Robitronic Pro-Master User manual

Robitronic Pro-Master Manual General Information
1
Contents
General information
Introduction...................................................................2
Scope of delivery ...........................................................2
Safety precautions..........................................................3
Pro-Master operating instructions
Setup.............................................................................4
Pro-Master keys and operation.......................................4
Selecting a function........................................................5
Preparing for the motor check........................................6
Checking the RPM sensor..............................................7
Starting the measurement...............................................8
Displaying motor data..................................................10
Printing on the protocol printer ....................................11
Setting parameters for a motor check...........................12
Ending the motor check ...............................................14
Charging battery packs.................................................15
Function diagrams........................................................18
PC Software
System requirements....................................................20
Keyboard layout...........................................................20
Key to symbols ............................................................20
Installing the PC software ............................................21
Connecting Pro-Master to a PC....................................21
Selecting a function......................................................22
Loading motor data......................................................23
Display modes for motor data ......................................24
Meaning of motor data.................................................25
Loading benchmark data ..............................................26
Motor data in table view ..............................................27
Printing motor data......................................................28
Program settings..........................................................28
Motor check ................................................................30
Saving motor data........................................................31
Example of setting motor timing...................................32
Overview of function keys............................................34
Test results ..................................................................35

Robitronic Pro-Master Manual General Information
2
General information
Introduction
Your Pro-Master is a professional motor testing device and a high-quality battery charging unit. The
device is equipped with modern technology and so delivers utmost precision. This makes Pro-Master
equally suited for hobby and industrial applications.
The features of the motor check function:
•Measurement of motor's characteristic curve according to flywheel principle
•Electronically regulated battery simulation for utmost precision of repetition
•Standalone operation with output of motor data on built-in display
•Output of motor data on protocol printer (optional) without a PC
•PC interface for data transfer to a PC
•PC software for MS-DOS, Windows 3.xx and Windows 95
•Evaluation on PC using graphics and tables
Features of the charging function:
•Battery pack charging function with temperature and delta-peak cut-off
•Linear and linear-flex charging methods
•Charging current range 0-10 amperes, set digitally
•Storage of five charging programs
Scope of delivery
Your Pro-Master includes the following components:
3Transport case
3Pro-Master main unit
3Motor support
3Flywheel
3Hex key
3Motor cable (red/black) with solder connectors
3Serial cable for PC
3Diskette with PC software (MS-DOS)
3Operating instructions
In addition, the following accessories are available:
RS409 Panasonic lead-acid battery Type LC-RC1217PG (12 Volt, 17 Ah)
RS114 Temperature sensor cable with clip
RS512 Charging cable (red/black) with battery clips
HP82240B Hewlett Packard Infrared printer

Robitronic Pro-Master Manual General Information
3
A T T E N T I O N P L E A S E R E A D T H I S
For best performance at the motor checking function use a small lead-acid
battery with 12 Volt and a capacity of at least 17 Ah but not much more.
We recommend a Panasonic lead-acid battery Type LC-RC1217PG.
Do not use a lead-acid battery with more than 40Ah !!!
Do not charge the lead-acid battery during a motor-check !!!
If you use a big automotive battery and check motor with 11 turns or less
the power limit of the Pro-Master will be reached. (Pro-Master message:
„High Power“). In this case you must use a battery with less capacity.
Don´t try a bigger one !!!!!
Safety precautions
This device is not suited for use by children under the age of 14.
The motor support must be placed on a slip-proof surface out of the reach of
small children.
The flywheel must be firmly attached to the motor armature by means of the hex
(Allen) screws.
The safety guard for the flywheel must be attached to the safety mount on the
motor support unit by means of the thumbscrew. See the assembly sketch on
page 7.
During the measuring procedure maintain a safe distance of at least ½ meter
from the motor support unit.
Always ensure that no cables or other moving parts are in the vicinity of the
rotating flywheel.

Robitronic Pro-Master Manual Operating Instructions
4
Pro-Master operating instructions
Setup
Using the motor checking function requires a 12-volt lead-acid battery with a capacity of at least
17 Ah but not much more. We recommend a Panasonic lead-acid battery Type LC-RC1217PG.
Do not use a lead-acid battery with more than 40Ah !!!
Do not charge the lead-acid battery during a motor-check !!!
If you use a big automotive battery and check a motor with 11 turns or less the power limit of the
Pro-Master will be reached. (Pro-Master message: „High Power“). In this case you must use a
battery with less capacity. Don´t try a bigger one !!!!!
For the battery charging function you can instead use a stabilized power supply delivering 5-10
amperes. Connect the supply voltage with the battery clips of the Pro-Master main unit. See
instructions on page 6and the assembly sketch on page 7.
Pro-Master allows you to change the default parameters (see page 12) such as battery simulation
voltage, and the default values can be reset by pressing the [START] key while connecting the
supply voltage.
Pro-Master keys and operation
Description of keys:
[Mode] selection key
[Start] activation key
[+] modification key (increase value)
[-] modification key (decrease value)
Key functions on selection of a function (menu item)
The [Mode] key allows selection of a function from the menu.
Pressing the [Start] key activates the selected function.
Key functions for setting values
The [Mode] key allows selection of a value; a small bar under a value marks the selected
parameter.
The [+] and [-] keys allow modification (increase or decrease, respectively) of the selected
value.
Pressing the [Start] key saves the modified values and terminates setup.

