User’s Manual
Micro Dyne System
Second Edition, rev C– May 2013
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. CopyrightCopyright ©2007–2013 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. trADEMArKSNational Instruments™ is a trademark of the National Instruments Corporation.
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: _____________________________
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Safety Precautions
• Secureallgroundingwirestotheappropriatelocationstoreducethechanceofshockanddamage to the equipment.
• Makesureallwiringandconnectionshavebeenproperlymade.
• AlwayswearsafetyglasseswhenworkingaroundMicroDyneequipment.
• DonotwearlooseclothingortieswhenoperatingtheMicroDyneequipment.
• Ensuremotorundertestisproperlymountedtothemotorfixture.
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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.
rEviSion DAtE
Second Edition, rev C – May 2013.
tAblE of rEviSionS
Date Edition Change Section(s)02/21/13 2nd Edition, rev. C Chapter 7 Calibration - Watt Meter added. Chapter 705/21/13 2nd Edition, rev. C Calibration commands updated. A.2.809/02/10 2nd Edition, rev. B Step 3 has been removed. It is no longer neccessary to move
the pendulum when installing the circular mass.4.1 step 3
09/02/10 2nd Edition, rev. B Speed Pick-up Connection has been removed from side of electronics box. It is now concealed in the dynamometer housing.
2.2.2
09/02/10 2nd Edition, rev. B Earth ground has been removed from rear of base plate. It is now concealed in dynamometer housing.
2.2.1
09/30/09 2nd Edition, rev. A The number of cycles performed changed from five to ten 6.3.2, step 407/11/08 2nd Edition New calibration software and procedure Chapter 6, A.2.810/21/07 1st Edition, rev. A Added option to print calibration data results at end of
calibration procedure.6.3
06/13/07 1st Edition Finalized version of preliminary manual various
Revisions To This Manual
iii
Table of Contents
SAfEty prECAutionS .........................................................................................................................i
rEviSionS to thiS MAnuAl ...............................................................................................................iiREvISIoN DATE .................................................................................................................................................................II
TAblE oF REvISIoNS ......................................................................................................................................................II
tAblE of ContEntS ..........................................................................................................................iiiTAblE oF FIgURES ......................................................................................................................................................... v
prEfACE .............................................................................................................................................. viiPURPoSE oF ThIS MANUAl .......................................................................................................................................vII
Who ShoUlD USE ThIS MANUAl ............................................................................................................................vII
MANUAl oRgANIzATIoN ...........................................................................................................................................vII
CoNvENTIoNS USED IN ThIS MANUAl ................................................................................................................ vIII
1. introDuCtion ................................................................................................................................11.1 UNPACkINg ThE MICRo DyNE .......................................................................................................................... 1
1.1.1 PACkAgINg .............................................................................................................................................. 1
1.1.2 PARTS lIST ................................................................................................................................................ 1
1.2 DATA ShEET ............................................................................................................................................................ 3
2. inStAllAtion/ConfigurAtion ....................................................................................................82.1 DyNAMoMETER SETUP ....................................................................................................................................... 8
2.1.1 UNloCkINg ThE ShIPPINg/RESTRAININg bolT ........................................................................... 8
2.1.2 DyNAMoMETER lEvElINg ................................................................................................................. 8
2.2 ElECTRICAl CoNNECTIoNS .............................................................................................................................. 9
2.2.1 EARTh gRoUND ...................................................................................................................................... 9
2.2.2 REAR PANEl CoNNECToRS ............................................................................................................... 10
2.3 MoToR PoWER .................................................................................................................................................... 10
2.3.1 PoWER CoNFIgURATIoN oPTIoNS .................................................................................................. 12
2.4 MoToR TESTINg SoFTWARE ............................................................................................................................ 13
2.4.1 SoFTWARE INSTAllATIoN ................................................................................................................. 13
2.4.2 M-TEST CoMMUNICATIoN ................................................................................................................. 13
2.5 CoMMUNICATIoN ChECk ................................................................................................................................. 14
2.6 INITIAl CAlIbRATIoN ....................................................................................................................................... 14
3. tESting ConSiDErAtionS ..........................................................................................................153.1 SAFETy .................................................................................................................................................................. 15
3.2 PoWER DISSIPATIoN ........................................................................................................................................... 15
3.2.1 PoWER AbSoRPTIoN CURvE ............................................................................................................. 16
3.3 ShAFT AlIgNMENT ............................................................................................................................................ 16
3.4 WINDAgE ............................................................................................................................................................... 16
3.5 FRICTIoN ............................................................................................................................................................... 17
3.6 vIbRATIoN ............................................................................................................................................................ 17
3.7 DyNAMoMETER lEvElINg .............................................................................................................................. 17
3.8 CoggINg ............................................................................................................................................................... 17
3.8.1 AvoIDINg CoggINg ............................................................................................................................ 18
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Magtrol Micro Dyne SystemTable of Contents
3.8.2 REMovINg CoggINg .......................................................................................................................... 18
3.9 EDDy CURRENTS ................................................................................................................................................. 18
3.10 TEMPERATURE RISE ........................................................................................................................................... 18
4. tESt SEtup .....................................................................................................................................194.1 ToRqUE CoNFIgURATIoN ................................................................................................................................ 19
4.2 MoToR MoUNTINg ............................................................................................................................................. 20
4.2.1 ShAFT CoUPlINg ................................................................................................................................. 20
4.2.2 ADAPTERS ............................................................................................................................................... 20
4.2.3 ClAMPINg STRAP ................................................................................................................................. 21
4.2.4 STAgE ADjUSTMENT ............................................................................................................................ 21
4.3 SoFTWARE CoNFIgURATIoN ........................................................................................................................... 22
4.3.1 MoToR REvERSAl ............................................................................................................................... 23
5. opErAting prinCiplES ...............................................................................................................255.1 ToRqUE MEASUREMENT .................................................................................................................................. 25
5.1.1 ToRqUE CAlCUlATIoN ..................................................................................................................... 25
5.2 SPEED MEASUREMENT ...................................................................................................................................... 26
5.3 CoNTRollER AND ThE PID looP .................................................................................................................. 26
5.3.1 P (PRoPoRTIoNAl gAIN) .................................................................................................................... 26
5.3.2 I (INTEgRAl) .......................................................................................................................................... 26
5.3.3 D (DERIvATIvE) ..................................................................................................................................... 26
5.3.4 ADDITIoNAl SCAlE FACToR ............................................................................................................ 27
5.3.5 hoW ThE PID looP WoRkS ............................................................................................................... 27
5.3.6 PID EqUATIoNS ..................................................................................................................................... 27
5.4 DC WATTMETER ................................................................................................................................................... 28
6. CAlibrAtion - DynAMoMEtEr ...................................................................................................296.1 CAlIbRATIoN SoFTWARE AND DRIvER INSTAllATIoN .......................................................................... 29
6.1.1 MICRo DyNE CAlIbRATIoN SoFTWARE ......................................................................................... 29
6.1.2 USb DRIvERS ......................................................................................................................................... 29
6.2 CAlIbRATIoN PREPARATIoN ........................................................................................................................... 30
6.3 CAlIbRATIoN PRoCEDURE .............................................................................................................................. 30
6.3.1 SETUP ....................................................................................................................................................... 30
6.3.2 RUN ........................................................................................................................................................... 31
6.3.3 PRINT REPoRT oR SAvE DATA ........................................................................................................... 35
7. CAlibrAtion - WAtt MEtEr ........................................................................................................367.1 CloSED-box CAlIbRATIoN ............................................................................................................................. 36
7.2 CAlIbRATIoN SChEDUlE ................................................................................................................................. 36
7.3 bASIC CAlIbRATIoN PRoCESS ........................................................................................................................ 36
7.3.1 INITIAl CAlIbRATIoN PRoCEDURE ................................................................................................ 36
7.3.2 volTS AND AMPS zERo AND gAIN .................................................................................................. 36
8. troublEShooting .......................................................................................................................38
AppEnDix A: hArDWArE CoMMAnDS ...........................................................................................39A.1 DATA FoRMAT ...................................................................................................................................................... 39
A.1.1 CoDES FoR CR - lF ............................................................................................................................... 39
A.2 MICRo DyNE CoMMAND SET .......................................................................................................................... 39
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Magtrol Micro Dyne System Table of Contents
A.2.1 CoMMUNICATIoN CoMMANDS ........................................................................................................ 40
A.2.2 RAMP CoMMANDS ............................................................................................................................... 40
A.2.3 SETUP CoMMANDS .............................................................................................................................. 41
A.2.4 SPEED CoMMANDS .............................................................................................................................. 41
A.2.5 ToRqUE CoMMANDS .......................................................................................................................... 42
A.2.6 PoWER ANAlyzER AND RElAy CoMMANDS ................................................................................ 42
A.2.7 MISCEllANEoUS CoMMANDS ......................................................................................................... 42
A.2.8 CAlIbRATIoN CoMMANDS ................................................................................................................ 43
AppEnDix b: SChEMAtiCS ...............................................................................................................44b.1 CoRE bloCk DIAgRAM .................................................................................................................................... 44
b.2 MAIN SChEMATIC ............................................................................................................................................... 45
b.3 DC WATTMETER ................................................................................................................................................... 46
AppEnDix C: CAlibrAtion rECorD .............................................................................................47
SErviCE inforMAtion ......................................................................................................................48RETURNINg MAgTRol EqUIPMENT FoR REPAIR AND/oR CAlIbRATIoN ..................................................... 48
RETURNINg EqUIPMENT To MAgTRol, INC. (UNITED STATES) ............................................................ 48
RETURNINg EqUIPMENT To MAgTRol SA (SWITzERlAND).................................................................. 48
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Magtrol Micro Dyne SystemTable of Contents
tAblE of figurES
1. introDuCtionFigure 1-1 Micro Dyne Accessories ............................................................................................................................2
2. inStAllAtion/ConfigurAtionFigure 2–1 Micro Dyne Dynamometer .......................................................................................................................8Figure 2–4 Electronics Unit Rear Panel ...................................................................................................................10Figure 2–5 Electronics Unit Front Panel ..................................................................................................................11Figure 2–6 Basic Motor Power Circuit .....................................................................................................................11Figure 2–7 Basic System Configuration ....................................................................................................................12Figure 2–8 Relay Configuration ...............................................................................................................................12Figure 2–9 Motor Drive Configuration ....................................................................................................................13
3. tESting ConSiDErAtionSFigure 3–1 Micro Dyne Power Absorption Curve ....................................................................................................16Figure 3–2 Hysteresis Brake Cross-Section ..............................................................................................................17
4. tESt SEtupFigure 4–1 Dynamometer, Inside View .....................................................................................................................19Figure 4–2 Micro Dyne Motor Fixture......................................................................................................................20Figure 4–3 Motor Fixture Adapters ..........................................................................................................................21Figure 4–4 M-TEST Configure Hardware Window ...................................................................................................22Figure 4–5 M-TEST Power Supply Configuration ....................................................................................................23Figure 4–6 Curve Test Parameters with Motor Reversal ..........................................................................................24
5. opErAting prinCiplESFigure 5–1 Illustrated Torque Principle....................................................................................................................25Figure 5–2 Micro Dyne Rotor ...................................................................................................................................26Figure 5–3 Control Loop and PID System Block Diagram ......................................................................................27
6. CAlibrAtion - DynAMoMEtErFigure 6–1 Hardware Update Wizard .......................................................................................................................29Figure 6–2 Calibration Setup Window ......................................................................................................................30Figure 6–3 Reset ZERO ............................................................................................................................................32Figure 6–4 Dynamometer Calibration ......................................................................................................................32Figure 6–5 Calibration Instruction and Progress Bars ............................................................................................33Figure 6–6 Calibration Complete .............................................................................................................................34Figure 6–7 Final Calibration Window ......................................................................................................................34Figure 6–8 Calibration Report .................................................................................................................................35
vii
purpoSE of thiS MAnuAl
This manual contains all the information required for the setup and general use of Magtrol’s Micro Dyne System. 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 intended for bench test operators who are going to use the Micro Dyne System in order to determine the torque and power of a miniature/micro 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 the dynamometer and its corresponding electronics 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.
