Magtrol DES 410 User manual

DES 410 & DES 411
Power Supply
User’s Manual
Via Paolo Uccello 4 - 20148 Milano

1st Edition - revision A - February 2014
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 ©2009 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
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.
Safety Precautions

ii
The contents of this manual are subject to change without prior notice.
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 - revision A - February 2014
DATE EDITION CHANGES SECTION
02/19/14 1st Edition - rev A Passing shielded cables into stufng gland
procedure added
2.6.2
02/19/14 1st Edition - rev A Figure 2-6 Update Stufng gland view 2.6
02/19/14 1st Edition - rev A Notes about EMC stufng gland was added 2.8, 2.9
02/19/14 1st Edition - rev A Figure 2-10 and 2-11 Update connecting
drawing
2.8, 2.9
October 2013 First Edition English
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 ...................................................................................................................................................... IV
PREFACE .............................................................................................................................................. V
PURPOSE OF THIS MANUAL ....................................................................................................................................... V
WHO SHOULD USE THIS MANUAL ............................................................................................................................ V
MANUAL ORGANIZATION ........................................................................................................................................... V
SYMBOLS USED IN THIS MANUAL ........................................................................................................................... VI
1. INTRODUCTION ...............................................................................................................................1
1.1 GENERAL INFORMATION ...................................................................................................................................... 1
1.2 DATA SHEET .............................................................................................................................................................. 2
2. INSTALLATION / CONFIGURATION ................................................................................................6
2.1 GENERAL DESCRIPTION ....................................................................................................................................... 6
2.2 DES 410 & DES 411 SAFETY WARNING ............................................................................................................... 7
2.3 MOUNTING WITHOUT COOLING ......................................................................................................................... 7
2.4 MOUNTING WITH COOLING PLATE (OPTIONAL) ............................................................................................ 8
2.5 CONNECTION BETWEEN THE VARIOUS UNITS.............................................................................................. 10
2.6 CONNECTING THE DES 410 AND DES 411 POWER SUPPLY.......................................................................... 11
2.6.1 Passing Unshielded Cables Into Stuffing Gland ......................................................................................... 11
2.6.2 Passing Shielded Cables Into Stuffing Gland (with EMC stuffing gland) .................................................. 12
2.7 CONFIGURATION OF THE DES 410 AND DES 411 POWER SUPPLY ............................................................. 13
2.7.1 DES 410 Main Board : F1,F2, F3, SL12, SW1 & SW2 Location .............................................................. 13
2.7.2 DES 411 Main Board: F1, F2, F3, SL12, SW1 & SW2 Location .............................................................. 14
2.7.3 DES 410 & DES 411 CPLD Board : R39, R102, SL1 Location ................................................................ 14
2.7.4 Main Board: F1, F2, F3, SL12, SL1, SL3, SW1 & SW3 Set-Up ............................................................... 15
2.7.5 CPLD Board: R39, R102, SL1 Set-Up ....................................................................................................... 15
2.7.6 Set-Up Values .............................................................................................................................................. 15
2.8 CONNECTING THE DES 410 TO THE DSP 7000 CONTROLLER ..................................................................... 16
2.9 CONNECTING THE DES 411 TO THE DSP 7000 CONTROLLER ..................................................................... 17
3. CALIBRATION ................................................................................................................................18
4. REPAIR ...........................................................................................................................................19
4.1 REPAIR ..................................................................................................................................................................... 19

