Magtrol WB Series User manual

User’s Manual
WB and PB Series
Eddy-Current and Magnetic
Powder Dynamometers
Via Paolo Uccello 4 - 20148 Milano
Tel [phone] Fax [phone] [email protected] www.dspmindustria.it

1st Edition - rev F – September 2015
While every precaution has been exercised in the compilation of this document to ensure
the accuracy of its contents, Magtrol 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 ©2005-2015 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.
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
Safety Precautions
WARNING! IN ORDER TO MINIMIZE RISKS, IT IS OF UTMOST
IMPORTANCE TO RESPECT THE CURRENT SAFETY
STANDARDS WHEN PLANNING, CONFIGURING AND
OPERATING THE MOTOR TEST SYSTEM.
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 electronic equipment.
3. Make sure that dynamometers and motors under test are equipped with appropriate safety
guards.
Note: Detailed information regarding Motor Test Protective Systems can
be found in Section 2.8 – Protective Systems.
4. Always select a coupling that matches the speed and braking torque of the tested system.
5. Wear protective glasses when working on a test bench.
6. Never wear a necktie or baggy clothes when standing close to the test bench.
7. Never stand too close to the running test bench or bend over a rotating shaft.
8. Electrically insulate the motor terminal block.
9. Always connect the motor envelope to earth ground.
10. Make sure that the safety circuitry of the motor control cannot be deactivated by accident.
WARNING! A DEFECT ON THE ELECTRICAL TRANSMISSION
LINE CAN CAUSE A SHORT-CIRCUIT WHICH CAN
PROPAGATE TO ALL CONNECTED INSTRUMENTS OR
PERSONS IN CONTACT WITH THE APPARATUS.

ii
The contents of this manual is subject to change without prior notice.
REVISION DATE
1st edition – rev. F - September 2015
TABLE OF REVISIONS
Revisions To This Manual
Date Edition Change Section(s)
09/02/15 1st Edition - rev F Page layout 3.1 / 3.1.2
04/21/15 1st Edition - rev E Remove WB2.7 HS version 1.2.1
04/21/15 1st Edition - rev E Remove the 1WB2.7 dynamometer 1.2.1 / 2.10 / 6.1.2
05/26/14 1st Edition - rev D Data sheets updated 1.2
02/26/14 1st Edition - rev C All references to DSP6001 changed to DSP7000 throughout manual
04/25/12 1st Edition - rev B Diagram (torque, power) for Tandem WB 115 updated 1.2.4
12/21/09 1st Edition - rev A The maximum input pressure was changed 3.1.2

iii
Table of Contents
1. INTRODUCTION .................................................................................................................................1
1.1 GENERAL DESCRIPTION ......................................................................................................................................... 1
1.2 DATA SHEETS ............................................................................................................................................................. 2
1.2.1 WB/PB 2.7 SERIES........................................................................................................................................ 2
1.2.2 WB/PB 43 SERIES......................................................................................................................................... 9
1.2.3 WB/PB 65 SERIES....................................................................................................................................... 17
1.2.4 WB/PB 115 SERIES..................................................................................................................................... 25
1.2.5 WB/PB 15 SERIES....................................................................................................................................... 33
2. INSTALLATION / MOUNTING ..........................................................................................................41
2.1 LOCKING THE DYNAMOMETER FOR TRANSPORT ......................................................................................... 41
2.1.1 WB/PB 2.7 SERIES...................................................................................................................................... 42
2.1.2 WB/PB 43 SERIES....................................................................................................................................... 43
2.1.3 WB/PB 65 SERIES....................................................................................................................................... 44
2.1.4 WB/PB 115 SERIES..................................................................................................................................... 45
2.1.5 WB/PB 15 SERIES....................................................................................................................................... 46
2.2 MOUNTING THE DYNAMOMETER TO THE TEST BENCH............................................................................... 47
2.2.1 ALIGNING THE DYNAMOMETERS ON THE TEST BENCH................................................................ 47
2.2.2 VIBRATIONS INDUCED BY THE TEST BENCH.................................................................................... 47
2.3 COUPLINGS............................................................................................................................................................... 48
2.4 MEASURING RANGE............................................................................................................................................... 49
2.5 DRAG TORQUE......................................................................................................................................................... 49
2.6 TOLERATED RADIAL AND AXIAL FORCES ....................................................................................................... 49
2.7 CONNECTING THE COOLING SYSTEM............................................................................................................... 50
2.8 PROTECTIVE SYSTEMS .......................................................................................................................................... 50
2.9 POWER/HEAT DISSIPATION ................................................................................................................................... 52
2.10TORQUE–SPEED–POWER CURVES ...................................................................................................................... 52
3. COOLING..........................................................................................................................................58
3.1 DYNAMOMETER COOLING................................................................................................................................... 58
3.1.1 CONNECTIONS........................................................................................................................................... 58
3.1.2 WATER FLOW AND PRESSURE ............................................................................................................... 58
3.1.3 COOLING WATER CONSUMPTION......................................................................................................... 58
3.1.4 TEMPERATURE SENSOR.......................................................................................................................... 58
3.2 OPEN-CIRCUIT COOLING SYSTEMS ................................................................................................................... 59
3.2.1 EXAMPLE.................................................................................................................................................... 59
3.3 CLOSED-CIRCUIT COOLING SYSTEMS .............................................................................................................. 60
3.3.1 EXAMPLE.................................................................................................................................................... 60
3.4 COOLING WATER ISSUES....................................................................................................................................... 61
3.4.1 IMPURITIES ................................................................................................................................................ 61
3.4.2 HARDNESS.................................................................................................................................................. 61
3.4.3 FILTERING .................................................................................................................................................. 62
3.4.4 CONTROLLING THE WATER FLOW RATE ............................................................................................ 62
3.4.5 WATER INHIBITORS.................................................................................................................................. 62
3.4.6 CONDENSATION........................................................................................................................................ 63
3.5 COOLING CIRCUIT PURGING ............................................................................................................................... 63

