Magtrol 7500 SERIES User manual

7500 Series
Power Analyzer
User’s Manual

1st Edition – October 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 ©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.
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. Securely ground the 7500 Series Power Wattmeter 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

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The contents of this manual are subject to change without prior notice. Should revisions be necessary, updates to all
Magtrol User’s Manuals can be found at Magtrol’s web site at www.magtrol.com/support/manuals.htm.
Please compare the date of this manual with the revision date on the web site, then refer to the manual’s Table of
Revisions for any changes/updates that have been made since this edition.
REVISION DATE
1st Edition – October 2017
Revisions To This Manual

iii
Table of Contents
SAFETY PRECAUTIONS .........................................................................................................................I
REVISIONS TO THIS MANUAL ...............................................................................................................II
REVISION DATE.................................................................................................................................................................II
TABLE OF CONTENTS ..........................................................................................................................III
TABLE OF FIGURES ......................................................................................................................................................... V
PREFACE............................................................................................................................................... VI
PURPOSE OF THIS MANUAL ........................................................................................................................................VI
WHO SHOULD USE THIS MANUAL.............................................................................................................................VI
MANUAL ORGANIZATION............................................................................................................................................VI
CONVENTIONS USED IN THIS MANUAL ..................................................................................................................VII
1. INTRODUCTION ................................................................................................................................1
1.1 UNPACKING YOUR 7500 SERIES POWER ANALYZER ........................................................................................ 1
1.2 NEW FEATURES OF THE 7500 SERIES POWER ANALYZER .............................................................................. 1
1.3 DATA SHEET................................................................................................................................................................ 2
2. CONTROLS.........................................................................................................................................6
2.1 FRONT PANEL............................................................................................................................................................. 6
2.2 FRONT PANEL CONTROLS AND BUTTONS.......................................................................................................... 6
2.2.1 ENABLING SECONDARY FUNCTIONS.................................................................................................... 7
2.2.2 USING FRONT PANEL CONTROLS AND BUTTONS .............................................................................. 7
2.3 VACUUM FLUORESCENT DISPLAY (VFD)............................................................................................................ 9
2.3.1 CONTRAST SETTINGS................................................................................................................................ 9
2.3.2 DISPLAY GUIDE......................................................................................................................................... 10
2.4 REAR PANEL............................................................................................................................................................. 11
2.5 REAR PANEL INPUTS AND OUTPUTS.................................................................................................................. 11
3. INSTALLATION/CONFIGURATION..................................................................................................14
3.1 POWERING UP THE 7500 ........................................................................................................................................ 14
3.1.1 LINE VOLTAGE ........................................................................................................................................... 14
3.1.2 DISPLAY SEQUENCE ................................................................................................................................ 14
3.1.3 MAIN MENU ............................................................................................................................................... 15
3.2 PROTECTING YOUR 7500 ....................................................................................................................................... 16
3.2.1 TRANSIENT OVERLOADS........................................................................................................................ 16
3.2.2 CURRENT OVERLOAD ............................................................................................................................. 16
3.2.3 SURGE PROTECTION ................................................................................................................................ 16
3.2.4 CIRCUIT BREAKERS................................................................................................................................. 17
3.3 TESTING INSTRUMENTATION SETUP ................................................................................................................. 18
3.3.1 WIRING MODE ........................................................................................................................................... 18
3.3.2 MEASUREMENT FILTER .......................................................................................................................... 24
3.3.3 EXTERNAL SENSOR ................................................................................................................................. 25
3.3.4 AMP SCALING............................................................................................................................................ 27
3.3.5 VOLTS SCALING ........................................................................................................................................ 29
3.3.6 PHASE SETUP............................................................................................................................................. 30

