................................................................................................46
7. OPTIONAL FEATURES
Figure 7–1 Analog Output ........................................................................................................................................48
Figure 7–2 Analog Output Setup Menu ....................................................................................................................49

vii
PURPOSE OF THIS MANUAL
This manual contains all the information required for the installation and general use of the Model
6510ePower Analyzer. To achieve maximum capability and ensure proper use of the instrument,
please read this manual in its entirety before operating. Keep the manual in a safe place for quick
reference whenever a question should arise.
WHO SHOULD USE THIS MANUAL
This manual is intended for those operators who are planning to use the Model 6510ePower Analyzer
for power measurement purposes either as a stand-alone instrument or in conjunction with any Magtrol
Hysteresis, Eddy-Current or Powder Brake Dynamometer, any Magtrol Dynamometer Controller
and M-TEST Motor Testing Software.
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 6510ePower
Analyzer, which describes the unit and provides its mechanical and electrical
characteristics.
Chapter 2: CONTROLS - Description of the elements located on the front and rear panels of
the unit.
Chapter 3: INSTALLATION/CONFIGURATION - Provides information needed for setup of the
6510eincluding wiring mode, measurement filter, external sensor, amp scaling and
volt scaling along with phase setup instructions and special functions available.
Chapter 4: OPERATING PRINCIPLES - Information pertaining to theory of operation including
analog processing, digital processing, measurement modes and measurement
methods.
Chapter 5: COMPUTER CONTROLLED OPERATION - How to run a test when the 6510e
is used with a PC. Includes information on IEEE-488 and RS-232 Interface, data
format, programming and command set.
Chapter 6: CALIBRATION - Provides recommended calibration schedules along with step-
by-step instructions for the calibration procedure.
Chapter 7: OPTIONAL FEATURES - Provides information regarding various optional features
available with the 6510eincluding analog outputs.
Chapter 8: TROUBLESHOOTING - Solutions to common problems encountered during setup
and testing.
Appendix A: SCHEMATICS - For the main board, input modules, key pad and analog output.
Glossary: List of abbreviations and terms used in this manual, along with their definitions.
Preface

viii
Magtrol Model 6510eSingle-Phase Power Analyzer
Preface
CONVENTIONS USED IN THIS MANUAL
The following symbols and type styles may be used in this manual to highlight certain parts of the
text:
Note: This is intended to draw the operator’s attention to complementary
information or advice relating to the subject being treated. It
introduces information enabling the correct and optimal functioning
of the product to be obtained.
Caution: this is used to draw the operator’sattention to information,
direCtives, proCedures, etC. whiCh, if ignored, may result
in damage being Caused to the material being used. the
assoCiated text desCribes the neCessary preCautions to take
and the ConsequenCes that may arise if the preCautions are
ignored.
WARNING! THIS INTRODUCES DIRECTIVES, PROCEDURES,
PRECAUTIONARY MEASURES, ETC. WHICH MUST BE
EXECUTED OR FOLLOWED WITH THE UTMOST CARE
AND ATTENTION, OTHERWISE THE PERSONAL SAFETY
OF THE OPERATOR OR THIRD PARTY MAY BE PUT AT
RISK. THE READER MUST ABSOLUTELY TAKE NOTE
OF THE ACCOMPANYING TEXT, AND ACT UPON IT,
BEFORE PROCEEDING FURTHER.