iv
Table of Contents Magtrol WB/PB Dynamometers
4. CONNECTIONS / CONFIGURATION ...............................................................................................64
4.1 CONNECTION TO MAGTROL MOTOR TESTING ELECTRONICS.................................................................... 64
4.1.1 MANUAL TEST CONFIGURATION ......................................................................................................... 64
4.1.2 PC-BASED TEST CONFIGURATION........................................................................................................ 65
4.2 TANDEM DYNAMOMETER CONFIGURATION................................................................................................... 66
4.2.1 ELECTROMAGNETIC CLUTCH............................................................................................................... 66
4.2.2 TRANSFORMER CONNECTION .............................................................................................................. 67
4.3 CONNECTION TO NON-MAGTROL ELECTRONIC CONTROL UNITS ............................................................ 68
4.3.1 POWER AND THERMOSTAT CONNECTION ......................................................................................... 68
4.3.2 TORQUE SIGNAL CONNECTION ............................................................................................................ 70
4.3.3 SPEED SIGNAL CONNECTION................................................................................................................ 71
5. OPERATING PRINCIPLES ...............................................................................................................72
5.1 EDDY-CURRENT DYNAMOMETERS (WB) .......................................................................................................... 72
5.2 MAGNETIC POWDER DYNAMOMETERS (PB) ................................................................................................... 72
5.3 WB VS. PB.................................................................................................................................................................. 72
6. CALIBRATION ..................................................................................................................................73
6.1 BASIC CALIBRATION INFORMATION ................................................................................................................. 73
6.1.1 CALIBRATION ARMS ................................................................................................................................ 73
6.1.2 CALIBRATION WEIGHT ........................................................................................................................... 74
6.2 CALIBRATION WITH MAGTROL MOTOR TESTING ELECTRONICS .............................................................. 75
6.3 CALIBRATION USING NON-MAGTROL ELECTRONIC CONTROL UNITS..................................................... 75
6.4 CALIBRATION OF OVERLOAD PROTECTION .................................................................................................... 75
6.4.1 WB/PB 43 SERIES....................................................................................................................................... 76
6.4.2 WB/PB 65 SERIES....................................................................................................................................... 77
6.4.3 WB/PB 115 SERIES..................................................................................................................................... 78
7. MAINTENANCE AND REPAIR .........................................................................................................79
7.1 MAINTENANCE........................................................................................................................................................ 79
7.2 REPAIR ....................................................................................................................................................................... 79
7.3 SENDING EQUIPMENT TO MAGTROL FOR MAINTENANCE/REPAIR........................................................... 79