iv
Table of contents Power supply unit Magtrol DES
TABLE OF FIGURES
2. INSTALLATION / CONFIGURATION
Figure 2–1 Dimensions of DES 410 and DES 411 case ............................................................................................6
Figure 2–2 DES 410 Power Supply mounted to the table of a test bench without cooling .........................................7
Figure 2–3 Cooling Plate (P/N 234-311-900-011) .....................................................................................................8
Figure 2–4 DES 411 Power Supply with cooling plate mounted to the test bench table ............................................9
Figure 2–5 Connection between the various units in a test bench ...........................................................................10
Figure 2–6 Stuffing gland (Overview and separated) ...............................................................................................11
Figure 2–7 Connect Shiel of EMC Stuffing gland .....................................................................................................12
Figure 2–8 Location of fuses F1, F2, F3; SolderLink SL12 & Contacts SW1, SW2 on the DES 410 circuit ...........13
Figure 2–9 Location of fuses F1, F2, F3; SolderLink SL12 & Contacts SW1, SW2 on the DES 411 circuit ...........14
Figure 2–10 Location of resistors R102, R39; SolderLink SL1 the DES 410 & DES 411 circuit ............................14
Figure 2–11 Connection of the DES 410 Power Supply to the Magtrol DSP 7000Controller. .................................16
Figure 2–12 Connection of the DES 411 Power Supply to the Magtrol DSP 7000Controller. .................................17

v
Preface
PURPOSE OF THIS MANUAL
This manual has all the necessary information regarding the installation, connection and use of
Magtrol's DES 410 and 411 Power Supply. To achieve maximum capability and ensure proper use
of the system, 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 for users who want to install and use the Magtrol DES 410 and 411 Power Supply
on a dynamometer test bench. The user should have suitable technical training in mechanics and
electronics in order to install and use this load monitoring unit without risk.
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.
Summary of the different chapters :
Chapter 1: INTRODUCTION – Contains the technical data sheet for the DES 410 and DES
411 Power Supply and gives its technical characteristics as well as a brief overview
of the application fields.
Chapter 2: INSTALLATION / CONFIGURATION – Contains the mounting and configuration
instructions for the DES 410 and DES 411 Power Supply, the dynamometer and
the DSP7001 Programmable Controller.
Chapter 3: CALIBRATION – Provides instructions
Chapter 4: REPAIR – Provides information on returning the unit to Magtrol for repair.

vi
Power supply unit Magtrol DESPreface
SYMBOLS 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 function
of the product.
Caution: this is used to draw the operator’s attention to information,
direCtives, proCedures, etC. whiCh, if ignored, may result
in damage to the material being used. the assoCiated
text desCribes the neCessary preCautions to take and the
ConsequenCes that may arise if these 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 AT RIsk. The ReAdeR musT AbsoluTely TAke
NoTe of The AccompANyING TexT, ANd AcT upoN
IT , befoRe pRoceedING fuRTheR.

1
1. Introduction
1.1 GENERAL INFORMATION
The Model DES 410 and 411 Power Supplies are designed for use with Magtrol's Eddy-Current
and Powder Brake Dynamometers. The DES 410 and DES 411 supply the current to the coils of
the brake within the dynamometer. They are controlled by an electronic peripheral, the Magtrol
DSP7000 High Speed Programmable Controller.
Note: The DES 41x is intended for use in an industrial environment and
meets the standard IEC 61326-1 class B / Industrial electromagnetic
environment. For the immunity test, a deflection +/-3% FSD and
+/- 6%FSD is admitted for each performance criteria A and B