Robitronic Pro-Master Manual Operating Instructions
5
Selecting a function
1. Motor check
-- Main Menu --
1:Motor Check
This menu item allows you to carry out a motor check without a personal computer. The motor data
are output to Pro-Master's own display. Pressing the [Start] key activates the motor check
function, while the [Mode] key lets you move to another function.
2. Battery charging
-- Main Menu --
2:Charge Battery
This menu item invokes Pro-Master's battery charging program and allows you to charge batteries
with a current of up to 10 amperes. Pressing the [Start] key activates the charging function,
while the [Mode] key lets you move to another function.
3. Pro-Master setup
-- Main Menu --
3:Setup Master
This menu item allows you to set the contrast of Pro-Master's multifunction LCD display and the
greeting message. Pressing the [Start] key activates the setup function, while the [Mode] key
lets you move to another function.

Robitronic Pro-Master Manual Operating Instructions
6
Preparing for a motor check
Connect Pro-Master to a 12-volt lead-acid battery with a capacity of at least 17Ah. Do not use a
power supply!
Place the test motor in the mount on the motor support unit. If, due to stickers, the motor is difficult
to place in the mount, the O-rings in the motor mount can be removed. Then attach the flywheel to
the motor armature with the hex key. The black/silver fields on the flywheel must be toward the
motor.
Connect the sensor cable of the motor support unit with the 7-pole plug to the front side of Pro-
Master.
Select Pro-Master's sensor check function to determine the correct position of the test motor in the
motor mount. The distance between the reflex sensor on the motor mount and the flywheel should be
2-4 mm. The sensor check should display a value of at most 30% for a silver field and at least 70%
for a black field.
Next solder the red/black motor cable to the test motor. We do not recommend a plug connection
because the motor's high starting current (up to 120 amperes) combined with the resistance of a plug
connector would cause a measurement error.
Connect the thin red/black measuring cable of the motor cable to the cable of the motor mount.
Next plug the motor cable into the socket marked "Output" on Pro-Master.
Check to assure that the flywheel has been firmly attached to the motor armature with the hex
(Allen) screws.
Check the tightness of the thumbscrew to fasten the test motor.
Then mount the safety cover over the flywheel, attaching the cover to the mounting block with the
thumbscrew.
To preclude the danger of injury by the rotating flywheel, the flywheel must be completely
covered by the safety cover.

Robitronic Pro-Master Manual Operating Instructions
7
Assembly sketch
Checking the RPM sensor
--Motor Check --
1:Sensor 12.5%OK [Mode] next function
The sensor check function in Pro-Master helps you to determine the correct position of the test
motor in the motor mount. This function tests the distance between the flywheel and the RPM
sensor; this distance should be 2-4 mm. For this test you need to turn the flywheel slowly by hand.
When a silver (reflecting) field passes the RPM sensor, a value should be displayed of at most 30%
and for a black field at least 70%.

Robitronic Pro-Master Manual Operating Instructions
8
Starting the measurement
--Motor Check -- [Start] start measurement
2:Start Test [Mode] next function
Check whether the flywheel has been firmly mounted to the motor armature with the hex (Allen)
screws.
Retighten the thumbscrews holding the test motor.
Maintain a safe distance of at least ½ meter from the rotating flywheel.
Press the [Start] key to begin measurement.
--Motor Check -- [Start] terminate measurement
Running ........ [Mode] terminate measurement
Measurement can be terminated at any time by pressing any key.
--Motor Check --
Calculate Pass15
Next comes the calculation of the motor's characteristic curve, followed by automatic display of
maximum values (see next section, "Display of motor data").
Starting another measurement
--Motor Check --
2:Please Wait30s [Mode] next function
After termination of a motor check, a further measurement is blocked for 30 seconds; i.e., a
measurement can be started at most once every 30 seconds.

Robitronic Pro-Master Manual Operating Instructions
9
Error message
--Motor Check -- [Start] return to sensor check
No RPM Signal [Mode] return to sensor check
On start of a motor check, no RPM sensor signal could be detected. Possibly the sensor cable was
not plugged in properly or the motor cable not connected properly. Test proper operation of the
RPM sensor (see section "Checking the RPM sensor" on page 7).
--Motor Check -- [Start] return to sensor check
High Power [Mode] return to sensor check
If you use a big automotive battery and check a motor with 11 turns or less the power limit of the
Pro-Master will be reached. (Pro-Master message: „High Power“). In this case you must use a
battery with less capacity. Don´t try a bigger one !!!!!
We recommend a Panasonic lead-acid battery Type LC-RC1217PG 12 Volt 17 Ah.
--Motor Check -- [Start] return to sensor check
High Amp Signal [Mode] return to sensor check
Check the motor or the Shottky diode.
--Motor Check -- [Start] return to sensor check
Battery Fault [Mode] return to sensor check
Check the voltage of the lead-acid battery.

Robitronic Pro-Master Manual Operating Instructions
10
Displaying motor data
--Motor Check -- [Start] display measurement values
3:Display Data [Mode] next function
Display of maximum values
Max:143.9W 69.3% [Start] return to function selection
38.541rpm 7.86s [Mode] next display function
Displays maximum power, maximum efficiency, maximum RPM and time until maximum RPM is
reached.
Display of average values
Average: 95.6W [Start] return to function selection
56.3% [Mode] next display function
Displays average power and efficiency.
Display of motor current table
20A 76.1W 60.3 [Start] return to function selection
29.879rpm 24.3N [Mode] next display function
[+] [-] display next value
Display motor data (power, efficiency, RPM and torque) in relation to motor current. The current
steps for the display can be set in the parameter setup function (see page 13).
Display of torque table
20N 65.9W 57.4 [Start] return to function selection
31.474rpm 18.0A [Mode] next display function
[+] [-] display next values
Display motor data (power, efficiency, RPM and motor current) in relation to torque. The torque
steps for the display can be set in the parameter setup function (see page 13).