The structure of the manual is as follows:
Chapter 1: INTRoDUCTIoN – Contains the technical data sheet for Magtrol’s Micro Dyne System which describes the system and all of its components, and provides detailed technical characteristics. A complete parts list, along with unpacking instructions, is also included in this section.
Chapter 2: INSTAllATIoN/CoNFIgURATIoN – Provides information needed for setup of the Micro Dyne System, primarily electrical connections and power configuration.
Chapter 3: TESTINg CoNSIDERATIoNS – Provides information on a number of factors that must be taken into consideration before running a test, including: safety, power dissipation, and influences that affect the apparent accuracy of the torque readout.
Chapter 4: TEST SETUP – Provides instructions on how to set up a motor test, including dynamometer setup, motor mounting and software configuration
Chapter 5: oPERATINg PRINCIPlES – Information pertaining to the theory of operation including torque measurement, speed measurement and the PID control loop.
Chapter 6: CAlIbRATIoN – Step-by-step instructions for the calibration procedure.
Chapter 7: TRoUblEShooTINg – Solutions to common problems encountered during setup, testing and calibration.
Appendix A: hARDWARE CoMMANDS – Provides command reference tables for users who wish to write their own application.
Appendix b: SChEMATICS – Contains a core block diagram, main schematic and wattmeter schematic.
Appendix C: CAlIbRATIoN RECoRD – Data record for tracking calibration results.
Preface
viii
Magtrol Micro Dyne SystemPreface
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.
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.
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1. Introduction
1.1 unpACKing thE MiCro DynE
1.1.1 Packaging
your Micro Dyne System was shipped in its own hard-sided carrying case with shock-resistant packing foam. The packaging is designed to protect the instruments during normal handling.
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.
1.1.2 Parts List
Make sure the case contains all the following:
A. Dynamometer with attached motor fixture
b. Electronics unit
Caution: the dynamometer and eleCtroniCs unit are shipped already ConneCted to one another by a series of Cables (bundled together). use Caution when lifting out of the Case.
C. CD-RoMs
1. M-TEST 5.0 CD-RoM
2. Micro Dyne Supplemental Programs and Utilities CD-RoM
3. Magtrol User Manual CD-RoM
D. bag of cables
1. USb cable
2. Three power supply cables with dual banana plugs on both ends
3. Main IEC power cord
E. A second bag of parts contains the following:
1. Circular weight and fastening (hex key) screw for torque configuration
2. hardware for motor fixturing
a. Two motor fixture adapters
b. Small Allen wrench (hex key)
c. Two small hex screws
3. Three bags of rubber couplings
a. Ten pieces of 0.5 mm inside diameter tubing, each 25 mm in length
b. Ten pieces of 0.8 mm inside diameter tubing, each 25 mm in length
c. Ten pieces of 1.6 mm inside diameter tubing, each 25 mm in length
4. Two calibration weights, one 5 g and one 10 g, tagged and labeled.
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5. Calibration documentation
a. Calibration certificate for Micro Dyne
b. Calibration test report for wattmeter
c. Calibration test report for dynamometer
6. Accessory tools
a. Tweezers
b. Medium Allen wrench
c. large Allen wrench
d. Five cable ties
Figure 1-1 Micro Dyne Accessories
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1.2 DAtA ShEEtMicro DyneData Sheet
Micro Dyne Motor Testing System
1 www.magtrol.com
MAGTROL
Features• designedspecificallyforminiatureandmicro
motors
• Torque:Easilyconvertiblefrom2.0mN·mto4.0mN·m(0.28oz·into0.57oz·in)
• Speed:upto100,000rpm
• Power:4W
• Lowinertia
• Soldasacomplete,out-of-the-boxmotortestingsystem.Componentsinclude:
• HysteresisDynamometer:providesprecisetorqueloadingindependentofshaftspeed
• MotorFixture:accommodatesmotorsfrom5mmto30mmindiameter.
• DedicatedElectronics:all-in-onedynamometercontroller,DCwattmeter,powerrelayandUSBinterface
• ComprehensiveMotorTestingSoftware
• Easy-to-usecalibrationsoftware
• Allnecessaryconnectioncables
• Calibrationweights:5gand10g
DesCrIPtIONWith over 50 years’ experience in dynamometer designand torque measurement, Magtrol has revolutionized theindustry.Magtrol’sNEWMicroDyne,capableofmeasuring
extremelylowtorques(2.0mN·mcanberesolvedto0.0004mN·m),isdesignedExCLUSivELyfortestingminiatureandmicro(low-torque)motors.
Fortheutmostconvenience,theMicroDyneispackagedasaCOMPLETEMOTOR TESTiNG SySTEM.Everythingthatisneededtoaccuratelyandefficientlytestminiaturemotorsandmicromotorsisincludedwiththepurchaseof aMagtrolMicroDyne.Theonlycomponentthatneedstobesuppliedbythecustomerisalaptopordesktoppersonalcomputerandmotorpowersupply.
aPPLICatIONsMagtrol motor test systems can be found in test labs, atinspectionstations,andonthemanufacturingfloorsofmostof the world’s leading motor manufacturers. The MicroDynesystem isusedexclusively forclosed-loop testingofminiaturemotorsandmicromotorsusedinlow-torque/high-speedapplications.
Motor sub-types include, but are not limited to, thefollowing:
• BrushedandbrushlessDCmotors• Gearmotors• BrushlessDCservomotors• vibratormotors• Miniatureairmotors
These mini/micro motors are used in a diverse range ofindustriesandproducts,including:
• Medicalandlaboratoryequipment• Roboticsandautomation• Toys• Handheldcommunicationdevices• Audio/videoequipment• Opticsandphotonics• Aerospaceanddefense• Securityandinstrumentation• industrialmachinery
Motor Characteristics
Measured/Calculated:
• Torque
• Speed
• Amps
• Volts
• Horsepower
• Efficiency
• Input Watts
• Output Watts
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Micro Dyne
MAGTROL
System Configuration
BLOCk DIagraM
PC with M‑TEST 7
and calibration software
DSP
Firmware
DSP
Power Supply
Mains(IEC 80 – 240 V AC,
60/50 Hz)
Motor Under Test
motor power
Slotted Disc
brake power
USB cablespeed signal (via fiber optic speed pickup)
torque signalBrake
systeM MODeL
Motor Fixture
motor under test
motor electrical
connectionmotor fixture adjustment knobs (height, width and depth)
Electronic Unitfunctions as a: • Dynamometer Controller • DC Wattmeter • Power Relay • USB Interface
Dynamometer
leveling knobs
motor clamping strap (with knurled cam grip)
voltage sense terminals
motor power IN terminals
motor power OUT terminals
shipping bolt knob
dynamometer shaft
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Micro Dyne
MAGTROL
Dynamometer
T he M ic ro DynedynamometerabsorbspowerwithMagtrol’sun ique HysteresisBr a k i ng Sys t em .Because it does notrequirespeedtocreatet o r q u e , t h edynamometer canconduct a full motorramp—fromfree-runtolockedrotor.
i n a d d i t ion t o ad e d i c a t e d m o t o rf i x t u r e , t h e
dynamometer base plate also includes leveling knobs andmotorpower terminals. Thehousingof thedynamometerprotectsallthemovingpartsofthebrake.
Electronic Unit
At thehubof theM i c r o D y n es y s t e m i s amultifunctionalelectronic unit.TheunitemploysDSP technologyfor h igh-speeddata acquisitionand complete PC
controlofthedynamometer.AUSBreceptacleenableseasyconnection to a personal computer. An integrated DCwattmeterreadsvoltsandamps,andcalculateswatts;andabuilt-inpowerrelaycontrolsmotorpower(on/off).
The front panel includes the terminals for motor powerin/outandvoltagesensing.LEDpowerandcommunicationindicatorsarelocatedontherearpaneloftheunit.
Motor Fixture
Attachedtothedynamometerbaseplateisamotorfixturedesignedexpresslyformicro/miniaturemotors.ThebaseofthefixturefeaturesanxyZstagewith3-axispositioningforexcellentadjustabilityandmotor centering. With the includedadapters,motorsfrom5mmto30mmindiametercanbeeasilymounted.Thefixtureiskeyedtohelpsecurethemotorundertestandarubberstrapwithknurledcamgripprovidesmotorclamping.
Motor Testing Software
Magtrol’sM-TEST7isas t a t e - o f - t h e - a r tcomprehensive motortestingprogramdesignedforusewithWindows®operating systems forP C - b a s e d d a t aacquisition.Thesoftwaremeasuresandcalculatesa motor’s performance
characteristicsbyemployingtheseuser-configurabletestingmethods:
Ramp: Selectfromaveragerampdown/uporrampdownwithinertiacorrectionfactor.Alsoallowsextrapolationoffree-runandlocked-rotordata,plusinterpolationofspecificspeedortorquedatapoints.
Curve: Testspeed,torque,amps,wattsinput,wattsoutputandopenloopparameters,andcomparesactualvaluestouser-definedlimits.Capableofadjustingsamplingrateandusingsteporrampfromoneloadpointtothenext.
Pass/Fail: Checksamps,inputwatts,speed,torqueandoutputwattsagainstuser-definedvalues.
Thedatageneratedcanthenbestored,displayedandprintedintabularorgraphicformats,andiseasilyimportedintoaspreadsheet.
System Information
Speed Measurement
TheMicroDynecontainsareflectivefiberopticspeedpickup.Eachrotorslotthatpassesbythesensingendofthefiberopticgeneratesanelectronicpulse,which is thenconverted toaspeedreading(inrpm).
Torque Measurement
Ahysteresisbrakeisusedtodeveloparesistancetorotationofamechanicalshaft.Atorsionalforceisproducedbythetestmotor and applied to thebrake’s rotor-shaft assembly.Reaction torque is measured by the angle of the brakependulum assembly and is interpreted by the Micro Dynesystemsoftware(M-TEST7).
OPeratINg PrINCIPLes
systeM COMPONeNts
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Micro Dyne
MAGTROL
SpecificationsDyNaMOMeter
MaximumTorque
NominalInput Inertia
Maximum Kinetic Power MaximumSpeed * Accuracy
5 minute continuous
mN·m kg·cm² W W rpm Torque Speed
4.0 or 2.0 5.43 × 10‑4 4 4 100,000 < 1% of full scale
< 0.02% of reading
Power Absorption Curve
Basedonthemaximumkineticpowerratings,thecurvebelowrepresentsthemaximumpower(heat)thatthedynamometercandissipateovertime. The area under the curve equals themaximumspeed/torquecombinationsforbothamotortestoflessthan5minutes(intermittentduty),andacontinuous-dutymotortest.
