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(217) 352-9330 | Click HERE Find the Magtrol HD-500-6N at our website:...
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HD and ED Series Hysteresis Dynamometers User’s Manual Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
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While every precaution has been exercised in the compilation of this document to ensure the accuracy of its contents, Magtrol, Inc./Magtrol SA 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.
Please take the time to read this page thoroughly before connecting and using your dynamometer. 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 operation on any dynamometer that uses AC input power.
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.
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09/25/03 2nd Edition - rev. C New "B" and "E" dimensions for HD-106 1.3.1 08/19/03 2nd Edition - rev. B New schematic drawing for HD-800–815 Brake Control Supply 03/17/03 2nd Edition - rev. A New "F" dimension for HSD-610M 1.3.5 03/17/03 2nd Edition - rev.
CoNVENTIoNS USED IN ThIS MANUAL ........................VII 1. introduCtion ..........................1 1.1 UNPACkINg YoUR hYSTERESIS DYNAMoMETER ................... 1 1.2 FEATURES oF ThE hYSTERESIS DYNAMoMETER .................... 2 1.2.1 hD SERIES ..............................2 1.2.2 ED SERIES ..............................2 1.3 DATA ShEET ................................3 2. inputs/outputs ...........................16 2.1 REAR PANEL ................................
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CoNTRoL SUPPLY ........................60 index ..............................61 serviCe information ........................63 RETURNINg MAgTRoL EqUIPMENT FoR REPAIR AND/oR CALIbRATIoN ............. 63 RETURNINg EqUIPMENT To MAgTRoL, INC. (UNITED STATES) ..............63 RETURNINg EqUIPMENT To MAgTRoL SA (SWITzERLAND) ..............63 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
Preface purpose of this manual This manual contains all the information required for the setup and general use of Magtrol’s hysteresis Dynamometers. To achieve maximum capability and ensure proper use of the dynamometer, please read this manual in its entirety before operating. keep the manual in a safe place for quick reference whenever a question should arise.
Magtrol Hysteresis 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 function of the product.
Cable Calibration Certificate 2. Inspect the contents for any evidence of damage in shipping. In the event of shipping damage, immediately notify the carrier and Magtrol’s Customer Service Department. Note: Save all shipping cartons and packaging material for reuse when returning the instrument for calibration or servicing.
Unique features of each series are listed below. 1.2.1 HD S erieS Magtrol’s hD Series Dynamometers are versatile and ideal for testing in low to medium power ranges. Features include: • Accuracy: ±0.25% to ±0.5% full scale, depending on size and system configuration.
Magtrol HD applications provides a NIST traceable certificate of calibration, and Magtrol motor test systems can be found in test labs, at calibration beam with each Engine Dynamometer. inspection stations, and on the manufacturing floors of most of the world’s leading manufacturers, users and certifiers of small...
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Dynamometer has advantages and limitations and choosing the correct one will depend largely on the type of testing to be performed. With over 50 models to choose from, Magtrol Sales professionals are readily available to assist in selecting the proper Dynamometer to meet your testing needs.
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Magtrol Hysteresis Dynamometers Chapter 1 – Introduction Ratings HD / ED Max. Power Ratings Nominal Maximum Torque Maximum Drag Torque Brake Input Inertia Speed 5 minute continuous*** Model Measure Torque De-Energized Cooling Unit Code Range at 1000 rpm Method lb·ft·s²...
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Magtrol Hysteresis Dynamometers Chapter 1 – Introduction Ratings HD / ED HD / ED electrical power anD Fuses Model Voltage Style Rating HD-1XX-XN 120 V UL/CSA 300 mA 250 V HD-1XX-XNA 240 V 125 mA 250 V HD-4XX-XN 120 V...
