46/07-W00-Wei

Instruction Sheet 732 689USB

3

Machine Test System 1.0

2A

consisting of
Control Unit (a) 732 689USB 01
Drive and Brake Unit (b) 732 689USB 02
[D&B Unit]

732 689USB 01

1 Area of application Technical data and additional features include:

The control unit 732 689USB-01 is used in conjunction with the • Power supply 230 V, 47…63 Hz, 2,5 kW, supplied via
D & B Unit 732 689USB -02 as a testing system in the electrical connection cable with earthing-pin connector
machine laboratory.
• Automatic digital speed control:
The D & B Unit is a cradle-type three-phase asynchronous
machine with integrated torque pick-up for connection to the (-5000 rpm ...0...+5000 rpm)
control unit. This special machine is equipped with sufficient
power and torque reserves to brake to standstill or drive any of • Automatic digital torque control (±30.0 Nm)
the machines contained in the electrical machine system
1.0 kW. Torque pick-up is performed with strain-gauges • Reference variable and limiting value can be set via
mounted to a durable, highly elastic stainless steel bending bar incremental control knob
and includes integrated electronics. • Automatic run-up and load characteristics
Overload protection is guaranteed using thermal circuit-breaker 2
protection. Connection is carried out using a round 7-pin • Load simulations: Load start-up (M ~ n ), Heavy load
connector plug and a 25-pin cable contained within the scope start-up (M ~ 1/n), arbitrary load characteristic Mi ~ ni,
of supply. Flywheel
The control unit is a microcontroller-controlled device with inte-
grated frequency converter for the power supply and control of • External control: -10 V...+10 V
the three-phase pendulum machine and display of the speed • Switchover between two / four quadrant operation
and torque measured values. Different operating modes permit
manual and automatic recording of characteristics. Further- • 26 mm seven-segment display; speed 4 digit, torque
more, the machines can approach unstable operating points, 3 digit
like when the squirrel-cage machines are set to lower speeds
1
than the pull-out speeds, which are then maintained exactly by • Temperature monitoring: device under test (DUT ),
digital control loops. The recording of the characteristics, even D & B Unit, control unit
over several quadrants, is performed point-by-point, via the XY
recorder or the PC. • Four-quadrant display for load type of DUT
• Adjustable torque limiting (overload protection) and
stop speed (for automatic recording of characteristics)
• Direct measurement of DUT’s voltage and current
without the need of isolation amplifier
• USB interface for measured value transmission and
remote control

1
DUT = Device under test – machine to be tested
 Seite 2/7

• Restart inhibit can be reset after fault induced switch- 2 Safety Instructions
off
• Analog outputs for connection of an XY recorder or
display meters
The device is designed according to protection
• Highest safety standard: leakage current < 5 mA class 1 and corresponds to the safety stipulations
laid out in VDE 0411. When the device is used
according to the stipulations the safety of both the
Furthermore the device is equipped with a error recognition operator as well as the device is guaranteed.
using six codes as well as protective functions. The following However, safety cannot be guaranteed if the device
parameters are continuously monitored: is used improperly or handled carelessly.
For that reason it is imperative that these
• Generator operation (ERR 1) instructions be read thoroughly and carefully before
• Temperature of the DUT (ERR 2) putting the control unit for the D & B Unit into
• Overvoltage in the link operation and that all of the points listed below be
circuit of the control unit (ERR 3) adhered to.
This device may not be operated by persons who
• Temperature of the D & B Unit (ERR 4) are unable to recognize contact hazards and
• Temperature of the control unit (ERR 5) incapable of meeting safety measures.
• DUT is switched off via the In general only work with safety connecting leads so
output DUT ENABLE by removing that contact hazards with dangerous voltages can be
the coupling guard or the excluded.
shaft end guard (ERR 6) Modifications to the experiment set up may only be
performed when the system is switched off (zero
current / zero voltage). For this turn off the three-
On switching on the control unit using the main switch (a1) and phase mains and the control unit for the D & B Unit
pressing the nSTOP (a28) button, the Software version is shown with switch a1.
on the displays (a29) and (a30). Before switch off operate the D & B Unit at no load
by actuating pushbutton M = 0.
Always use coupling and shaftend guards to protect
against contact to rotating parts.
Normally it is not necessary to open the device's
housing. However, should this prove necessary, this
may only be performed by a technician and only
under the condition that the mains plug and all
connecting leads have been disconnected.
Only apply safety extra-low voltages to the
CONTROL IN sockets.
Never connect external voltage sources to the
outputs.
Warning: This operating equipment defined class A,
group 1 as set forth in the EN55011 standard and
may cause radio interference in residential areas. In
this case it may be required of the person operating
the equipment to take necessary preventative
measures and to bear the expenses. However, when
the equipment is operated in the appropriate
technical setting or lab of a general education or
vocational institution or other training center it is
assumed that no radio interference will arise in
residential areas as long as a safety zone of at least
30 m exists and the operating equipment is operated
only intermittently.