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Magtrol 7500 Series Power WattmeterTable of Contents
3.3.7 SPECIAL FUNCTIONS ............................................................................................................................... 31
4. OPERATING PRINCIPLES ...............................................................................................................33
4.1 ANALOG PROCESSING ........................................................................................................................................... 33
4.1.1 VOLTS .......................................................................................................................................................... 33
4.1.2 AMPS............................................................................................................................................................ 34
4.1.3 EXTERNAL SHUNT ................................................................................................................................... 35
4.2 DIGITAL PROCESSING............................................................................................................................................ 35
4.2.1 AC DETAILS ................................................................................................................................................ 36
4.2.2 DC DETAILS................................................................................................................................................ 38
4.3 MEASUREMENT MODES........................................................................................................................................ 38
4.3.1 PEAK ........................................................................................................................................................... 38
4.3.2 PEAK HOLD / INRUSH CURRENT........................................................................................................... 40
4.3.3 DC ................................................................................................................................................................. 40
4.3.4 RMS .............................................................................................................................................................. 41
4.3.5 CREST FACTOR .......................................................................................................................................... 41
4.4 MEASUREMENT METHODS .................................................................................................................................. 41
4.4.1 CYCLE-BY-CYCLE MODE ........................................................................................................................ 41
4.4.2 CONTINUOUS MODE................................................................................................................................ 41
5. COMPUTER CONTROLLED OPERATION ......................................................................................42
5.1 ABOUT THE GPIB INTERFACE.............................................................................................................................. 42
5.1.1 INSTALLING THE GPIB/IEEE-488 CONNECTOR CABLE.................................................................... 42
5.1.2 CHANGING THE GPIB PRIMARY ADDRESS......................................................................................... 42
5.2 USB DRIVER SETUP FOR WINDOWS OPERATION SYSTEM........................................................................... 43
5.3 ETHERNET CONNECTION ..................................................................................................................................... 45
5.4 CHECKING THE 7500-TO-PC CONNECTION....................................................................................................... 45
5.5 DATA FORMAT.......................................................................................................................................................... 46
5.5.1 OT EXAMPLE ............................................................................................................................................. 46
5.5.2 OE EXAMPLE ............................................................................................................................................. 47
5.5.3 OA/OV/OW/OF EXAMPLE......................................................................................................................... 47
5.6 PROGRAMMING....................................................................................................................................................... 47
5.6.1 DATA TERMINATION CHARACTERS ..................................................................................................... 47
5.7 7500 MAG.NET COMMANDS.................................................................................................................................. 48
5.7.1 ‘||*| COMMANDS ........................................................................................................................................ 48
5.7.2 |MEAS|URE COMMANDS ......................................................................................................................... 48
5.7.3 |CONF|IGURATION COMMANDS ............................................................................................................ 50
5.7.4 |FUNC|TION COMMANDS ........................................................................................................................ 54
5.7.5 |COMM|UNICATION COMMANDS .......................................................................................................... 54
5.8 WEB INTERFACE OPERATION .............................................................................................................................. 55
6. CALIBRATION ..................................................................................................................................56
6.1 CLOSED-BOX CALIBRATION ................................................................................................................................ 56
6.2 CALIBRATION SCHEDULE..................................................................................................................................... 56
6.3 CALIBRATION COMMANDS.................................................................................................................................. 56
6.4 BASIC CALIBRATION PROCESS............................................................................................................................ 57