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Chapter 1 – Introduction Magtrol Hysteresis Dynamometers Dimensions HD / ED NOTE: Original dimensions are in English units. Dimensions converted to Metric units have been rounded and are for reference only. HD-100/400/500 series witH long Base plate ØB ØN SHAFT END DETAIL (2:1)
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Magtrol Hysteresis Dynamometers Chapter 1 – Introduction Dimensions HD / ED HD-700 series witH long Base plate ØB SHAFT END DETAIL (2:1) ØN (FLAT) Model units Ø B Ø N Weight 1.25 0.4995/0.4999 5.875 24 12.75 11 0.625 22.5 9.5 0.375 0.06...
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Chapter 1 – Introduction Magtrol Hysteresis Dynamometers Dimensions HD / ED HD-800 series witH long Base plate ØB ØN NOTE: For detailed dimension drawings of dynamometers with the T-slot base plate option, visit Magtrol’s Web site. Model units Ø B Ø...
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Magtrol Hysteresis Dynamometers Chapter 1 – Introduction Power Absorption Curves HD / ED 36000 Maximum Rated Maximum Kinetic Power Rating Speed for 30000 Curve for Less Than Five Dynamometer Minutes: Area under curve 24000 equals the maximum speed and 18000 torque combinations for a motor test of less than five minutes.
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Magtrol offers both open loop manual test systems and PC-based closed loop test systems. A typical open loop system will consist of a Dynamometer and a Magtrol 6200 Open-Loop Controller. A Magtrol Single or Three-Phase Power Analyzer, which allows for the capturing of volts, amps, watts and power factor, can be included as an option.
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System Configurations HD / ED custom motor test system HD Series Hysteresis Dynamometers can be incorporated into a Customized Motor Test System. These PC based, turn-key systems are custom designed and built to meet specific user requirements. heavy-duty equipment rack...
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Calibration Beam Assemblies and Calibration Weights CB and WT Series CALIBRATION * Mounting of ED Engine Dynamometers to dynamometer tables requires certain modifications. Contact Magtrol for details. Due to the continual development of our products, we reserve the right to modify specifications without forewarning. www.magtrol.com www.magtrol.com...
The bolts are identified with red heads. Refer to the diagrams below for the bolt location on your model. Note: Retain the shipping/restraining bolt for future use when moving or shipping your Magtrol Dynamometer. 3.1.1 HD-100, -400 -500 S...
Magtrol Hysteresis Dynamometers Chapter 3 – Installation/Configuration 3.1.2 HD-700 S erieS The shipping/restraining bolt is located on the front side of the hD-700 Series hysteresis Dynamometers as shown in Figure 3–2. SHIPPING BOLT Figure 3–2 HD-700 Series Shipping/Restraining Bolt Location 3.1.3...
Chapter 3 – Installation/Configuration Magtrol Hysteresis Dynamometers earth ground before proceeding any further, the dynamometer must be connected to earth ground. The earth ground is located on the top of the dynamometer as indicated in the following diagrams by the earth ground symbol.
The dynamometer can be set up as a manual test system for quick pass/fail testing on the production line or at incoming inspection. A typical manual test system will consist of a Magtrol hysteresis Dynamometer used in conjunction with a Magtrol 6200 open-Loop Controller.
3.3.2 PC-B aSeD ySTeMS In a PC-based motor test system, data is collected on a personal computer using Magtrol’s M-TEST Software, a DSP7000 Programmable Dynamometer Controller and requisite interface cards and cables. Note: Magtrol’s Single or Three-Phase Power Analyzer can be integrated into this system as well as Magtrol’s Temperature Testing hardware...
When used with the DSP7000, pin 1 is internally pulled high with a resistance to 5 volts. If not using a Magtrol controller, it is assumed the user will pull pin 1 to the 5 volts supplied to the amplifier board (pin 7) with a 1 k to 10 k resistor.
Chapter 3 – Installation/Configuration Magtrol Hysteresis Dynamometers 3.3.3.1 Blower Setup If an hD-710, hD-715, hD-810, hD-815, ED-715 or ED-815 dynamometer is being used, a blower input is integrated into the unit. Figure 3–10 Dynamometer with Blower Connection For more information, see Section 4.1.3.2.2 – Blower.