DyNAMoMETEr ENvIroNMENTAl rEqUIrEMENTSOperating Temperature 0 °C to +70 °CRelative Humidity < 60% without condensation
EMC In accordance with IEC 61326:2002
MoTor ACCoMMoDATIoNMotor Diameter 5 mm – 30 mmMotor Length 5 mm – 50 mmMotor Shaft Diameter 0.75 mm – 3 mmMaximum Load 100 g
MOtOr FIxture
ADjUSTAbIlITyX/Y/Z Adjustable Range ±5 mm (all axes)Controllable Motion 0.005 mmTravel per Knob Revolution 0.318 mm
eLeCtrONIC uNIt
GENErAl ElECTrICAl CHArACTErISTICSFuse (5 × 20 mm) IEC 315 mA 250 V TPower Requirements 14 VAVoltage Requirements 85 – 264 V AC, 60/50 HzENvIroNMENTOperating Temperature 0 ºC to +70 ºCRelative Humidity < 60% without condensation
TheMicroDyneofferstwodifferenttorqueconfigurationsinoneunit.Dependingonthemotor’smaximumtorquerating,theusercaneasilyswitchbetweenthe2.0mN·mand4.0mN·mtorquesettingsviathedynamometer’srearaccesspanel.Theratingsarethesameforeitherconfiguration.
0
1.0
2.0
3.0
4.0
0 20000 40000 60000 80000 100000
SPEED (rpm)
To
rq
UE
(m
N·m
)
MaximumRated Speed
MaximumRated Torque
PowEr MEASUrEMENT (DC)
Current Input (isolated) ± 5 A ±(0.1% Reading + 0.2% Range)
Voltage Input (isolated) ± 30 VDC ±(0.1% Reading + 0.2% Range)
Conversion Rate 15/second/inputPower Accuracy 0.4% of VA rangeIsolation, to earth 50 V DCIsolation, channel‑to‑channel 100 V DC
* Because the MicroDyne is optimized for high speeds, the lowest measurable speed is 50 rpm. If a motor is operating at less than 50 rpm, the speed measurement will read zero.
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Micro Dyne
Due to the continual development of our products, we reserve the right to modify specifications without forewarning.
www.magtrol.com
MagtrOL INC70 Gardenville ParkwayBuffalo, New York 14224 USAPhone: +1 716 668 5555Fax: +1 716 668 8705E‑mail: [email protected]
MagtrOL saRoute de Montena 771728 Rossens / Fribourg, SwitzerlandPhone: +41 (0)26 407 3000Fax: +41 (0)26 407 3001E‑mail: [email protected]
Subsidiaries in:Germany • France
China • IndiaWorldwide Network
of Sales Agents
Dimensions (mm)
MD
-US
04/1
4
3 DIMENSIONAL VIEWSCALE 1 : 4
72
190
195
245
264
267
THIS DRAWING AND SPECIFICATIONCONTAINS PROPRIETARY INFORMATIONTO MAGTROL INC. ANY DISCLOSUREOR REPRODUCTION OF THIS DOCUMENTWITHOUT WRITTEN AUTHORIZATION FROMMAGTROL INC. IS EXPRESSLY PROHIBITED
DRAWN
CHECKED
DESIGN
DGAJC
DG
09/06/0609/06/06
09/06/06 MAGTROL INC.BUFFALO, NEW YORK 14224-132270 GARDENVILLE PKWY, W.
THIRDANGLEPROJECTION
FINISH:
TITLE:
USED ON:
SIMILAR TO: 005729006542
REVDRAWING NUMBER:
006541 -
1:3 3 OF 3SHEET #SCALE
BSIZE
MATERIAL:
XX.X
UNLESS OTHERWISE SPECIFIED:DIMENSIONS ARE IN MILLIMETERS,DIAMETERS CONCENTRIC: 0.08 TIR,FACES PERPENDICULAR: 0.08INTERPRETATION PER ASMEY14.5M-1994REMOVE ALL BURRS AND BREAKSHARP EDGES 0.13/0.25 X 45°, ALLINSIDE CORNERS TO BE R 0.5 MAX.TOLERANCES:
X.XXANG.
SURFACE FINISH 3.2 µm MAX. U.O.S.
± 0.4± 0.25
± 0.13± 1°
MICRO DYNE ELECTRONICS BOX
DyNaMOMeter
eLeCtrONIC uNIt
BINDING POST FOR MOTOR POWER CONNECTION
LEVELING HARWARE
3 AXIS MOTOR FIXTUREADJUSTABLE ±5mm ON ALL AXES
MOTOR CLAMPING BAND
75SHAFT
HEIGHT
34
113
229
140
POSITION-2: 37.81POSITION-3: 49.24
*Z-AXIS:POSITION-1: 26.38
WIRE BUNDLE
180
*Y-AXIS: 58.4(TO V-BLOCK
VIRTUAL SHARP)
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2.0 h6DETAIL B
SCALE 2 : 3
DYNAMOMETER SHAFT
THIS DRAWING AND SPECIFICATIONCONTAINS PROPRIETARY INFORMATIONTO MAGTROL INC. ANY DISCLOSUREOR REPRODUCTION OF THIS DOCUMENTWITHOUT WRITTEN AUTHORIZATION FROMMAGTROL INC. IS EXPRESSLY PROHIBITED
DRAWN
CHECKED
DESIGN
AJCJEF
KC
09/24/0706/15/06
4/14/06 MAGTROL INC.BUFFALO, NEW YORK 14224-132270 GARDENVILLE PKWY, W.
THIRDANGLEPROJECTION
-FINISH:
-
TITLE
USED ON:
SIMILAR TO: -005784
REVDWG. NO.
006529 B
1:3 6 OF 6SHEET #SCALE
BSIZE
MATERIAL:
.XX.XXX
UNLESS OTHERWISE SPECIFIED:DIMENSIONS ARE IN INCHES,DIAMETERS CONCENTRIC: .003 TIR,FACES PERPENDICULAR: .003INTERPRETATION PER ASMEY14.5M-1994REMOVE ALL BURRS AND BREAKSHARP EDGES .005/.010 X 45°, ALLINSIDE CORNERS TO BE .02 R MAX.TOLERANCES:
FRAC. ANG.
SURFACE FINISH 125 RMS MAX. U.O.S.
± .01± .005
± 1/64"± 1°
MICRO DYNE, DYNAMOMETER ONLY
Weight 4.2 kg 9.3 lb
Weight 1.5 kg 3.2 lb
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2. Installation/Configuration
2.1 DynAMoMEtEr SEtup
Shipping bolt knob
Motor electrical connection
Leveling knobsBubble level
Figure 2–1 Micro Dyne Dynamometer
2.1.1 UnLocking the shiPPing/restraining BoLt
before dynamometer operation, the shipping/restraining bolt must be unlocked. A knob attached to the bolt is located on the top of the dynamometer housing, as shown in Figure 2–1. To unlock, lift up on the knob and turn it 90° to the “Unlock” position.
2.1.2 Dynamometer LeveLing
Simply level the dynamometer with the two leveling knobs at the front of the base plate, using the embedded bubble level as a guide.
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2.2 ElECtriCAl ConnECtionS
The Micro Dyne is shipped with the dynamometer and the electronics unit already connected to one another by a set of cables. These four cables are bundled together at the dynamometer end, and branch out into the following for connection to the electronics unit:
Connection Cable Attaches to DescriptionEarth ground Mounting plate of speed
pickupProvides safety against electric shock.
Dynamometer brake cable BRAKE Output Delivers power from electronics unit to dynamometer brake.
15-pin instrument cable ENCODER Input Quadrature encoder; reads torque measurement.
2.2.1 earth groUnD
For your safety, the dynamometer has been earth grounded and shipped with the ground strap already in place. This protective wire provides an alternate path to ground in case of short circuits or heavy electrical currents.
The other end of the ground strap should be connected to the metal tab attached to the speed pickup mounting plate, located on the Micro Dyne Electronics Unit. See Figure 2–3 Speed Pickup.
The complete earth ground path is as follows:
Dynamometer —> Electronics unit —> Main power cord —> Earth
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2.2.2 rear PaneL connectors
Figure 2–4 Electronics Unit Rear Panel
The rear panel connectors, from left to right, are:
Connector Attaches to Connection CablePOWER Input Power source Main power cordBRAKE Output Dynamometer Dynamometer brake cableSPEED Output External speed sensor 6-pin sensor cable USB Port Personal computer USB cable ENCODER Input Dynamometer 15-pin instrument cable
Using the table above, make the necessary connections with the cables provided. As noted in Section 2.2 – Electrical Connections, some of the cables have been installed prior to shipping.
2.3 Motor poWEr
Note: For detailed instructions on motor mounting, refer to Section 4.2.
Using the three power supply cables provided, make the following basic connections. other power configuration options are shown in Section 2.2.1.
Caution: pay attention to whiCh pin on the banana plug is positive and whiCh one is negative. ConneCt to the red (+) and blaCk (–) terminals aCCordingly.
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Magtrol Micro Dyne System Chapter 2 – Installation/Configuration
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terminal on Electronics unit Connected to Description
Motor Power In User’s power supply Allows power measurement and on/off switching from electronics unit.
Motor Power Out Motor connection point on dynamometer
Outputs power to the motor. Controlled by relay inside electronics unit which turns motor power on/off.
Voltage Sense Motor connection point on dynamometer
Measures voltage directly from the motor, thus eliminating voltage drop. Results in increased power measurement accuracy and efficiency.
Figure 2–5 Electronics Unit Front Panel
Figure 2–6 illustrates the internal wattmeter and relay layout, showing the complete basic power circuit from power supply to motor.
Motor
+
–
+
–
– +
MOTORPOWER
IN
MOTORPOWER
OUT
VOLTAGESENSE
MOTORPOWER
IN
MOTORPOWER
OUT
A
VCurrentMeter
VoltageMeter
Bananaplugs on
dynamometerpower terminal
MotorpowerSupply
DCSource
Relay
inside Micro Dyne Electronics box
Figure 2–6 Basic Motor Power Circuit
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2.3.1 Power configUration oPtions
2.3.1.1 Basic Configuration
This standard Micro Dyne setup shows a (customer-provided) motor power supply wired to the Micro Dyne Electronics Unit. This setup allows the Micro Dyne’s electronics to control on/off power to the motor under test, and to monitor input power.
(Customer)Motor Power Supply
+–
M-tESt
Micro Dyne Electronics unit
Micro DyneDynamometer
+
–
PC
USB
Motor Power Out
MotorPowerIn
Voltage Sense Leads
MotorLeads
MotorUnderTest
voltAgESEnSE
MotorpoWEr
out
MotorpoWEr
in
Figure 2–7 Basic System Configuration
2.3.1.2 Relay Configuration
To run a motor in both clockwise and counter-clockwise directions, without having to rewire during the middle of a test, a relay card is required. A National Instruments™ PCI relay card (available for purchase from Magtrol) allows for the automatic reversing of motor leads when the motor power supply is connected to the relay card. like the basic system configuration, the Micro Dyne controls on/off power to the motor under test and monitors motor input power. For more information regarding motor reversal, refer to Section 4.3.1.
(Customer)Motor Power Supply
+–
RelayCard
PC
M-tESt
Micro Dyne Electronics unit
Micro DyneDynamometer
+
–
Motor Power Out
MotorPower In
Voltage Sense LeadsUSB
MotorLeads
MotorUnderTest
voltAgESEnSE
MotorpoWEr
out
MotorpoWEr
in
Figure 2–8 Relay Configuration
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2.3.1.3 Motor Drive Configuration
This setup allows for the addition of a motor drive unit. The advantage to this is that the Micro Dyne is now measuring the drive/motor efficiencies, instead of the just the motor alone. This is especially beneficial when the motor is dependent on the motor drive for operation. With the power supply unit attached to the Micro Dyne relay, the power to the motor drive can be controlled through M-TEST.