LD DIDACTIC GMBH . Leyboldstrasse 1 . D-50354 Huerth . Phone +49 2233 604-0 . Fax +49 2233 604-222 . e-mail: [email protected]

by LD Didactic GmbH Printed in the Federal Republic of Germany

Technical alterations reserved
Page 3/7

3 Equipment Description machine-generator set sheds its load and the stop speed
flashes for approx. 5 seconds.
3(a) Control unit a4 The pushbutton M = 0 serves to interrupt any given
operating state. At the same time the torque display shows
OFF. The D & B Unit no longer develops any torque, comes to
a standstill or is set to its no-load speed by the machine under
test. Consequently, the activation of the pushbutton M = 0
results at all times to the load shedding of the machine-
generator set. Reactivation of the pushbutton M = 0 results in
the reactivation of the control unit and there with the frequency
converter.
a5 Operating mode switch (MODE)
Switchover to the next operating mode occurs each time this
pushbutton is pressed. The current operating mode is
displayed by an LED (a6).
a6 Modes of operation:
a6.1 Load characteristic
The rotation speed, specified by the incremental control knob
or externally, is kept constant. The load of the DUT is the
product of its speed / torque characteristic. The recording of the
characteristic is started by pressing the START button.
a6.2 Run-up characteristic
The speed, which is preset using the incremental control knob
or externally, is kept constant. The load of the DUT is the prod-
uct of its speed / torque characteristic. The recording of the
/
+ characteristic is started by pressing the START button.
a6.3 Automatic torque control (TORQUE CONTROL)
The torque, which is set by means of the incremental control
knob or externally, is kept constant. The DUT operates under
constant load.
2
a6.4 Load simulation M ~ k n
732 689USB 01 2
The D & B Unit simulates the load response of a fan (M ~ k * n
with k = 1).
a6.5 Load simulation M ~ k / n
The D & B Unit simulates the load response of a winding drive
(M ~ k / n with k = 1).
a1 Main switch a6.6 Load simulation Mi ~ ni
The D & B Unit simulates the load response with arbitrary
ON / OFF switch for the control electronics and supply voltages
characteristic edited by the user.
for the pendulum machine.
a6.7 Load simulation flywheel
a2 2- or 4-quadrant operation (ONLY MOTOR OPERATION)
The D & B Unit simulates the load response of a flywheel.
If this LED lights up the control unit automatically switches off
when the DUT is operating in the 2nd or 4th quadrants a7 Error message LED (ERROR)
(generator operation). This is a function used to protect power A multicolored LED is situated with the following significance:
sources which are not energy recovery-proof, if the DUT is off: normal operation
being supplied by such a source. green: An error has been eliminated and has to be
acknowledged
After the device is switched on at switch S ,the LED lights up
(only 2-quadrant operation possible). If the device is switched red: An error appears and is displayed as ERR n
on by pressing the START button (directly below the LED), the (n stands for 1 to 6, see table below
display (a29))
LED does not light up (4-quadrant operation possible).
Acknowledge by pressing RESET button (a8).
a3 Pushbutton to start automatic recording of the
characteristics. a8 RESET
If the operating mode load characteristic or run-up If an error message is displayed or switch off has been carried
characteristic is actice, automatic recording of characteristics out because the torque limit has been exceeded, the
can be started by pressing the pushbutton. control unit can be switched on using this button. However, this
In the case of the load characteristic the speed range, starting is only possible if the corresponding error has been eliminated.
In the case of switch-off due to overheating this entails a
from the momentary speed value and automatically proceeding cooling off of the corresponding components (LED lights
up to the stop speed. For the run-up characteristic the green).
machine-generator set is rapidly braked to the stop speed in or-
der to run up again to the speed applicable for start or a9 Four-quadrant display
recording. Before starting the characteristic recording the Display of the instantaneous load type of the DUT.
momentary speed can be changed using the incremental Quadrant Load type Rotation direction
control knob . At the end of the characteristic recording the 1st quadrant Motor operation clockwise
2nd quadrant Generator operation couterclockwise
 Seite 4/7