4. Testing testing Considerations A number of factors must be taken into consideration before running a test including safety, accuracy, power dissipation, fixturing, couplings, windage, friction, vibration, cogging, eddy currents and temperature rise. The following sections describe these factors, and their effects, in further detail. 4.1.1 afeTy for general safety considerations, please follow these few common-sense rules:...
4.1.3 ower iSSiPaTion All Magtrol Dynamometers are power absorption instruments. As a dynamometer loads a test motor, it is absorbs horsepower from the motor into the hysteresis brake. The brake then converts this mechanical energy into heat. There are finite limits to the amount of energy and resulting temperature rise that any absorption brake can withstand.
Magtrol Hysteresis Dynamometers Chapter 4 – Testing • Maximum brake temperature = 100 °C (212 °F) • Maximum rotor temperature = 460 °C (860 °F) • Ambient temperature = 25 °C (77 °F) • The dynamometer cooling system is running The following values are sufficiently accurate (within 1%) to establish watts (W) for use in the heat rise curves.
4.1.3.2.1 Compressed Air Magtrol’s hD-510, 515, 800 and 805 dynamometers are internally ported for compressed air cooling. Always use the filter and line regulator supplied with the unit. These elements should be installed Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
NoT exceed The pRessuRes GIveN. The air supply should be enabled whenever the unit is in operation. 4.1.3.2.2 Blower Magtrol’s hD-710/715/810/815/825 and ED-715/815 dynamometers are internally ported for blower cooling. The following diagram illustrates the connection. Figure 4–21 Dynamometer with Blower Connection WARNING!
Windage effects on accuracy tests have been conducted on all Magtrol dynamometers. The percentage of torque loss due to windage ranges between 0.025% and 0.20% of full scale at maximum rated rpm.
“settle” negating frictional effects. If excessive drag is present, mechanical realignment may be required, dependent upon dynamometer size. Certain mechanical factors need to be determined before corrective action proceeds. Please contact Magtrol Technical Assistance. 4.1.7 iBraTion All rotating dynamometer assemblies are precision balanced, however, the dynamometer shaft is cantilevered.
Chapter 4 – Testing Magtrol Hysteresis Dynamometers 4.1.8 ogging Rotor Poles Case Rotor Assembly Pole Figure 4–23 Hysteresis Brake Cross-Section This cross-section shows (by one tooth) the magnetic relationship of the hysteresis brake elements. If the dynamometer shaft is at rest with torque applied, and if the torque control is then reduced to zero, a magnetic salient pole will be temporarily imposed on the rotor of the brake.
1000 rpm of applied speed. Note: If highly accurate long-term torque stability is required, consider the Magtrol DSP7000 Dynamometer Controller. This is a computer- controlled closed loop system capable of maintaining either constant torque or speed.
5. Operating Principles speed Inside the dynamometer enclosure is an optical speed transducer. A high-speed optical switch, consisting of an Infrared (IR) LED and IR receiver, senses the passage of light through a slotted disk that is attached to the end of the dynamometer shaft. Light passing through a slot in the disk causes the speed output signal to go to a logic low (near 0 VDC).
The clockwise calibration (CW CAL) adjustments should not typically need readjustment. In the event that a “CW CAL” adjustment is needed, a precision calibration beam and weight must be used. The calibration beam may be purchased from Magtrol. Note: Use only an insulated screwdriver or a plastic trim pot adjustment tool when adjusting the “CW CAL,”...
Control poWer Any Magtrol Dynamometer Controller is universal in that it must operate all dynamometers. Due to the higher level of current required by Magtrol’s larger dynamometers, a booster power amplifier is used to increase the control current.