M-tESt
Micro Dyne Electronics unit
Micro DyneDynamometer
+
–
PC
USBvoltAgESEnSE
MotorpoWEr
out
MotorpoWEr
in
+–+–+–
MotorPower Out
VoltageSenseLeads
MotorLeads
MotorUnderTest
(Customer)Motor Power Supply
MotorDrive
INOUT
MotorPowerIn
Figure 2–9 Motor Drive Configuration
2.4 Motor tESting SoftWArE
2.4.1 software instaLLation
For detailed installation instructions, refer to Magtrol’s M-TEST 5.0 User’s Manual.
2.4.2 m-test commUnication
In order to use M-TEST with the Micro Dyne, the CoM port to which the USb interface is connected must first be determined.
1. Power up the Micro Dyne.
2. Find the CoM port.
For Windows 95/98/2000: go to Start menu > Settings > Control Panel > System > hardware > Device Manager > Ports. look for the USb Serial Port and note the CoM port number in parenthesis.
For Windows xP: go to Start menu > Control Panel > Switch to classic view > System > hardware > Device Manager > Ports. look for the USb Serial Port and note the CoM port number in parenthesis.
Note: To configure M-TEST for the Micro Dyne, refer to Section 4.3 – Software Configuration.
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2.5 CoMMuniCAtion ChECK
When powering up the Micro Dyne, check to make sure that all four lEDs on the rear panel of the electronics unit (see Figure 2–4) are illuminated according to the table below.
lED Color indicates
USB Yellow Flashing: USB communication is taking place.
24 V Green The 24 volt power is OK.CPU Yellow The power-up sequence has been initiated.5 V Green The 5 volt power is OK.
2.6 initiAl CAlibrAtion
After communication is verified, it is highly recommended to calibrate the dynamometer before performing any tests. Refer to Chapter 6 – Calibration for a detailed procedure.
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3. Testing Considerations
A number of factors must be taken into consideration before running a test, including: safety, power dissipation, and influences that affect the apparent accuracy of the torque readout (such as shaft alignment, windage, friction, vibration, dynamometer leveling, cogging, Eddy currents and temperature rise). The following sections describe these factors, and their effects, in further detail.
Note: If you have not already done so, please take a moment to familiarize yourself with the Micro Dyne System’s technical specifications. See Section 1.2 – Data Sheet.
3.1 SAfEty
WARNING! foR GeNeRAl sAfeTy coNsIdeRATIoNs, pleAse folloW These feW commoN-seNse Rules:
• Makesureallwiringandconnectionshavebeenproperlymade.
• Secureallgroundingwirestotheappropriatelocationstoreducethechanceofshockanddamage to the equipment.
• AlwayswearsafetyglasseswhenworkingaroundMicroDyneequipment.
• DonotwearlooseclothingortieswhenoperatingtheMicroDyneequipment.
• Ensuremotorundertestisproperlymountedtothemotorfixture.
3.2 poWEr DiSSipAtion
All Magtrol dynamometers are power absorption instruments. As a dynamometer loads a test motor, it is absorbing power from the motor into the hysteresis brake. The brake is converting this mechanical energy into heat.
There are finite limits to the amount of energy and resulting temperature rise that any absorption brake can withstand. Excessive power over extended periods of time may result in more obscure damage including breakdown of bearing lubricants and degradation of magnetic coil insulation. Extreme temperatures due to inappropriate operation can not only warp the rotor and surrounding housings, but also alter the magnetic characteristics. Absolute best-case scenario under such circumstances would be a reduced torque output from the brake assembly, if complete dynamometer failure were not realized.
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3.2.1 Power aBsorPtion cUrve
based on the maximum kinetic power ratings, the curve represented in Figure 3–1 illustrates the maximum power (heat) that the dynamometer can dissipate over time. The area under the curve equals the maximum speed/torque combinations for both a motor test of less than 5 minutes (intermittent duty), and a continuous-duty motor test.
Conditional Environmental ParametersMaximum brake temperature 100 °C (212 °F)Ambient temperature 25±5 °C (77±9 °F)
0
1.0
2.0
3.0
4.0
0 20000 40000 60000 80000 100000
SPEED (rpm)
TO
RQ
UE
(m
N·m
)
MaximumRated Speed
MaximumRated Torque
Figure 3–1 Micro Dyne Power Absorption Curve
3.3 ShAft AlignMEnt
In motor testing, shaft alignment is one of the most important factors to consider. An improper coupling and/or shaft alignment can lead to unwanted side loads and vibration, damaging both the test equipment and motor. To accommodate micro motor sizes, while preventing side loading on the dynamometer shaft, a coupling of small flexible rubber tubing should be used. The friction of the rubber tube on the shaft alone suffices as a clamping agent. Several pieces of rubber tubing, in various diameters, are included with the Micro Dyne for this purpose. Refer to Section 4.2.1 – Shaft Coupling for detailed coupling instructions.
3.4 WinDAgE
Windage is proportional to the square of speed. The air friction is tangential to the surface and impinges upon the stationary field assembly. This acts as viscous drag and becomes part of the motor load and torque reading. There is also a small amount of air dissipated as pumping loss. Since this appears as a load on the motor, not measured by the dynamometer, it becomes a source of error. Considering the size of the parts affected by windage in the Micro Dyne, this source of error will be less pronounced then if similar speeds were seen on larger dynamometers.
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3.5 friCtion
Friction of the carrier bearings is a measurable load. When correctly loaded and lubricated, the friction is insignificant. During actual motor testing there is usually enough system vibration to “settle” negating frictional effects. If excessive drag is present, mechanical realignment may be required. In the design of the Micro Dyne, careful attention was paid to carrier bearing friction for the proper operation of the pendulum assembly; mainly in ensuring the pendulum returned to the zero position within the published error bands.
Note: Friction is the largest source of error in the Micro Dyne but it is relatively small in comparison to the overall range and accuracy (< 1%) of the dynamometer.
3.6 vibrAtion
All rotating dynamometer assemblies are precision balanced. At high speeds, some vibration and noise are inevitable but not necessarily harmful. however, excessive resonant vibrations caused by bent shafts and poor alignment will produce data errors and are a safety hazard.
Caution: severe vibration left unattended Could ultimately lead to permanent damage to the test equipment or the motor under test.
3.7 DynAMoMEtEr lEvEling
An improperly leveled dynamometer will alter the torque calculations in proportion to the deviation from a true level surface. The base plate of the Micro Dyne is equipped with two leveling knobs and an embedded bubble level for easy leveling.
3.8 Cogging
Pole
Case
Rotor Poles
Rotor Assembly
SSS
NN
N
Figure 3–2 Hysteresis Brake Cross-Section
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This cross-section shows (by one tooth) the magnetic relationship of the hysteresis brake elements. If the dynamometer shaft is at rest with the 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.
If the shaft is then rotated slowly, the magnetic poles on the rotor will attempt to align with the adjacent case-pole tooth form. This is often referred to as “cogging”. The action is sinusoidal. First it tries to resist rotation and then, as the rotor passes through the tooth form, it subsequently supports rotation.
The most obvious results of cogging are uncontrolled oscillations within the torque/speed curve. It will become difficult for the motor under test to tune in the PID loop, along with a possible increase in resonant noise from the dynamometer and motor.
3.8.1 avoiDing cogging
To avoid magnetic cogging, before the shaft comes to rest, slowly reduce the torque control to zero.
3.8.2 removing cogging
To most effectively remove cogging, once established, reapply current on the dynamometer. Then, slowly ramp the current to zero while maintaining a very low speed (only a few rpms). The current ramp to zero can be increased slightly in speed when the dynamometer rotation is sped up during this process.
3.9 EDDy CurrEntS
There is some Eddy current generation within the brake rotor. These magnetically-induced currents cause an increase in braking torque proportional to speed. While more pronounced in larger dynamometers (which exhibit higher rotor surface velocities), in a pure loading system it becomes a benefit of the dynamometer. Since the Eddy currents effect the rotor surface, this torque is measured by the torque pendulum and becomes another load source (and not a source of error).
3.10 tEMpErAturE riSE
Temperature rise has a more complex effect on hysteresis brake load torque and is difficult to quantify. As the temperature of the brake increases, differential expansions cause dimensional changes that tend to increase torque. Conversely, electrical resistance in the rotor increases with temperature, resulting in decreased Eddy current generation and load, all in a variable frame.
Caution: under no CirCumstanCes should the maximum wattage ratings for the dynamometer be exCeeded. the resulting rise in temperature Can Cause permanent damage to the rotating assembly, inCluding altering the magnetiC properties of the rotor itself.
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4. Test Setup
4.1 torquE ConfigurAtion
The Micro Dyne can be configured to either a 4 mN·m or 2 mN·m torque scale. The Micro Dyne is shipped as the 2 mN·m configuration. To convert it to 4 mN·m, follow the procedures below.
1. locate the small parts bag labeled 4 m·Nm configuration components.
Pendulum
Circular weight for4 mN·m torque scale
Figure 4–1 Dynamometer, Inside View
2. Attach the circular weight with the provided flat head cap screw, using the provided Allen wrench included with the 4 m·Nm configuration components.
3. Calibrate the dynamometer with the 10 gram calibration weight. Refer to Chapter 6 for complete calibration instructions.
Note: Re-calibration is necessary after every conversion between the 2 mN·m and 4 mN·m torque configurations.
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4.2 Motor Mounting
Clamping strap
Horizontal adjustment knob
Vertical adjustment
knob
Depth adjustment
knob
Knurled cam grip
Figure 4–2 Micro Dyne Motor Fixture
4.2.1 shaft coUPLing
If the motor shaft diameter is 0.5 mm to 1.6 mm, it is highly recommended to use one of the provided rubber couplings to adapt the motor shaft to the 2.0 mm Micro Dyne Dynamometer shaft.
1. Trim the tubing to allow about 2 mm of tubing over the dynamometer shaft and 3 mm of tubing over the motor shaft.
2. Place the tubing snugly around the dynamometer shaft, being careful not to bend the shaft.
3. After the motor is mounted, as described in Sections 4.2.2, 4.2.3 and 4.2.4, place the other end of the rubber tubing around the motor shaft.
4.2.2 aDaPters
When testing motors with diameters less than 20 mm, the appropriately-sized adapter must be used.
Motor Diameter Adapter5 mm – 10 mm V-Adapter I
10 mm – 20 mm V-Adapter II20 mm – 30 mm No adapter necessary
Attach the adapters to the fixture using the provided hex screws and Allen wrench. The threaded holes are found in the groove of the v-adapters.
Note: The adapter should be secured in place but be careful not to overtighten.
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Motor Fixture with
V-Adapter I
Motor Fixture without adapter
Motor Fixture with
V-Adapter II
Adapter
Figure 4–3 Motor Fixture Adapters
4.2.3 cLamPing straP
1. Place the motor under the rubber strap.
2. Tighten by pulling on the strap. A knurled cam will lock the strap in place when the strap is let go.
3. To release the motor, rotate the cam upward and the strap will loosen.
Note: Ideally, the clamping strap should be secured at the middle of the motor.
4.2.4 stage aDjUstment
For precise motor alignment, the stage of the motor fixture may be axially adjusted using the three colored adjustment knobs.