2
DES 410/411 Power SupplyChapter 1 – Introduction
1.2 DATA SHEET
DES410 /DES411
Data Sheet
DES 410 and DES 411
Power Supplies
1
www.magtrol.com
MAGTROL
FEATURES
• For use with Magtrol WB Eddy-Current and PB
Powder Brake Dynamometers
• Controlled current supply, with overvoltage factor > 5
•Analog input for current set-point
•Selection of nominal current
• Control by digital inputs/outputs
•General alarm provided by relay
•2 alarm outputs (temperature and electrical circuit)
•Available in either 115 or 230 VAC
SYSTEM CONFIGURATION
DESCRIPTION
DES 410 and DES 411 Power Supplies are specially designed
for the full range of Magtrol’s Eddy-current and Powder
brake dynamometers with the design goal providing the best
response time. The DES 410 / DES 411 supplies are packaged
in an industrial housing made of cast aluminum. This offers
superior protection against radiated emissions in order to avoid
any disruption of the surrounding electronics modules. This
housing must be installed directly on the test bench, next to
the brake, as close as possible.
The DES 410 / DES 411 supplies can be controlled by
digital signals and analog set point coming from peripheral
electronics. The DSP7000 Dynamometer Controller has been
designed to work with the DES 41x.
Control
The Power supply can be switched ON by remote control. The
Stand-by signal enables the output current to be delivered. This
excitation current is controlled by a set-point in the 0-10VDC
range. The nominal value of the excitation current is set by
internal resistors. There are two discrete outputs for alarms
(open collector). The first is the “Temperature Alarm”. It will
Eddy-Current (WB)
OR Powder Brake (PB)
Dynamometer
Excitation
Torque
Speed
TSC 401
Torque-Speed
Conditioner
DES 41X POWER SUPPLY
GPIB
USB
or
PC
M-TEST
DSP7000 Dynamometer Controller
This drawing illustrates a complete motor test system. A
basic test stand can also be configured with just a WB/PB
Dynamometer and the DES 41X Power Supply.
indicate if the cooling water of the Dynamometer or the inner
temperature of the DES 41x are out of limits. The second is the
”Electrical Alarm”. It occurs when an over current or a short
circuit is detected. The output current is immediately turned
OFF and latched while the General Alarm Relay is set under
its Alarm position. A low state for 200 ms of the Stand-by
signal resets the latch.
For applications with tandem dynanometers, the DES
410/DES 411 units also control the power supply of the
electromagnetic clutch.
Supply Voltage
The main supply voltage of the DES 410/DES 411 is in
the 115/230VAC/50/60Hz range. No selection is required.
The DES 410 power supply features a galvanic insulation
between the main circuit and the dynamometer power.
The DES 411 does not have galvanic separation. For safety
reasons, the DES 41x case has to be grounded and the use
of a ground fault current circuit breaker is recommended.

3
DES 410/411 Power Supply Chapter 1 – Introduction
2
DES410 /DES411
MAGTROL
Specifications
ratINGs
DES 410 DES 411
NETWORK SUPPLY
Voltage 115 VAC / 230 VAC ±15 %
Frequency 50 Hz / 60 Hz
Fuse T1A or T2A depending on the brake(s)/
115 VAC / 230 VAC
T2A to T12A depending on the brake(s)/
115 VAC / 230 VAC
Maximum current 1 A + clutch 3 A + clutch / 230 VAC
6 A + clutch / 115 VAC
ELECTROMAGNETIC CLUTCH SUPPLY
Voltage 115 VAC / 230 VAC
Current 1 A
SUPPLY FOR EXTERNAL USE
Voltage 12 VDC ±5 %
Maximum Current 300 mA
SELECTION OF NOMINAL CURRENT
(Selected by resistors) 0.5 A; 1.0 A; 1.5 A; 2.0 A 2.5 A; 4.0 A; 5.0 A; 7.5 A; 10.0 A; 12.0 A
EXCITATION SET-POINT
Voltage 0 to 10 VDC
Impedance > 50 kΩ
DIGITAL INPUTS (GALVANICALLY INSULATED)
Remote Control of the Network Input
(PSC) Relay coil +24 VDC / 11 mA
Control of the Electromagnetic Clutch Optocoupler activated by +24 VDC / 2.5 mA
Stand-by (enable) Optocoupler activated by either +24 VDC or +12VDC / 2.5 mA max
DIGITAL OUTPUTS (GALVANICALLY INSULATED)
Temperature Alarms 2 open collector outputs:
Umax = 40 VDC, Imax = 3 mA
Electrical Alarm
GENERAL ALARM
Relay Contact 2 A / 30 VDC
ENVIRONMENTAL CHARACTERISTICS
Operating Temperature 0°C to +50°C
Storage Temperature -20°C to +70°C
Humidity 0 to 90% as per DIN 40040
Protection Class IP 66
Assembly The housing must be electrically and thermally coupled to the
metal frame of the test bench to allow heat dissipation.
MECHANICAL CHARACTERISTICS
Housing Extruded cast aluminium
Weight (without cable) 5.2 kg; 11.5 lb
Weight (with integrated cable) 6.2 kg; 13.7 lb

