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
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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
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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
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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.

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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
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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
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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
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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
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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
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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).

Robitronic Pro-Master Manual Operating Instructions
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Printing on the protocol printer
To print the data, you need a protocol printer (available as option) and a printer cable.
--Motor Check -- [Start] print data
4:Print Data [Mode] next function
Print data
Print Data [Start] print additional data
Please Wait ....
If, in addition to the motor data, you also want to print the current table and the torque table, press
the [Start] key again during printing.
Printing motor data: Printing additional data:

Robitronic Pro-Master Manual Operating Instructions
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Setting parameters for a motor check
--Motor Check -- [Start] display parameters
5:Setup Motor [Mode] next function
Voltage for battery simulation
TestVoltage:7.5V [Start] return to function selection
Current Lim:120A [Mode] next parameter
[+] [-] change motor test voltage
Here the voltage can be set for the motor test; to simulate a 6-cell Ni-Cad battery pack requires a
voltage of 7,5 volts. The set value is the no-load voltage, i.e., the voltage applied to the motor with
no current flowing. Since even under no-load conditions some current flows in the motor, maximum
motor voltage drops by a factor of the motor current multiplied times 0,04 (= 40 mΩinternal
resistance of battery pack).
Current Limiter
TestVoltage:7.5V [Start] return to function selection
Current Lim:120A [Mode] next parameter
[+] [-] change sensitivity
Here the current limiter can be set between 50 and 150 Amps.
Maximum detection of RPM
TestVoltage:7.5V [Start] return to function selection
Rpm Detection: 1 [Mode] next parameter
[+] [-] change sensitivity
There are two sensitivity levels for detecting final RPM. For modified motors, use level 1. For
motors with worn commutators or stock motors, RPM detection with level 2 can be used.

Robitronic Pro-Master Manual Operating Instructions
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Flywheel's moment of inertia
Flywheel: 45.00 [Start] return to function selection
Armature: 4.20 [Mode] next parameter
[+] [-] change flywheel values
Using a different flywheel requires you to enter the moment of inertia here. This value is needed for
the computation of torque, power and efficiency of the motors. Entering an incorrect moment of
inertia results in falsified motor data. The moment of inertia for the included flywheel is 45,00 x 10e-6
kgm2.
Armature's moment of inertia
Flywheel: 45.00 [Start] return to function selection
Armature: 4.20 [Mode] next parameter
[+] [-] change motor armature value
In addition to that of the flywheel, the moment of inertia of the motor armature must also be
considered for a measurement. The value above is an average of various commonly available
armatures. The value should not be changed initially, but can be adapted for special applications. The
factory setting is 4.20 x 10e-6 kgm2.
Changing step values for current and torque table
The motor's characteristic curve is displayed in the form of a current table and a torque table with 10
entries each, where the 10 current and 10 torque values in the table are factory set and the
corresponding motor data is computed. These 10 default values each for current and torque can be
modified here.
Step Amp Torque [Start] return to function selection
01: 20A 20Nmm [Mode] next parameter
[+] [-] change table index
Select the number of the table value; there are a total of 10 table values.
Step Amp Torque [Start] return to function selection
01: 20A 20Nmm [Mode] next parameter
[+] [-] change current value
Change the current value for a table entry.

Robitronic Pro-Master Manual Operating Instructions
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Step Amp Torque [Start] return to function selection
01: 20A 20Nmm [Mode] next parameter
[+] [-] change torque value
Change the torque value for a table entry.
Overview of table with default values
No. Default current Default torque
120 A 20 Nmm
230 A 40 Nmm
340 A 60 Nmm
450 A 80 Nmm
560 A 100 Nmm
670 A 120 Nmm
780 A 140 Nmm
890 A 160 Nmm
9100 A 180 Nmm
10 110 A 200 Nmm
Ending the motor check
--Motor Check -- [Start] return to main menu
6:-> Main Menu [Mode] next function
This terminates the motor check function and returns to the main menu.