To perform a successful dynamometer calibration, a precision weight heavy enough to apply a torque at or close to the full scale rating is required. Magtrol offers precision weights (WT Series) and calibration beams (Cb Series) rated specifically for each hysteresis Dynamometer.
Chapter 6 – Calibration Magtrol Hysteresis Dynamometers Calibration preparation before beginning the calibration procedure, the following items must be checked. • Be sure all equipment is set for the correct power-line input voltage as specified on the original order. •...
5. Adjust the CW Calibration trim pot so that the torque reading equals the weight times the distance. Note: If using Magtrol Cb Calibration beams in conjunction with WT Calibration Weights, simply calibrate to the full scale torque listed in the table in Section 6.1 – Calibration Beams and Weights.
The dynamometer is calibrated and ready for motor testing. Calibration frequenCy Magtrol load cells are temperature compensated and designed for stability. It is a good idea to calibrate, frequently at first, maintaining a record (see Appendix A – Calibration Record) until you have established a history.
7. Optional Features speed enCoder All Magtrol dynamometers come standard with a 60-bit speed encoder, best suited for high-speed systems. For low speed motors, with maximum speeds of less than 200 rpm, Magtrol offers several additional encoder options, which include: •...
8. Troubleshooting torque readout problems 8.1.1 ynaMoMeTer If the dynamometer is new (never operated before) and the torque reading is near full scale and constant, the probable cause is failure to remove the shipping restraining bolt. This applies to all dynamometers with model numbers from 106 to 715.
If the torque reading is erratic, then the problem could be a defective load cell or electronic component in the dynamometer or readout device. It will be necessary to establish specifically what is defective. At this time contact Magtrol Technical Assistance. 8.1.3...
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Magtrol Hysteresis Dynamometers If the reading is within ±10% of the value specified in the table, proceed to Section 8.1.3.2 – Current Check . If the reading is not within the values specified, contact Magtrol Technical Assistance. Note: The resistance check in the table is accurate for Magtrol hD- 106, -100, -400, -500 and -700 Series, ED-715 and hD-825 Dynamometers.
Magtrol Hysteresis Dynamometers Chapter 8 – Troubleshooting 8.1.4 eCHaniCal oTaTional lignMenT Refer to the drawing and the instructions below if the dynamometer will apply torque but the torque reading will not calibrate full scale, even though the zero balance is within tolerance. See Figure 5–1 Mechanical Layout of a Load Cell.
It must be tight on the rotor shaft and the shaft must rotate freely. Also, make sure that the disk is not bent or distorted. If the disk is damaged, contact Magtrol Technical Assistance for a replacement disk.
Magtrol Hysteresis Dynamometers Appenidix B: Schematics speed sensor board (Pin 7 of 14 Pin, 0PB963 Brown Wire) (Pin 10 of 14 Pin, White Wire) (Pin 8 of 14 Pin, Green Wire) 2015 and later dynamometers: OPB963N 51 .01uF 4.7uF PA D6...
Appenidix B: Schematics Magtrol Hysteresis Dynamometers load Cell sChematiC VOLTAGE LEVELS: TEMP COMP +5 VDC 50 OHM 0-11 MILLIVOLT SIGNAL LEVEL BLUE TO GREEN BLUE S.G. = (4)-350 OHM 0-15 mVDC 4.42K OHM GREEN 1 OHM (2) WHITE -5 VDC...
Magtrol, Inc. in the United States or Magtrol SA in Switzerland. returning equipment to magtrol, inc. (united states) When returning equipment to Magtrol, Inc.’s factory in the United States for repair and/or calibration, a completed Return Material Authorization (RMA) form is required.
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Testing, Measurement and Control of Torque-Speed-Power • Load-Force-Weight • Tension • Displacement www.magtrol.com MAgTROL INC MAgTROL SA subsidiaries in: 70 Gardenville Parkway Route de Montena 77 Germany • France China • India Buffalo, New York 14224 USA 1728 Rossens / Fribourg, Switzerland...
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