4
DES 410/411 Power SupplyChapter 1 – Introduction
3
DES410 /DES411
MAGTROL
DIMeNsIONs
O
VERHEAD VIEW
B
A
FRONT VIEW
C
D
F
M
K
H
E
J Mounting
Screw
M6×30
DES 411
OVERHEAD VIEW
N
FRONT VIEW
P
Q
NOTE: Original dimensions are in Metric units.
Dimensions converted to English units have been rounded up
to 2 decimal places.
DES 411 Water Cooling System
(For all 15 series Dynamometers
except 1 WB 15 and 1 PB 15)
A B C D E F H J K M
mm 287 272 190 175 ≈17 ≈219 12 10 90 30
in 11.30 10.71 7.48 6.89 0.63 8.58 0.47 0.39 3.54 1.06
N P Q
mm 200 290 15
in 7.87 11.42 0.59
Specifications
The DES 410/DES 411 supplies are delivered with integrated cables (including connectors) with a length of 1.5 meters
on the dynamometer connection side and 5 meters on the controller side. The DES 410/DES 411 units are to be mounted
on a metallic surface in order to allow ample heat dissipation. For safety reasons, the DES 41x case has to be grounded.
For 2-3-4 WB 15 and 2-4 PB 15 dynamometers, the DES 411/12x Power Supply with integrated Water Cooling System
(see above drawing) should be used.

5
DES 410/411 Power Supply Chapter 1 – Introduction
4
DES410 /DES411
MAGTROL
OPtIONs aND OrDerING INFOrMatION
NOTE: All DES 41X Power Supplies include the corresponding dynamometer connection cables. The last digit of the part
Number refers to the cable lenght in accordancewith the following table.
If the DES is ordered separately (from the dynamometer), it is absolutely necessary to specify which model of Eddy-current/
powder brake will be used with the DES power supply in order to limit the operating current and prevent possible damage to
the dynamometer brake. Mains voltage (115 VAC or 230 VAC) should also be defined when ordering.
Specifications
Primary Supply CircuitExcitation Circuit
Control
Interface
Control Inputs/Outputs Supply Inputs/Outputs
Fuse
Network
Filter
Differential
Input
Selection
of
Nominal
Current
Electrical Alarm
Excitation Temp.
Dynamometer Temp.
Clutch Control
General Alarm
Control
Clutch
Feedback Current
Excitation
Current
Control
Excitation Set-point
Stand-by
Clutch
Electrical Alarm
Temperature Alarm
Excitation Current
+12 VDC
Primary Supply
Control
Excitation
Control
BlOCk DIaGraM
DESCRIPTION MODEL PART NUMBER
Power Supply for WB/PB 2.7 and 43 Dynamometers DES 410/11x 234-410-000-11x
Power Supply for WB/PB 65, 115, 1 PB 15 and 1 WB 15 Dynamometers DES 411/11x 234-411-000-11x
Power Supply with Water Cooling Plate for 2, 3, 4 WB 15 and 4 PB 15 Dynamometers DES 411/12x 234-411-000-12x
LAST DIGIT
X
CABLE LENGTH
DYNAMOMETER SIDE
CABLE LENGTH
CONTROLLER SIDE
1 1.5 m 5 m
2 1.5 m 10 m
3 1.5 m 20 m
4 2.5 m 5 m
5 2.5 m 10 m
6 2.5 m 20 m