Knob Color Axis Adjustment DirectionRed X Horizontal (side-to-side positioning)Yellow Y Vertical (shaft height)Green Z Depth (of motor to input shaft of
dynamometer)
Note: The entire motor fixture can also move (as one unit) along the length of the dynamometer base plate, in line with the bolt pattern. The fixture is locked in place by screwing into the tapped holes with the provide hex key screws.
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4.3 SoftWArE ConfigurAtion
This section only provides very basic instructions for setting up M-TEST to run with the Micro Dyne. For detailed information about selecting, configuring and running a test, refer to Magtrol’s M-TEST 5.0 User’s Manual.
1. Power up the Micro Dyne.
2. Start M-TEST.
3. open the Configure hardware window.
Figure 4–4 M-TEST Configure Hardware Window
4. Enter the following settings:
a. Under Dynamometer Controller, select “Micro Dyne” for the Model.
b. For the Interface, select the CoM port where the USb interface is connected (as determined in Section 2.4.2 – M-TEST Communication).
c. Under Power Measurement, select “Micro Dyne” as the Device.
Note: For increased power measurement capabilities, other power analyzers (such as Magtrol’s 6510e or 6530) may be used in conjunction with the Micro Dyne. If applicable, the supplemental power analyzer should be selected as the “Device.” If using a third-party measurement device not found on the list, by selecting “None”, M-TEST will no longer be responsible for measuring the input power.
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4.3.1 motor reversaL
If it is desired to perform a motor test in both clockwise and counter-clockwise directions, a relay card is required. Motor direction is configured in M-TEST and requires a power supply supported by M-TEST. Supported power supplies are found in the Device text box, under the Power Supply options in the Configure hardware window. See Figure 4–5.
4.3.1.1 Reversing Motor Direction Before Test is Run
To reverse the motor direction and keep the direction of rotation constant throughout the entire test, use the Configure hardware window for motor reversal setup.
1. open the Configure hardware window.
2. Under Power Supply, click on the Device text box and scroll through for a list of supported power supplies.
3. After selecting a power supply, set the voltage and current output for that voltage supply. If a negative voltage is entered, M-TEST switches relays to change the polarity of the motor voltage and, in turn, reverses the direction of rotation (for a DC motor).
-
Figure 4–5 M-TEST Power Supply Configuration
4.3.1.2 Automatic Reversal of Motor Direction During Test
Curve tests and Pass/Fail tests allow for reversing the motor direction during a test.
Note: because Ramp tests do not allow motor voltage control, the motor must ramp up and down in the same direction for the entire test. To reverse the direction of rotation for a ramp test, after running the first test, enter a negative power supply voltage in the Configuration hardware window (as described in Section 4.3.1.1) and then run the test a second time.
1. If not already done so, select a power supply supported by M-TEST in the Configure hardware window.
2. open the Configure Test window. If Curve Test or Pass/Fail Test is selected, an extra column in the Control Data table, under Test Parameters, labeled “volts” should appear.
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3. To have the motor direction reversed during a test, simply enter a negative voltage, as shown in Figure 4–6.
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5. Operating Principles
5.1 torquE MEASurEMEnt
An innovative approach to measuring small torques is implemented in the Micro Dyne. The design employs a very small pendulum and brake assembly hung in a precision-machined carrier. The basic concept, a textbook physics problem, is described below.
θ
mpg
p sin (θ)
Brake
Pendulum
mpg
p cos (θ)
mpg
p
Lp
Torque = Lcm
mg sin (θ)
Symbol representsLp the length to the center of mass of the pendulum
mpgp the force applied by the mass and gravity
mpgp sin (θ) the force in the radial direction
Figure 5–1 Illustrated Torque Principle
5.1.1 torqUe caLcULation
At calibration time, a known mass at a known distance is applied to the pendulum system and a precise calibration is accomplished.
Lpmpgp sin (θ) = Lcmcgc cos (θ)
Symbol representsLc the length from the center to the calibration weight
mcgc the force applied by the known mass and gravity
The coefficient Lpmpgp is calculated and stored. Torque data is calculated using this coefficient, along with position data.
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5.2 SpEED MEASurEMEnt
The Micro Dyne contains a reflective fiber optic speed pickup. As each rotor slot passes by the sensing end of the fiber optic, an electronic pulse is generated, which is then converted to a speed reading (in rpm). The incoming pulses from the speed pickup can be resolved down to 5 hz or 5 pulses per second. With 6 slots on the rotor, this results in a minimum speed setting of 50 rpm. (The speed reading will drop to zero at 50 rpm.)
Note: The rotor/speed measuring mechanism of the Micro Dyne has been optimized for motors running from 10,000 rpm to 100,000 rpm.
Figure 5–2 Micro Dyne Rotor
5.3 ControllEr AnD thE piD loop
The Micro Dyne has PID adjustment capability for both the speed and torque modes to provide the best system response. The PID loop comprises the following three variables:
P = proportional gainI = integralD = derivative
other important variables include:
• Setpoint-desiredloadorspeed• Error-differencebetweenthesetpointandtheactualmeasurement• Additionalscaling–usedtobroadentherangeofthecontrolloop
5.3.1 P (ProPortionaL gain)
With proportional gain, the controller output is proportional to the error or to a change in measurement. Deviation from the set point is usually present. Increasing the proportional gain will make the PID loop unstable. Increasing the integral value will eliminate this instability. For best loop control, set the proportional gain as high as possible without causing the loop to become unstable.
5.3.2 i (integraL)
With integral, the controller output is proportional to the amount of time the error is present. Increasing the integral value eliminates the offset from the set point. If the response becomes oscillatory, increase the derivative value.
5.3.3 D (Derivative)
With derivative, the controller output is proportional to the rate of change of measurement or error. Derivative can compensate for a changing measurement. Derivative takes action to inhibit more rapid changes of the measurement than proportional gain.
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5.3.4 aDDitionaL scaLe factor
The Additional Scale Factor (PS, IS and DS) is a multiplier of the P, I or D term. Due to the fact there are so many different motor combinations, this multiplier is needed to extend the range of the PID. The letters represent the following values:
A = 0.001 D = 0.05 g = 1 * The default multipliers are g, g, and g
b = 0.005 E = 0.10 h = 5
C = 0.010 F = 0.50 I = 10
Using the multiplier, PID values from 0.001 (0.001 × 1%) to 990 (10.0 × 99%) may be inputted.
5.3.5 how the PiD LooP works
The following diagram demonstrates the correlation between the variables in the PID loop.
Derivative Proportional
Integral
Set Point
Reading
-
e(t) Yd(t) Yp(t)
Yi(t)
Yt(t)Ys(t)
+ +Scale
0 to 120,000 rpm0 to 20 kHz
PowerWattmeter
0 to 1
BrakeCoil
FilterFilter Position
Filter SpeedFilter
0 to 75°0 to 6826 counts
TORQUE
SPEED (rpm)
Figure 5–3 Control Loop and PID System Block Diagram
5.3.6 PiD eqUations
Where Skp, Ski and Skd are factory-determined system coefficients…
yd(t) = (e(t) - e(t-3) + 3 * [e(t-1) - e(t-2)]) * (10/Skd) * D% * DS
yp(t) = (e(t) + yd(t)) * (10/Skp) * P% * PS
yi(t) = yi(t-1) + [e(t) + yd(t)] * (10/Ski) * I% * IS
yt(t) = yp(t) + yi(t)
ys(t) = Scale * yt(t)
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Magtrol Micro Dyne SystemChapter 5 – Operating Principles
OP
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5.4 DC WAttMEtEr
The data acquisition stage in the hardware of this DC power measurement instrument is very simple. The input voltage is divided by an amplifier circuit and applied directly to a lTC2515 A/D converter. The input is differential and isolated from the amps circuitry. The input current is applied to a shunt resistor and the resulting voltage is amplified and applied directly to a lTC2515 A/D converter. The input is differential and isolated from the voltage circuitry. The wattage presented is a multiplication of the amps and voltage. See Section B.3 – DC Wattmeter Schematic.
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6. Calibration - Dynamometer
6.1 CAlibrAtion SoftWArE AnD DrivEr inStAllAtion
6.1.1 micro Dyne caLiBration software
1. Insert the “Micro Dyne Calibration And Driver Disk” into your CD-RoM drive.
2. The calibration software installer will start automatically.
6.1.2 UsB Drivers
1. Connect Micro Dyne USb cable to PC.
2. Connect power to Micro Dyne and turn on. (Windows will detect the Micro Dyne as an unknown USb device until drivers are loaded.)
3. Install the appropriate drivers by directing the automatic hardware Update Wizard to the “USb Driver” directory of the Micro Dyne Calibration and Driver Disk.
Note: If a problem arises with the automatic driver installation, continue to step 4 and proceed with manual installation.
4. go to Start menu > Control Panel > Performance and Maintenance > System
5. Under the hardware tab, select device manager6. Expand the “other devices” folder
7. Right-click dlp-usb245m8. Select update driver9. When the hardware Update Wizard opens, click Install from a list, or specific location
(Advanced).10. In the hardware Update Wizard, locate the USb Driver directory of the Micro Dyne
Calibration and Driver Disk and follow the prompts until installation is complete.
Figure 6–1 Hardware Update Wizard
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Magtrol Micro Dyne SystemChapter 6 – Calibration - Dynamometer
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6.2 CAlibrAtion prEpArAtion
A detailed description of the electrical, mechanical and software setup for calibration is conveniently located within the Calibration Software. In the calibration software setup window (next to Setup help), click INsTRucTIoNs.
Caution: read and follow the on-sCreen instruCtions Carefully before Continuing with the Calibration proCedure.
6.3 CAlibrAtion proCEDurE
The Micro Dyne Calibration Software walks the user through every step in the calibration process. Simply follow the instructions and prompts that appear on the screen.
6.3.1 setUP
Start the Micro Dyne Calibration Software by opening the micro dyne calibration software from the Start menu. The calibration setup window will appear.
Figure 6–2 Calibration Setup Window
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Magtrol Micro Dyne System Chapter 6 – Calibration - Dynamometer
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Open/Print Button Access previously saved calibration data with option to reprint calibration report.
Calibrate Button Perform calibration
Model Number Enter model number; default is “Micro Dyne”
Serial Number Enter serial number; default is blank
Condition Select from list; options are “New Unit” (default), “Recal after repair” and “Recal as received” Selection will appear on calibration report.
Nominal Value Select torque value in mN·m from “2.000” (default) or “4.000”
Exact Mass of Calibration Weight Enter mass of calibration weight (in grams) as printed on tag. Required for calibration to proceed.
VISA Resource Name Selectable from all detected COM ports of PC. To identify Micro Dyne COM port, click Setup Help inStruCtionS.
Initialize Communication button/indicator
Click to initialize communication with Micro Dyne. Unit information will be displayed (see Detected Unit Info) and indicator will turn green.
Setup Help Instructions button Provides a detailed description of the electrical, mechanical and software setup required for calibration.
Technician Enter calibration technician’s name
Date Current date is automatically entered.
Remarks Entered remarks will appear on calibration report.
Detected Unit Info Displays data about Micro Dyne unit after communication is successfully initialized. (See Initialize Communication button/indicator.)
Yellow Message Box A note reminding which calibration weight to use will be displayed, depending on the nominal torque value selected: • For 2 mN·m range, use 5 g weight • For 4 mN·m range, use 10 g weight
6.3.2 rUn
1. After completing all required setup data, click calibrate to begin calibration. Carefully follow the instructions given in the bar at the top of the screen.