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Charging battery packs
Preparing to charge a battery pack
To use the battery pack charging function, you need a 12-volt lead-acid battery or a stabilized power
supply. Connect to the supply voltage to Pro-Master main unit using the battery clips.
The battery pack to be charged is connected to the socket labeled "Output" and the temperature
probe (with clip attachment) to the "Sensor" socket on Pro-Master.
Selecting the charging function:
-- Main Menu --
2:Charge Battery
The charging function is selected in the main menu by pressing the [Start] key.
Selecting a charging program
- Charge Menu -
1:Start Progr: 1
This function invokes a battery pack charging program. The [+] and [-] keys allow you to select
from among five charging programs. Pressing the [Start] key launches the charging program.
With menu item 2 "Set up charge" you can modify the charging programs. This allows you to set
different charging currents and cutoff methods to match your applications.
Start charging
After selecting a charging program, you can initiate charging by pressing the [Start] key again.
L 21.4/p15 00:00
0.0A 0.0V 0000
Pressing the [Mode] key terminates charging.

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Setting charging current
L 21.4/p15 00:00
Setup Amps: 5.0A
The charging current can be modified during charging with the [+] and [-] keys.
No general recommendations can be made for setting the charging current as it depends on both the
battery packs and the intended application. A general rule is that higher charging current yields
higher stored voltage (= power) and lower charging current yields more capacity (= operating time)
when discharging the battery pack. For quick-charging battery packs, you should select a charging
current between 3 and 6 amperes.
SANYO battery pack: charging current 4.5A - 5.5A (standard 5.0 A)
PANASONIC battery pack: charging current 4.0A - 5.0A (standard 4.5 A)
Settings for hobbyists:
Charging current: 3.5 amperes
Cutoff method: peak 0.10V 10min
Settings for competition:
Charging current: 5.0 amperes
Cutoff method: peak 0.10V 5min
or temp 40°C 2800 mAh
Modifying a charging program
- Charge Menu -
2:Setup Charge
Selecting the function "Setup Charge" allows you to modify the five charging programs. This enables
you to store different charging options for different applications.

Robitronic Pro-Master Manual Operating Instructions
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Setting the delta peak charging method
Progr:1 L 5.0A
Peak 0.15V 0min
Selecting the delta peak charging method Peak at the bottom left of the setup display allows you to
set the value of the voltage peak (default value: 0,1V). Excessive peak voltage can overload and
destroy a battery pack.
In addition, a delay time can be set. Here the battery pack voltage is tested for a voltage drop only
after the set time. This enables charging even old battery packs with poor voltage characteristics
using the delta peak method. CAUTION: the delay is not suited for recharging (repeaking) battery
packs.
Setting the temperature charging method
Progr:1 L 5.0A
Temp 42C 3000mAh
Selecting the temperature charging method Temp at the bottom left of the setup display allows you
to set the cutoff temperature and the maximum charged capacity; i.e., charging is terminated when
the preset battery pack temperature or the preset charged capacity is attained. If the temperature
probe is not connected properly, the set maximum charged capacity still largely protects the battery
pack against overloading. The setting for charged capacity must accommodate the respective battery
pack type. This value can be determined via several test charges, where the highest possible capacity
value is used. Experience puts the values for Sanyo battery packs at ca. 2500-2800 mAh and for
Panasonic battery packs at ca. 2600-3000 mAh.

Robitronic Pro-Master Manual Operating Instructions
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Function diagrams
Pro-Master function overview

Robitronic Pro-Master Manual Operating Instructions
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Pro-Master function overview

Robitronic Pro-Master Manual PC Software
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PC software
System requirements
The PC Software requires an IBM compatible computer with the MS-DOS operating system with a
VGA board and at least one serial port.
Keyboard layout
Key to symbols
[key] A word or letter in square brackets indicates a key on your PC keyboard,
e.g., [Space], [F10] - function key, [J] - letter
[key1] + [key2] Two keys must be pressed simultaneously; e.g., [Ctrl] + [D] means that you
press and hold the control key [Ctrl] and then key [D].
<function> These functions (in angled brackets) can be selected from the menu with the
mouse pointer or cursor keys.
Function keys [F1],[F2],[F3],[F4],[F5],[F6],[F7],[F8],[F9],[F10],[F11],[F12]
Enter key [Enter]
Control key [Ctrl]
Cursor keys [Cursor up], [Cursor down], [Cursor left], [Cursor right]
Paging keys [Page up], [Page down]
Plus & minus keys [Plus], [Minus]
Functions <Motor Check>, <File>, <Show Data>, <View Axis>, <Print Data>,
<Setup>, <Export>, <Exit>; <Save>, <Cancel>; etc.