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Magtrol 7500 Series Power Wattmeter Table of Contents
7. TROUBLESHOOTING.......................................................................................................................59
APPENDIX A: SCHEMATICS ...............................................................................................................60
A.1 BLOCK DIAGRAM.................................................................................................................................................... 60
APPENDIX B: COMPATIBLE COMMAND SETS.................................................................................61
B.1 CONFIGURATION COMMANDS ............................................................................................................................ 61
B.2 DATA OUTPUT COMMANDS.................................................................................................................................. 64
SERVICE INFORMATION......................................................................................................................65
RETURNING MAGTROL EQUIPMENT FOR REPAIR AND/OR CALIBRATION ..................................................... 65
RETURNING EQUIPMENT TO MAGTROL, INC. (UNITED STATES) ................................................................ 65
RETURNING EQUIPMENT TO MAGTROL SA (SWITZERLAND)..................................................................... 65
TABLE OF FIGURES
2. CONTROLS
Figure 2–2 Secondary Function Menu........................................................................................................................7
Figure 2–3 Device Setup Menu...................................................................................................................................9
Figure 2–4 Rear Panel ..............................................................................................................................................11
Figure 2–5 Input Module ..........................................................................................................................................11
Figure 2–6 GPIB/IEEE-488 Interface ......................................................................................................................12
Figure 2–7 USB Interface ..........................................................................................................................................12
Figure 2 –8 Ethernet Connector ................................................................................................................................12
3. INSTALLATION/CONFIGURATION
Figure 3–1 Initial Display.........................................................................................................................................14
Figure 3–2 Title Display ...........................................................................................................................................14
Figure 3–3 Revision Display.....................................................................................................................................15
Figure 3–4 Phase Main Menu...................................................................................................................................15
Figure 3–5 Summation Main Menu ..........................................................................................................................15
Figure 3–6 Custom Main Menu ................................................................................................................................16
Figure 3–7 Transient Voltage Suppression................................................................................................................17
Figure 3–8 Single-Phase, Two-Wire Wiring Schematic.............................................................................................19
Figure 3–9 Single-Phase, Two-Wire Wiring Connection ..........................................................................................19
Figure 3-10 Single-Phase, Three-Wire Wiring Schematic.........................................................................................20
Figure 3–11 Single-Phase, Three-Wire Wiring Connection......................................................................................20
Figure 3–12 Three-Phase, Three-Wire Wiring Schematic.........................................................................................21
Figure 3–13 Three-Phase, Three-Wire Wiring Connection.......................................................................................21
Figure 3–14 Three-Phase, Four-Wire Wiring Schematic ..........................................................................................22
Figure 3–15 Three-Phase, Four-Wire Wiring Connection ........................................................................................22
Figure 3–16 Three-Voltage, Three-Ampere Wiring Schematic..................................................................................23
Figure 3–17 Three-Voltage, Three-Ampere Wiring Connection................................................................................23
Figure 3–18 Sensor Substitution Wiring Schematic..................................................................................................25
Figure 3–19 Sensor Substitution Wiring Connection................................................................................................25
Figure 3–20 External Sensor Scale Factor Setup Menu ...........................................................................................26
Figure 3–21 Current/Potential Transformer Connection..........................................................................................27
Figure 3–22 Amp Scaling Setup Menu......................................................................................................................27
Figure 3–23 Amp/Volt Scaling Activated ..................................................................................................................28
Figure 3–24 Volt Scaling Setup Menu.......................................................................................................................29
Figure 3–25 Cycle-by-Cycle Mode ...........................................................................................................................30
Figure 3–26 Hold Mode............................................................................................................................................31
Figure 3–27 Average Mode.......................................................................................................................................31
Figure 3–28 Peak Hold Clear Display......................................................................................................................32
Figure 3–29 Custom Display ....................................................................................................................................32
Figure 3–30 Custom Display Menu ..........................................................................................................................32

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Magtrol 7500 Series Power WattmeterTable of Contents
4. OPERATING PRINCIPLES
Figure 4-1 Peak Example ..........................................................................................................................................39
Figure 4–2 Peak Hold/Inrush Current Example .......................................................................................................40
Figure 4–3 Crest Factor Example.............................................................................................................................41
5. COMPUTER CONTROLLED OPERATION
Figure 5–1 GPIB Installation ...................................................................................................................................42
Figure 5–2 GPIB Address Setup Menu .....................................................................................................................43
Figure 5–3 Web Interface Home Page.......................................................................................................................55
6. CALIBRATION
Figure 6–1 Calibration/Verification Test Setup.........................................................................................................57

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PURPOSE OF THIS MANUAL
This manual contains all the information required for the installation and general use of the 7500
Series Power 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 7500 Series Power 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 7500 Series Power
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 7500 including 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 7500
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 7500 including 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.
Preface

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Magtrol Model 6530 Three-Phase Power AnalyzerPreface Magtrol 7500 Series Power Analyzer
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.
danger: the symbol indiCates danger of injury or death from eleCtriC
shoCk due to high voltages and Current. donot touCh. use
extreme Caution. aC voltages over 33 v rms, 46.7 v peak and
dC voltages over 70 v are deemed to be hazardous in terms
of ieC 61010. further material damage may happen.
Cat ii 1000v: this Category refers to loCal-level eleCtriCal distribution,
suCh as that provided by astandard wall outlet or plug
in loads. examples of measurement Category ii are
measurements performed on household applianCes, portable
tools, and similar modules. 1000v is working voltage.