6
2. Installation / Configuration
2.1 GENERAL DESCRIPTION
The housing of the power supply must be electrically and thermally connected to the metal
frame of the test bench to allow heat dissipation.
The test bench as well as it's structure must be connected to earth (ground).
For safety reasons, the DES 41x case has to be grounded and the use of a ground fault current
circuit breaker is recommended.
The dimensions necessary for mounting the housing of the power supply are provided in Figure
1. The data sheet provides all other dimensions necessary for the installation of the power
supply. The housing of the DES 410 and DES 411 has four holes for mounting and includes
the necessary four M6 × 30 hexagon socket head fixing screws.
To reach the mounting holes, it is necessary to remove six screws from the cover of the power
supply.
Once the unit is installed and calibrated, for safety reasons, it is necessary to replace and secure
the cover of the power supply.
The cover has to be mounted with the Yellow warnings placed as shown.
Figure 2–1 Dimensions of DES 410 and DES 411 case

7
DES 410/411 Power Supply Chapter 2 – Installation / Configuration
2.2 DES 410 & DES 411 SAFETY WARNING
WARNING! The des 41x poWeR supply musT AlWAys be
GRouNded. mAke suRe The des 41x Is TuRNed off
ANd dIscoNNecTed fRom The coNTRolleR foR 3
mINuTes befoRe RemovING The housING coveR.
The useR oR A ThIRd pARTy could be seRIously
oR eveN fATAlly INjuRed If These WARNINGs ARe
IGNoRed. The use of A 6A/30mA GRouNd fAulT
cIRcuIT bReAkeR Is RecommeNded
2.3 MOUNTING WITHOUT COOLING
For any DES 410 and for DES 411 Power Supply providing an excitation current up to 5A included
(dynamometer models 1WB/PB 65, 2WB/PB 65, 1WB/PB 115, 2WB/PB 115 and 1WB/PB 15),
a cooling plate is not required
The power supply can be mounted on a support fixed to the table or directly to the test bench. An
example of such mounting is given in Figure 2-2
Figure 2–2 DES 410 Power Supply mounted to the table of a test bench without cooling
DES41x
Power Supply
Metallic case
support
Test bench

8
DES 410/411 Power SupplyChapter 2 – Installation / Configuration
2.4 MOUNTING WITH COOLING PLATE (OPTIONAL)
For a DES 411 Power Supply providing an excitation current higher than 5 A (dynamometer models
2 WB/PB 15 and larger), a cooling plate is required.
Magtrol recommends the use of the Cooling Plate , P/N: 234-311-900-011. (see Figure 2-3).
Another solution is to mount the DES 411 on a metal plate having a minimal dimensions of 500
mm × 500 mm × 2 mm. It is necessary to mill holes in the plate for the feet of the unit in order
to get a good thermal contact using heat sink compound to improve the thermal coupling. This
plate can then be mounted to the test bench table. In both cases, with the power supply fixed to the
cooling plate, it is recommended to attach the plate to the test bench.
An example of assembly is given in Figure 2-4.
The water flow through the cooling plate must be equal to 30 l/h. The differencial pressure should
not be less than 0.05 bar. Furthermore, the absolute pressure at the inlet should not exceed 1.5 bar.
Figure 2–3 Cooling Plate (P/N 234-311-900-011)

9
DES 410/411 Power Supply Chapter 2 – Installation / Configuration
Figure 2–4 DES 411 Power Supply with cooling plate mounted to the test bench table
DES41x
Power Supply
Metallic case
support
Cooling plate
Test bench

10
DES 410/411 Power SupplyChapter 2 – Installation / Configuration
2.5 CONNECTION BETWEEN THE VARIOUS UNITS
A test bench includes not only the dynamometer, but also a TSC 401 Torque/Speed Conditioner and
DES Series Power Supply. The test bench is controlled by a DSP 7000 Programmable Controller.
Figure 2-5 shows the connection between the various units in a test bench.
DES 410/411
Power Supply
DSP7000 High Speed
Programmable Controller
WB or PB Dynamometer
TSC 401
Torque/Speed
Conditioner
Figure 2–5 Connection between the various units in a test bench
Note: The DES 410/411 is fully compatible with the DSP 6001
Programmable controler