Note: Calibration Constants are displayed for units with firmware version 2.4 or later.
The Reset zERo dialog box will appear.
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Magtrol Micro Dyne SystemChapter 6 – Calibration - Dynamometer
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Figure 6–3 Reset ZERO
2. To zero the pendulum at its current rest state (without weights), click send Zero.
Note: If reading in dialog box is more than a few counts away from zero (after clicking “Send zero” once), click send Zero again before continuing.
3. The next prompt asks the user to hang the calibration weight, starting with the right side. Carefully hang the appropriate calibration weight from the calibration peg, as show in Figure 6–4. Tweezers have been included in the accessory tool bag for your convenience.
Pendulum
Calibration weight
Calibration
Figure 6–4 Dynamometer Calibration
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Magtrol Micro Dyne System Chapter 6 – Calibration - Dynamometer
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4. Continue to follow the instructions in the bar at the top of the screen, alternating between hanging the weight on opposite sides of the pendulum and removing the weight. An example of the screen display during this process is shown in Figure 6–5.
Instruction bar
Progress bar
Figure 6–5 Calibration Instruction and Progress Bars
This entire cycle will be performed a total of ten times. After each cycle, the message/instruction bar will display the status of the calibration routine. The blue progress bar will also update.
5. When the calibration is complete, a dialog box appears prompting the user to write calibration constants to the unit (to be saved in the Micro Dyne’s internal firmware).
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Magtrol Micro Dyne SystemChapter 6 – Calibration - Dynamometer
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Figure 6–6 Calibration Complete
6. After calibration, the obtained data will be displayed as passed or failed.
PASS!, hit CONTINUE to report or STOP to exit
Figure 6–7 Final Calibration Window
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Magtrol Micro Dyne System Chapter 6 – Calibration - Dynamometer
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7. If calibration passed:
To view/print a calibration report or save calibration data, click continue and proceed to Section 6.3.3.
To quit the Micro Dyne Calibration program without printing the results or saving the data, click stop.
If calibration failed:
Click stop or continue to quit program.
6.3.3 Print rePort or save Data
After clicking “Continue” at the completion of a calibration procedure, the calibration report will be displayed in the window and a dialog box will appear with the option of printing the report.
Figure 6–8 Calibration Report
Whether “ok” is selected, or “Cancel”, the Save As dialog box will appear next in order to save the calibration data.
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7. Calibration - Watt Meter
7.1 CloSED-box CAlibrAtion
The Micro Dyne features closed-box calibration. The advantage of closed-box calibration is that the user does not have to disassemble the case or make mechanical adjustments.
The unit can be calibrated using external reference sources. Correction factors for offset and gain are stored in nonvolatile memory. They remain in effect until the user or the calibration house updates them.
7.2 CAlibrAtion SChEDulE
Calibrate the Micro Dyne:
• Afteranyrepairsareperformed.
• Atleastonceayear;morefrequentlytoensurerequiredaccuracy.
7.3 bASiC CAlibrAtion proCESS
The basic calibration process consists of two procedures which must be performed in the following order:
1. Initial Procedure
2. zero for both volts and Amps
3. volts gain
4. Amps gain
Items needed for calibrating the Micro Dyne:
• Externalvoltagereferenceof0to30voltsDC
• Currentreferenceof0to5ampsDC
• Digitalmultimeter(DMM)
both measuring instruments should have a accuracy of 0.005% or better.
7.3.1 initiaL caLiBration ProceDUre
1. Allow the Micro Dyne to stabilize in an environment with:
• Anambienttemperatureof18°Cto25°C.
• Relativehumiditylessthan80%.
2. Turn on the Micro Dyne.
3. Allow the Micro Dyne to warm up for at least 30 minutes.
7.3.2 voLts anD amPs Zero anD gain
1. Send the command CAl to the unit via the serial port.
2. The response will be zERo.
3. Apply 0.0000 volts to the volts input/0.0000 amps to the amps input.
4. Send the command zERo.
5. The response will be FSv=x.xxxx
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Magtrol Micro Dyne System Chapter 6 – Calibration - Watt Meter
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6. Apply 30 volts to the input (this can vary a few mv but must be measured accurately).
7. Send the command FS=x.xxxx (where x.xxxx is your meter reading).
8. The response will be FSA=x.xxxx.
9. Apply 5 amps to the amps input (this can vary few mA but must be measured accuratly).
10. Send the FSA=x.xxxx (where x.xxxx is your meter reading).
11. Unit will respond CAl CoMPlETE.
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8. Troubleshooting
If you require additional assistance, please contact Magtrol Customer Service at 1-716-668-5555.
problem reason SolutionSpeed MeasurementSpeed is erratic or there is no speed reading.
Speed pickup is in incorrect mode.
Switch speed pickup to SHS Mode.
CalibrationMicro Dyne revision is not displayed in the calibration software window.
Lost communication with electronics unit.
Check USB connections.
Calibration Error message appears at completion of calibration procedure.
Pendulum not fully returning to zero after the weight is removed
Make sure the dynamometer is level and restart calibration procedure.
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Appendix A: Hardware Commands
Although most motor tests can be performed with M-TEST, the following command reference tables are included for users who wish to write their own application.
A.1 DAtA forMAt
Speed-torque data is a fixed-length string in ASCII format with a floating point decimal. Use the following string format:
SdddddTdddd.R(cr)(lf)
or
SdddddTdddd.l(cr)(lf)
Where…
S = Speed in rpm. (No leading zeroes are used.)
d = Decimal digit 0 through 9.
T = Torque in mN·m. (The torque value always contains a decimal point.)
l = Counterclockwise dynamometer shaft rotation (left).
R = Clockwise dynamometer shaft rotation (right).
. = Decimal point. (The decimal point location depends on the specific dynamometer and torque range in use.)
Note: The (cr) and (lf) characters will not display.
exAmple
If a motor is running at 1725 rpm clockwise, with the dynamometer loading the motor to 22.6 oz.in., the Micro Dyne will return:
S 1725T22.60R
by manipulating the string, the speed-torque and shaft direction (if required) can be extracted. Then separate numerical variables can be assigned to them for data processing.
a.1.1 coDes for cr - Lf
bASiC hEx DECCr = CHR$(13) 0D 13lf = CHR$(10) 0A 10
A.2 MiCro DynE CoMMAnD SEt
When entering a command code:
1. Type all characters in uppercase ASCII format.
2. End all commands with a CR-lF (hex 0D-0A).
3. Do not string multiple commands together in one line.
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Magtrol Micro Dyne SystemAppendix A: Hardware Commands
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The character # represents a floating-point numerical value following the command. leading zeroes are not required.
a.2.1 commUnication commanDs
Command Code function Explanation
*IDN? Returns Magtrol Identification and software revision.
Example: “MD 1.4 FP 2” Micro Dyne REV 1.4 and FPGA REV 2
B0 Brake Off. ---B1 Brake On. ---OD Returns speed-torque value. Output Data prompt to return data string with
this format:SxxxxxTxxxxxRcrlf
orSxxxxxTxxxxxLcrlf
R or L is the shaft direction indicator, as viewed looking at the dynamometer shaft where: R = right; clockwise (CW) L = left; counterclockwise (CCW)
a.2.2 ramP commanDs
Command Code
function Explanation
DILXX.XX Sets dynamic scale coefficient. When using dynamic scaling, XX.XX is multiplied by the I term to give the end I value.
DPLXX.XX Sets dynamic scale coefficient. When using dynamic scaling, XX.XX is multiplied by the P term to give the end P value.
DS# Enable or disables dynamic scaling.
Values for # are: 0 = disable 1 = enable
PD# Program Down: Sets ramp down rate to #rpm per second and starts ramp.
Specify speed range (F#) AND a stop speed (S#) before using this command. This command programs a decreasing shaft speed at a rate of #rpm per second.
PR • Resets ramp up or down. • Sets speed to maximum speed.• Turns brake off.
This command resets the ramp function, halting the ramp’s progress, and returns the motor to free run.
PU# Program Up: Sets ramp up rate to #rpm per second and starts ramp.
Specify speed range (F#) AND a start speed (S#) before using this command. This command increases the shaft speed at a rate of #rpm per second.
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Magtrol Micro Dyne System Appendix A: Hardware Commands
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a.2.3 setUP commanDs
Command Code function Explanation
R Resets as follows:• Brake OFF.
Use this command to cancel any previous commands.
RQ1 Resets quadrature counter. Use this command to reset torque count to zero.
a.2.4 sPeeD commanDs
Command Code function Explanation
F# Sets maximum speed to # rpm. Sets a speed range for the controller. Must be specified before using the speed or ramp mode. Sets the range of the PID calculation.
N • Resets speed point to maximum speed.• Sets speed mode OFF.• Sets brake OFF.
Use this command, sent alone, to reset any previous speed-stabilized setting to the maximum speed range.
N# • Sets speed point to #.• Sets brake ON.
Use this command to load the motor under test to a specific speed value #. Issue a speed range command (F#) first for best dynamic response. The controller is functioning with the dynamometer as a closed loop system. Adjust the speed PID values to tune the response.
ND# Sets speed derivative to #. Derivative value (#) can be any number from 0 to 99.
NDS# Sets scaling factor. Values for # are: A (0.001) D (0.05) G (1) B (0.005) E (0.10) H (5) C (0.01) F (0.50) I (10)
NI# Sets speed integral to #. Integral value (#) can be any number from 0 to 99.
NIS# Sets scaling factor. Values for # are: A (0.001) D (0.05) G (1) B (0.005) E (0.10) H (5) C (0.01) F (0.50) I (10)
NP# Sets speed proportional to # gain.
Proportional gain value (#) can be any number from 0 to 99.
NPS# Sets scaling factor. Values for # are: A (0.001) D (0.05) G (1) B (0.005) E (0.10) H (5) C (0.01) F (0.50) I (10)
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Magtrol Micro Dyne SystemAppendix A: Hardware Commands
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a.2.5 torqUe commanDs
Command Code function Explanation
Q • Resets torque to 0.0.• Turns torque mode OFF.• Turns brake OFF.
Resets any previous torque-stabilized command, and returns the motor to free run.
Q# • Sets torque point to #. • Turns brake ON.
Closed-loop command with its own set of PID parameters. Units are in mN·m.
QD# Sets torque derivative to #. Derivative value (#) can be any number from 0 to 99.
QDS# Sets scaling factor. Values for # are: A (0.001) D (0.05) G (1) B (0.005) E (0.10) H (5) C (0.01) F (0.50) I (10)
QI# Sets torque integral to #. Integral value (#) can be any number from 0 to 99.
QIS# Sets scaling factor. Values for # are: A (0.001) D (0.05) G (1) B (0.005) E (0.10) H (5) C (0.01) F (0.50) I (10)
QP# Sets torque proportional gain to #.
Proportional gain value (#) can be any number from 0 to 99.
QPS# Sets scaling factor. Values for # are: A (0.001) D (0.05) G (1) B (0.005) E (0.10) H (5) C (0.01) F (0.50) I (10)
a.2.6 Power anaLyZer anD reLay commanDs
Command Code function Explanation
OA1,0 Reads amps. ---OV1,0 Reads volts. ---OW1,0 Reads watts. ---PWR0 Switches off the power relay. ---PWR1 Switches on the power relay. ---
a.2.7 misceLLaneoUs commanDs
Command Code function Explanation
I# Sets current output to #. The Micro Dyne power supply outputs a fixed value of current. Use any value (#) between 0 and 99.99%. (99.99% = FS).