v
Table of ContentsMagtrol WB/PB Dynamometers
TABLE OF FIGURES
2. INSTALLATION / MOUNTING
Figure 2–1 WB/PB 2.7 Load Cell Locking System................................................................................................................................... 42
Figure 2–2 WB/PB 43 Load Cell Locking System.................................................................................................................................... 43
Figure 2–3 WB/PB 65 Load Cell Locking System.................................................................................................................................... 44
Figure 2–4 WB/PB 115 Load Cell Locking System.................................................................................................................................. 45
Figure 2–5 WB/PB 15 Load Cell Locking System.................................................................................................................................... 46
Figure 2–6 Couplings Using Key Clamping ............................................................................................................................................ 48
Figure 2–7 Example of Protective System................................................................................................................................................ 51
Figure 2–8 WB 2.7 Ratings Curve ........................................................................................................................................................... 52
Figure 2–9 PB 2.7 Ratings Curve ............................................................................................................................................................ 53
Figure 2–10 WB 43 Ratings Curve .......................................................................................................................................................... 53
Figure 2–11 PB 43 Ratings Curve ........................................................................................................................................................... 54
Figure 2–12 WB 65 Ratings Curve .......................................................................................................................................................... 54
Figure 2–13 PB 65 Ratings Curve ........................................................................................................................................................... 55
Figure 2–14 WB 115 Ratings Curve ........................................................................................................................................................ 55
Figure 2–15 PB 115 Ratings Curve ......................................................................................................................................................... 56
Figure 2–16 WB 15 Ratings Curve .......................................................................................................................................................... 56
Figure 2–17 PB 15 Ratings Curve ........................................................................................................................................................... 57
3. COOLING
Figure 3–1 Open-circuit Cooling Example.............................................................................................................................................. 59
Figure 3–2 Closed-circuit Cooling Example ........................................................................................................................................... 60
4. CONNECTIONS / CONFIGURATION
Figure 4–1 Manual Test Configuration.................................................................................................................................................... 64
Figure 4–2 PC-Based Test Configuration with M-TEST Software........................................................................................................... 65
Figure 4–3 Tandem Configuration ........................................................................................................................................................... 66
Figure 4–4 Supply Cable Between 24 V DC Transformer and DES Power Supply ................................................................................. 67
Figure 4–5 Control Signal Cable for WB/PB 2.7 and 43 Tandem Dynamometer Clutches..................................................................... 67
Figure 4–6 Control Signal Cable for WB/PB 65, 115 and 15 Tandem Dynamometer Clutches .............................................................. 67
Figure 4–7 Connector Pin Configuration for WB/PB 2.7 Dynamometer Power ..................................................................................... 69
Figure 4–8 Connector Pin Configuration for WB/PB 43 Dynamometer Power and Temperature Measurement ................................... 69
Figure 4–9 Connector Pin Configuration for WB/PB 65, 115 and 15 Dynamometer Power and Temperature Measurement ............... 69
Figure 4–10 Connector Pin Configuration for WB/PB 2.7 and 43 Dynamometer Torque Signals ......................................................... 70
Figure 4–11 Connector Pin Configuration for WB/PB 65, 115 and 15 Dynamometer Torque Signals .................................................. 70
Figure 4–12 Connector Pin Configuration for WB/PB 2.7 and 43 Dynamometer Speed Signals........................................................... 71
Figure 4–13 Connector Pin Configuration for WB/PB 65, 115 and 15 Dynamometer Speed Signals.................................................... 71
6. CALIBRATION
Figure 6–1 Calibration Arm Mounting .................................................................................................................................................... 73
Figure 6–2 WB/PB 43 Overload Protection Calibration......................................................................................................................... 76
Figure 6–3 WB/PB 65 Overload Protection Calibration......................................................................................................................... 77
Figure 6–4 WB/PB 115 Overload Protection Calibration....................................................................................................................... 78

vi
Preface
PURPOSE OF THIS MANUAL
This manual contains information required for the installation and general use of Magtrol’s WB
Series and PB Series Dynamometers. To achieve maximum capability and ensure proper use, 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 bench test operators who are going to use a WB Eddy-current or PB
Magnetic Powder Dynamometer in order to determine the torque and power of a motor in relation
to its speed. It is assumed that the user has sufficient knowledge in mechanics and electronics to be
able to install/operate these WB/PB Dynamometers without risk.
MANUAL ORGANIZATION
This section gives an overview of the structure of the manual and the information contained therein.
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 technical data sheets of all Magtrol WB/PB Series
Dynamometers, which describe their technical characteristics and give a brief
overview of their application fields.
Chapter 2: INSTALLATION / MOUNTING – Provides information needed for the mounting of
the dynamometers, as well as limits and precautions to observe during operation.
Chapter 3: COOLING – Describes the necessary measures to take in order to guaranty an
optimal dynamometer operating temperature.
Chapter 4: CONNECTION / CONFIGURATION – Provides information about the wiring
between the dynamometers and the electronic control units, as well as tandem setups
of dynamometers.
Chapter 5: OPERATING PRINCIPLES – Describes the physical phenomena on which the Eddy-
current (WB) and magnetic powder (PB) dynamometer technology is based.
Chapter 6: CALIBRATION – Provides recommended calibration schedules along with step-
by-step instructions for the calibration procedure.
Chapter 7: MAINTENANCE AND REPAIR – Provides information on how to return a WB/PB
series dynamometer to Magtrol for servicing, preventative maintenance or repair.

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Magtrol WB/PB Dynamometers 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
ANDATTENTION, OTHERWISE THE PERSONAL SAFETY
OF THE OPERATOR OR THIRD PARTIES MAY BE PUT
AT RISK. THE READER MUSTABSOLUTELY TAKE NOTE
OF THE ACCOMPANYING TEXT, AND ACT UPON IT,
BEFORE PROCEEDING FURTHER.

viii
Magtrol WB/PB DynamometersPreface
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