11
DES 410/411 Power Supply Chapter 2 – Installation / Configuration
2.6 CONNECTING THE DES 410 AND DES 411 POWER SUPPLY
The DES 410 and DES 411 Power Supplies are sold as a kit, with the cables already connected.
The DES 410 and DES 411 Power Supplies are equipped with a stuffing gland which allows cables
to pass through the wall of the housing of the unit while maintaining the seal of the housing and
holding the cables.
2.6.1 Passing Unshielded Cables into stUffing gland
1. Strip the conductors from the various cables.
2. Remove the lid of the power supply housing by unscrewing its six screws.
3. Pass the cables into the stuffing gland by proceeding as follows (see Figure 2-6):
a. Unscrew element Counterclockwise. Element must not be removed from the
housing.
b. Remove joints and from element . These two elements allow the stuffing gland
to adapt to various diameters of cable. Element Can be removed from element by
simply pushing it outwards.
c. Pass the cables through elements , (if used), and .
d. Reassemble the elements of the stuffing gland and, before replacing element , lubricate
the seal with silicone as indicated in Figure 2-6. Tighten element so that it projects
beyond joints and/or to provide the degree of seal required.
4. Connect the conductors of the various cables to the terminals of the power supply unit.
5. Replace the cover of the power supply housing and tighten its six screws.
Caution : do not damage the seals with sharp edged objeCts. CheCk that
no foreign body Can slide between the elements of the stuffing
gland. de-grease the surfaCe of the Cable that will Come
in ContaCt with the seal. the stuffing gland seal Cannot be
guaranteed if these instruCtions are not followed.
Overflowing of the joint
Stuffing gland mounted
Cable
Top
Internal joint
External joint Down
Grease
the frontal
part only
Figure 2–6 Stuffing gland (Overview and separated)

12
DES 410/411 Power SupplyChapter 2 – Installation / Configuration
2.6.2 Passing shielded Cables into stUffing gland (with eMC stUffing gland)
For ER 405, EH 147 and EN 104 cables (see drawings, paragraphe 2.8 and 2.9), EMC type stuffing
gland are used.
1. Strip the conductors from the various cables.
2. Remove the lid of the power supply housing by unscrewing its six screws.
3. Pass the cables into the stuffing gland by proceeding as follows (see Figure 2-6):
a. Unscrew element Counterclockwise. Element must not be removed from the
housing.
b. Remove joints and from element . These two elements allow the stuffing gland
to adapt to various diameters of cable. Element Can be removed from element by
simply pushing it outwards.
c. Pass the cables through elements , (if used), .
d. Strip the cable (outer sheath) to the elements output and cut the shield over 5-8 mm
as show in Figure 2-7. Pass the stripped cable through the element .
e. Connect the shield on the metallic part of element as show in Figure 2-7.
f. Reassemble the elements of the stuffing gland (take care that the shield remains in
place) and, before replacing element , lubricate the seal with silicone as indicated
in Figure 2-6. Tighten element so that it projects beyond joints and/or to provide
the degree of seal required.
4. Connect the conductors of the various cables to the terminals of the power supply unit.
5. Replace the cover of the power supply housing and tighten its six screws.
Caution : do not damage the seals with sharp edged objeCts. CheCk that
no foreign body Can slide between the elements of the stuffing
gland. de-grease the surfaCe of the Cable that will Come
in ContaCt with the seal. the stuffing gland seal Cannot be
guaranteed if these instruCtions are not followed.
Figure 2–7 Connect Shiel of EMC Stuffing gland
This manual suits for next models
1
Table of contents
Other Magtrol Power Supply manuals