SAVE Saves present configuration of unit to non-volatile memory. ---
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Magtrol Micro Dyne System Appendix A: Hardware Commands
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a.2.8 caLiBration commanDs
Command Code function Explanation
CAL Sets unit into calibration mode. See Chapter 6 - Calibration - Dynamometer and Chapter 7 - Calibration - Watt Meter
CGL Returns average gain after calibration on left side. (Available with firmware revisions 2.4 and above.)
Output, floating point
CGR Returns average gain after calibration on left side. (Available with firmware revisions 2.4 and above.)
Output, floating point
CZL Returns average of zero calibration reading on left side. (Available with firmware revisions 2.4 and above.)
Output, floating point
CZR Returns average of zero calibration reading on right side. (Available with firmware revisions 2.4 and above.)
Output, floating point
FSA=X.XXX Calibrate full scale amps to this value.
See Chapter 6 - Calibration - Dynamometer and Chapter 7 - Calibration - Watt Meter
FSV=X.XXX Calibrate full scale volts to this value.
See Chapter 6 - Calibration - Dynamometer and Chapter 7 - Calibration - Watt Meter
ZERO Sets the offset to the value at the input.
See Chapter 6 - Calibration - Dynamometer and Chapter 7 - Calibration - Watt Meter
GL=xxxx Sets average gain after calibration on left side.
Input, floating point
GR=xxxx Sets average gain after calibration on right side.
Input, floating point
ZL=xxxx Sets average of Zero calibration reading on left side.
Input, floating point
ZR=xxxx Sets average of Zero calibration reading on right side.
Input, floating point
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Appendix B: Schematics
b.1 CorE bloCK DiAgrAM
1
1
2
2
3
3
4
4
5
5
6
6
D D
C C
B B
A A
U178B212_CORE_DSP_REVB
RAM128K x 24
GSI GS73024AB3.3V
FLASH1M x 8
SST SST39LF0803.3V
DSP
MOTOROLA DSP56303GC1003.3V
FPGA
ACTEL APA0752.5V
119 PBGA48 FBGA
196 PBGA 144 BGA
2.5V REG
JTAG-1 JTAG-2
XTAL8 MEG
RESET
EEPROM
93C66A
RS232
DRIVER
JP1JP2
CORE BLOCK3.3V
D[D0..D23]D[D0..D23]
3.3V
GA1GA2GA3
GA4GA5GA6GA7GA8
GA9GA10GA11GA12
GA13GA14GA15
GA16
GA17GA18GA19
GA20GA21GA22
GA23GA24GA25
GA26GA27GA28
GA29GA30GA31
GA32
GA33
GA34GA35GA36
GA37
GA38GA39 GA40GA41
GA42GA43GA44
GA45
GA46GL4 GA48
A[A0..A19]
WRRD
RS TXDRS RXD
RESETMODA
MODBMODCMODD
PC0
PC1PC2
PC3
PC4PC5
PB2PB3PB4PB5
PB6
PB7PB8
PB9PB10
PB11
PD0
PD1PD2
PD3
PD4PD5
GA49GA50GA51GA52GA53GA54GA55GA56GA57RESET
AA2TIO0TIO1TIO2
COREV(3.3)
D0D1D2D3D4D5D6D7D8D9D10D11D12D13D14
D15
A0A1A2A3
A[A0..A19]
13579
1113151719212325272931333537394143454749515355575961636567697173757779
2468101214161820222426283032343638404244464850525456586062646668707274767880
SAMTEC# BSE-040-01-F-D-A
JP1
CONN_80PIN_080
13579
1113151719212325272931333537394143454749515355575961636567697173757779
2468101214161820222426283032343638404244464850525456586062646668707274767880
SAMTEC# BSE-040-01-F-D-A
JP2
CONN_80PIN_080
3.3V
MT2
MOUNT HOLE .128" DIA
MT1
1
Magtrol Inc.70 Gardenville Pkwy.Buffalo NY, 14224USA
3
CORE BOARD
78B212 B
TITLE
SIZE DWG NO. REV.
Sheet of
CCAGE CODE
03692SCALE: NONE
SCHEMATIC,APPROVED BY:
DRAWN BY:
DATE:
DATE:
3/13/06
2/22/04
PJ
SDS
THIS DRAWING AND SPECIFICATIONCONTAINS PROPRIETARY INFORMATIONTO MAGTROL INC. ANY DISCLOSUREOR REPRODUCTION OF THIS DOCUMENTWITHOUT WRITTEN AUTHORIZATION FROMMAGTROL INC. IS EXPRESSLY PROHIBITED
CHECKED BY: DATE:3/13/06DG
REVISIONSREV DESCRIPTIONDATE ECN
TP17TP16 TP18 TP19
81 8283 8485 8687 8889 9091 9293 9495 9697 9899 100101 102103 104105 106107 108109 110111 112113 114115 116117 118119 120121 122123 124125 126127 128129 130131 132133 134135 136137 138139 140141 142143 144145 146147 148149 150151 152153 154155 156157 158159 160
2.5V
1
1
2
2
3
3
4
4
5
5
6
6
D D
C C
B B
A A
U178B212_CORE_DSP_REVB
RAM128K x 24
GSI GS73024AB3.3V
FLASH1M x 8
SST SST39LF0803.3V
DSP
MOTOROLA DSP56303GC1003.3V
FPGA
ACTEL APA0752.5V
119 PBGA48 FBGA
196 PBGA 144 BGA
2.5V REG
JTAG-1 JTAG-2
XTAL8 MEG
RESET
EEPROM
93C66A
RS232
DRIVER
JP1JP2
CORE BLOCK3.3V
D[D0..D23]D[D0..D23]
3.3V
GA1GA2GA3
GA4GA5GA6GA7GA8
GA9GA10GA11GA12
GA13GA14GA15
GA16
GA17GA18GA19
GA20GA21GA22
GA23GA24GA25
GA26GA27GA28
GA29GA30GA31
GA32
GA33
GA34GA35GA36
GA37
GA38GA39 GA40GA41
GA42GA43GA44
GA45
GA46GL4 GA48
A[A0..A19]
WRRD
RS TXDRS RXD
RESETMODA
MODBMODCMODD
PC0
PC1PC2
PC3
PC4PC5
PB2PB3PB4PB5
PB6
PB7PB8
PB9PB10
PB11
PD0
PD1PD2
PD3
PD4PD5
GA49GA50GA51GA52GA53GA54GA55GA56GA57RESET
AA2TIO0TIO1TIO2
COREV(3.3)
D0D1D2D3D4D5D6D7D8D9D10D11D12D13D14
D15
A0A1A2A3
A[A0..A19]
13579
1113151719212325272931333537394143454749515355575961636567697173757779
2468101214161820222426283032343638404244464850525456586062646668707274767880
SAMTEC# BSE-040-01-F-D-A
JP1
CONN_80PIN_080
13579
1113151719212325272931333537394143454749515355575961636567697173757779
2468101214161820222426283032343638404244464850525456586062646668707274767880
SAMTEC# BSE-040-01-F-D-A
JP2
CONN_80PIN_080
3.3V
MT2
MOUNT HOLE .128" DIA
MT1
1
Magtrol Inc.70 Gardenville Pkwy.Buffalo NY, 14224USA
3
CORE BOARD
78B212 B
TITLE
SIZE DWG NO. REV.
Sheet of
CCAGE CODE
03692SCALE: NONE
SCHEMATIC,APPROVED BY:
DRAWN BY:
DATE:
DATE:
3/13/06
2/22/04
PJ
SDS
THIS DRAWING AND SPECIFICATIONCONTAINS PROPRIETARY INFORMATIONTO MAGTROL INC. ANY DISCLOSUREOR REPRODUCTION OF THIS DOCUMENTWITHOUT WRITTEN AUTHORIZATION FROMMAGTROL INC. IS EXPRESSLY PROHIBITED
CHECKED BY: DATE:3/13/06DG
REVISIONSREV DESCRIPTIONDATE ECN
TP17TP16 TP18 TP19
81 8283 8485 8687 8889 9091 9293 9495 9697 9899 100101 102103 104105 106107 108109 110111 112113 114115 116117 118119 120121 122123 124125 126127 128129 130131 132133 134135 136137 138139 140141 142143 144145 146147 148149 150151 152153 154155 156157 158159 160
2.5V
45
Magtrol Micro Dyne System Appenidix B: Schematics
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b.2 MAin SChEMAtiC
1 23
J5
BRAK
E
BAN
ER
RS T
XDRS
RXD
RS T
XDRS
RXD
RESE
T
RESE
T
QU
AD1_
AQ
UAD
1_B
QU
AD1_
IND
TACH
2
+24V
24V
COM
GAT
EFI
BER-
OPT
IC C
ABLE
S TO
DYN
O
1 2 3 4 5 6 7 89 10 11 12 13 14 15
17 16
J3 D C
onne
ctor
15
ENCO
DER
/B
ENCO
DER
B
ENCO
DER
/A
ENCO
DER
A
IND
EX
IND
EX /
BRAK
E CI
RCU
IT
D0
24
D1
23
D2
22
3V3O
UT
6
BOAR
D ID
1
GND
2
RESE
T#3
RESE
TO#
4
GND
7
SLEE
P8
SND
/WU
P9
VCC-
IO10
EXTV
CC11
PORT
VCC
12
GND
5D
321
D4
20
D5
19
D6
18
D7
17
RD#
16
WR
15
TXE#
14
RXF#
13
DLP
-USB
245M
U2
USB
D[D
0..D
23]
D[D
0..D
23]
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
A0A1A2A3
A[A0
..A19
]A[
A0..A
19]
QU
AD1_
A
QU
AD1_
B
QU
AD1_
IND
15KR710
0R3
15K
R6
100
R4
3.3
OH
MS
R10
100
R5
+3.3
V
+5.0
V
+24V
0.1u
FC1
1
120
pFC8
0.1u
FC1
2
+5.0
V
D0
D1
D2
D3
D4
D5
D6
D7
D[D
0..D
7]
TXE#
RXE#
+3.3
V
TXE#
RXE#
1 2 3
P1BR
OW
N W
IRE
BLU
E W
IRE
WH
ITE
WIR
E
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 73 75 77 79
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80
81 83 85 87 89 91 93 95 97 99 101
103
105
107
109
111
113
115
117
119
121
123
125
127
129
131
133
135
137
139
141
143
145
147
149
151
153
155
157
159
82 84 86 88 90 92 94 96 98 100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
148
150
152
154
156
158
160
JP1
JP2
CORE
BO
ARD
J1
+3.3
V+3
.3V
.1C7
FERR
ITE
L5
.1C547
UF
C6
AC(L
)1
AC(N
)2
V+4
V-3
FG5
DCD
C2AC
(N)
EART
H
AC(L
1)
FERR
ITE
L1
220U
FC4
FERR
ITE
L2
FERR
ITE
L3
FERR
ITE
L6
MT5
MT6
MT3
MT4
MT2
MT1
.01
C1TP
1
TP2
TP3
TP4
TP5
AC(L
)1
AC(N
)2
V+4
V-3
DCD
C1 24V
FERR
ITE
L4
+5V
+5.0
V
+3.3
V
+24V
USB
CPU
47U
FC2
1A2
2Y5
2B7
2A6
EN4
1Y3
1B1
DS3
4LV8
6TM
U3A
3B9
3Y11
4B15
3A10
4Y13
4A14
EN12
U3B
DS3
4LV8
6TM
TACH
2
123456
J4 RS23
2
VCC
5
VOU
T6
C2-
3
C1-
1
C1+
2
C2+
4G
ND
8SH
DN
7
LTC1
263
U5
Volta
ge R
egul
ator
+5.0
V
10U
FC1
3
VB8
HO
7
COM
3
VCC
1
IN2
NC
4N
C5
VS6
IR21
17SP
BF
U4
1N58
19H
WD
2
.047
uFC9
.047
uFC1
0
+12V
+24V
10K
R13
+12V
2N39
04Q
210
KR1
21KR1
1+3.3
V
PWM
_DRI
VE
G
D
S
+3.3
V
+3.3
V
FEM
ALE
LAST
DES
IGN
ATO
RS U
SED
:R1
4, C
18, L
6
1 2 43 5 6 7 8LE
D 1
LED
2
LED
3
LED
4
YELL
OW
YELL
OW
GRE
EN
GRE
EN
DS1
PS27
02-1
0.1u
FC1
4+3.3
V DEC
UP
U3
IN3
OU
T2
1
GN
D
LT11
17U
1
25V
35V
35V
10V
+12V
1A
+5.0
V
PWM
_DRI
VE
24V
COM
24V
COM
24V
COM
RESE
T
TIO
0
CPU
USB
PB2
PB3
CPU
USB
10KR1
10K
R2IN
TERN
AL R
ESIS
TOR
+24V
24V
COM
+24V
+5V
12
SW1
SWIT
CH P
USH
BU
TTO
N
2.2K
R8
2N39
04Q
4
2N39
04Q
3
D1
DIO
DE,
1N
914
1 2 3 4 5 6 7 8
P2 Hea
der 8
+5.0
V
RELA
YCL
K
PVCS
SDO
ASD
OV
WAT
TMET
ER I
NPU
TRE
LAY
CLK
SDO
VSD
OA
PVCS
1.0
OH
MS
R9 1W 50V
1%
IRLL
110
Q1
(TO
P LE
D)
(BO
TTO
M L
ED)
PB11
PB9
PB10
TIO
1
TIO
1
TIO
1
GA1
GA2
GA3
GA4
PB8
PB4
PB5
PB7
PB6
GA2
2Q
UAD
RES
ET 1
MO
DD
WR_
RD_
24
U6
INVE
RTER
NC7
S14
RESE
T
2.2K
R14
+3.3
V
2.2U
FC1
62.
2UF
C17
2.2U
FC1
8
2.2U
FC3
2.2U
FC1
5
TO 7
8P21
6 BO
ARD
ASS
EMBL
Y
46
Magtrol Micro Dyne SystemAppenidix B: Schematics
AP
PE
ND
ICE
S
b.3 DC WAttMEtEr
11
22
33
44
55
66
DD
CC
BB
AA
1
Mag
trol
70 G
arde
nVill
e Pkw
y.Bu
ffalo
NY,
142
24U
SA
1
MIC
RO
DYN
E, W
ATT
ME
TER
IN
PUT
78B2
16B
TITL
E
SIZE
DW
G N
O.
REV
.
Shee
tof
CCA
GE
COD
E
0369
2SC
ALE
: NO
NE
SCH
EM
ATI
C,
APP
ROV
ED B
Y:
DRA
WN
BY
:
DA
TE:
DA
TE:
7/21
/06
06/0
9/06
DG
DG
THIS
DRA
WIN
G A
ND
SPE
CIF
ICA
TIO
NCO
NTA
INS
PRO
PRIE
TAR
Y IN
FOR
MA
TIO
NTO
MA
GTR
OL
INC
. AN
Y D
ISCL
OSU
REO
R R
EPR
OD
UC
TIO
N O
F TH
IS D
OC
UM
ENT
WIT
HO
UT
WRI
TTEN
AU
THO
RIZA
TIO
N F
RO
MM
AG
TRO
L IN
C. IS
EX
PRES
SLY
PR
OH
IBIT
ED
CHEC
KED
BY
:D
ATE
:7/
18/0
6SS
REV
ISIO
NS
REV
DES
CRIP
TIO
ND
ATE
ECN
10.0
KR5
120P
FC2
2
120P
FC1
8
10.0
KR9
1KR1
GN
D1
VCC
2
REF+
3
REF-
4
IN+
5
IN-
6
GN
D7
GN
D8
GN
D9
GN
D10
CS11
SDO
12SC
K13
Fo14
GN
D15
GN
D16
U4
LTC
2415
NC1
1
VIN
2
SHD
N3
GN
D4
NC4
5V
OU
T6
NC3
7N
C28
U3
LT14
61A
IS8-
3
.1C5.1C6
.1C7
.1C13
.1C14
.1C15
3 V
olts
0 to
3 v
olts
in
332KR3 332K
R11
2.2U
FC2
010
KR7
10K
R12
6 57 U
1BO
P291
2 31
U1A
OP2
91
10.0
KR4 10.0
KR1
0
.01
C23
.01
C19
.01
C17
.01
C21
GN
D1
VIN
2
OV
3
+V4
DCD
C1D
CDC
NK
E
TP3
TP5
TP4
TP6
.1C410
UF
C2
FERR
ITE
L2
FERR
ITE
L1
TP1
5 V
A V
5 V
IN
GN
D A
V
56
U5C
MM
74H
C14M
1312
U5F
MM
74H
C14M
116
46 8
1311 9
RLY
1
21
J3
1
2
R2*
21
J2
21
J1
2N39
04Q
1
NPN
249K
R17
120P
FC2
9
120P
FC2
5
249K
R21
GN
D1
VCC
2
REF+
3
REF-
4
IN+
5
IN-
6
GN
D7
GN
D8
GN
D9
GN
D10
CS11
SDO
12SC
K13
Fo14
GN
D15
GN
D16
U7
LTC
2415
NC1
1
VIN
2
SHD
N3
GN
D4
NC4
5V
OU
T6
NC3
7N
C28
U6
LT14
61A
IS8-
3
3 V
olts
0 to
3 v
olts
in
15.0
KR1
5
15.0
KR2
3
2.2U
FC2
710
KR1
9
10K
R24
6 57 U
2BO
P291
8 4
U2C
OP2
91
249KR16
249K
R22
.01
C30
.01
C26
.01
C24
.01
C28
TP7
TP9
TP8
TP10
2 31
U2A
OP2
91
5 V
IN
1N91
4D
1
1 2345
U8
PS91
15
5 V
D V
GN
D D
V
.1C310
UF
C1
GN
D1
VIN
2
OV
3
+V4
DCD
C2D
CDC
NK
E
.1C12
10U
FC1
0
FERR
ITE
L4
FERR
ITE
L3
TP2
5 V
A A
5 V
IN
GN
D A
A
5 V
D A
GN
D D
A
.1C11
10U
FC9
5 V
A A
5 V
A A
GN
D A
AG
ND
A A
GN
D A
A
GN
D A
A
GN
D A
A
GN
D A
V
5 V
A V
5 V
A V
GN
D A
V
GN
D A
VG
ND
A V
GN
D A
V
5 V
D A
1 2345
U9
PS91
15G
ND
D A
1 2345
U10
PS91
15
470
R13
1KR14
GN
D D
A
12
U5A
MM
74H
C14M
470
R6
5 V
IN
470
R83
4
U5B
MM
74H
C14M
1 2345
U11
PS91
15
5 V
D V
1 2345
U12
PS91
15G
ND
D V
1 2345
U13
PS91
15
470
R25
5 V
IN
98
U5D
MM
74H
C14M
470
R18
1110
U5E
MM
74H
C14M
470
R20
1KR26
GN
D D
V
12345678
P1
RELA
Y
RELA
Y
5 V
IN
5 V
A V
GN
D A
V
8 4
U1C
OP2
91
5 V
A A
GN
D A
A
5 A
MPS
RA
TIN
GD
ESIG
N F
OR
7.5
30 V
OLT
S RA
TIN
GD
ESIG
N F
OR
50
4 5
1 2 3
Q2
TIN
Y_L
OG
IC(N
C7SZ
14)
4 5
1 2 3
Q3
TIN
Y_L
OG
IC(N
C7SZ
14)
5 V
D A
5 V
D V
2 W
ATT
S0.
01 O
HM
S
1%
MO
TOR
POW
ER IN
MO
TOR
POW
ER O
UT
VO
LTA
GE
SEN
SE
CLKSDOVSDOAPVCS
10U
FC3
1.1C3
2
FERR
ITE
L5FE
RRI
TEL6
IC1IC2IC3IC4IC5
IMPE
D C
HIP
, 1K
OH
M 3
00m
A
BRE
LEA
SE T
O P
ROD
UCT
ION
2/19
/07
-
TO 7
8P21
3 BO
ARD
ASS
EMBL
Y
47
AP
PE
ND
ICE
S
Appendix C: Calibration Record
DAtEDynAMoMEtEr MoDEl/SEriAl #
AppliED torquE
inDiCAtED torquE
Error tEStEr
48
Service Information
rEturning MAgtrol EquipMEnt for rEpAir AnD/or CAlibrAtion
before returning equipment to Magtrol for repair and/or calibration, please visit Magtrol’s Web site at http://www.magtrol.com/support/rma.htm to begin the Return Material Authorization (RMA) process. Depending on where the equipment is located and which unit(s) will be returned, you will be directed to either ship your equipment back to 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. 1. visit Magtrol’s Web site at http://www.magtrol.com/support/rma.htm to begin the RMA process.2. Complete the RMA form online and submit.
3. An RMA number will be issued to you via e-mail. Include this number on all return documentation.
4. Ship your equipment to: MAgTRol, INC. 70 gardenville Parkway buffalo, Ny 14224 Attn: Repair Department
5. After Magtrol’s Repair Department receives and analyzes your equipment, a quotation listing all the necessary parts and labor costs, if any, will be faxed or e-mailed to you.
6. After receiving your repair estimate, provide Magtrol with a P.o. number as soon as possible. A purchase order confirming the cost quoted is required before your equipment can be returned.
returning Equipment to Magtrol SA (Switzerland)
If you are directed to ship your equipment to Switzerland, no RMA form/number is required. just send your equipment directly to Magtrol SA in Switzerland and follow these shipment instructions:
1. Ship your equipment to: MAgTRol SA After Sales Service Route de Montena 77 1728 Rossens / Fribourg Switzerland
vAT No: 485 572
2. Pleaseuseourforwarder:TNT•1-800-558-5555•AccountNo154033 only ship ECoNoMIC way (3 days max. within Europe)
3. Include the following documents with your equipment: • DeliverynotewithMagtrolSA’saddress(aslistedabove)
• Threeproformainvoiceswith: • YourVATnumber • Value-forcustomspurposesonly • Descriptionofreturnedgoods • Originofthegoods(ingeneral,Switzerland) • Noticedfailures4. A cost estimate for repair will be sent to you as soon as the goods have been analyzed. If the repair charges
do not exceed 25% the price of a new unit, the repair or calibration will be completed without requiring prior customer authorization.
www.magtrol.comTesting, Measurement and Control of Torque-Speed-Power • Load-Force-Weight • Tension • Displacement
MAgTROl InC70 Gardenville ParkwayBuffalo, New York 14224 USAPhone: +1 716 668 5555Fax: +1 716 668 8705E-mail: [email protected]
MAgTROl SARoute de Montena 771728 Rossens / Fribourg, SwitzerlandPhone: +41 (0)26 407 3000Fax: +41 (0)26 407 3001E-mail: [email protected]
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