3rd quadrant Motor operation counterclockwise ±10 V corresponds to ±5000 rpm

4th quadrant Generator operation clockwise The setpoint value is supplied to the selected controller via a
run-up generator. This means that setpoint step changes are
a10 L1IN, L2IN, L3IN resp. (-)-pole or N (Neutral) possible and lead to a slight overshoot of the controller in
Input sockets to the internal DUT’s measurement circuits for question.
connection of external power supply:
Input ranges for voltages: 0…600 V AC/DC a14 Temperature monitoring of the DUT: TERR
currents: 0…20 A AC/DC This input is connected to the thermal contact of the DUT. This
frequenties: 0…120 Hz connection is always established as otherwise there would be
no overload protection for the DUT.
a11 L1OUT, L2OUT, L3OUT
Output sockets for connection of different DUT-machines a15 DUT ENABLE-sockets
(DC, AC, 3~) Potential-free relay-driven output sockets in the operation mode
as
- a switcher used with the INH input of Control Unit
PWM Characterisitc Method, cat. no. 735 291,
732 689USB
- a cut-off used with power circuit breakers e.g. cat. no.
745 561
The operation modes dut nc (normally closed) and dut no
(normally open) are displayed after the lamp test as dut
nc or
dut no and can be changed by pressing the MODE key (a5)
during the first seconds when control unit is switched on. With
each pressing a delay time will be started. The setting will be
saved, the default mode of DUT ENABLE is dut no.

a16 Connection socket to supply the D & B Unit.

a17 Control connection input

Multifunction Input for the connection of the D & B unit’s build-in
Fig. 3.1 Connection of a sqirral cage motor in ∆ to the sockets a10 incremental tacho-generator, torque measurement- and protec-
and a11 tion circuits.

a18 Digital speed output (TACHOOUT)

The signals of the tacho-generator are automatically forwarded.

732 689USB
a19 USB interface (USB)
This interface is electrically isolated and outputs the speed and
torque of the D & B Unit. If the sockets in the DUT sockets field
are connected, also the current consumption and the voltage
supply of the DUT is transmitted. Control of the control unit can
also be carried out using the software CBM10.

a21 Incremental control knob to change the reference variable

and the limit
The reference variable to be changed depends on the
operating mode set and thus on the control loop currently
activated. The speed setpoint is varied in the operating modes
load characteristic and run-up characteristic
Fig. 3.2 Connection of a universal motor as an AC machine to the
sockets a10 and a11 Setting range: -5000 rpm...0 rpm...5000 rpm
In the automatic torque control mode (TORQUE CONTROL)
a12 INTERN / EXTERN-switch the setpoint value for the torque control loop is varied.
INTERN: Depending on the operating mode reference
variable is set for speed, or torque via the incremental Setting range: -30.0 Nm...0 Nm...+30.0 Nm
control knob. In the case of external operation the incremental control knob
EXTERN: Depending on the operating mode the cannot induce a change in the setpoint.
reference variable is set for speed or torque via the If the stop speed or the torque limit is displayed (by pressing or,
external input CONTROLIN (a13).
the incremental control knob can be used to vary the value
currently being displayed.
a13 External control input CONTROLIN
This input is active if the INTERN / EXTERN-switch is set to Setting range stop speed: 0 rpm…+/-5000 rpm
EXTERN. For external operation the setpoint value for the Setting range torque limit: 0 Nm…+/-30.0 Nm
control loop selected by the MODE button is supplied via this
socket. Here the following linear relationships apply to some The load simulation operating modes only permit an effective
extent: setting of the torque limit, for load simulation of a winding drive
(M ~ k/n) the maximum adjustable torque limit is at 10 Nm (this
Automatic torque control (TORQUE CONTROL): torque has to be overcome during start up).
±10 V corresponds to ±30 N
Automatic speed control (SPEED CONTROL): a22 Auxiliary ground sockets

LD DIDACTIC GMBH . Leyboldstrasse 1 . D-50354 Huerth . Phone +49 2233 604-0 . Fax +49 2233 604-222 . e-mail: [email protected]

by LD Didactic GmbH Printed in the Federal Republic of Germany

Technical alterations reserved
Page 5/7

In the following the function of the Machine Test System 1.0 is

a23 Analog DUT’s current output (I [ 1 V / 2 A ]) described in conjunction with a squirrel-cage machine,
The voltage is proportional to the DUT’s supply current when cat. no. 732 804 as the DUT.
connected to DUT socket field (1 V corresponds to 2 A). However any other type of machine in the 1.0 kW machine
program can be used.
a24 Analog DUT’s voltage output (U [ 1 V / 100 V ]) Equipment list:
The voltage is proportional to the DUT’s supply voltage when
732 689USB Machine Test System 0.3
connected to DUT socket field (1 V corresponds to 100 V).
735 297 Universal Converter 3 x 230 V
a25 Analog torque output (M [ 1 V / 3 Nm ]) 735 291 Control Unit PWM Characterisitc Curve
The voltage is proportional to the instantaneous torque of the Method
D & B Unit (1 V corresponds to 3 Nm). 726 71 Single-phase Supply Unit
735 09 Load, Power Electronics
a26 Analog speed output (n [ 1 V / 1000 rpm ])
728 421 Disk CBM 10 V5
The voltage is proportional to the momentary speed of the
machine-generator set (1 V corresponds to 1000 rpm). 729 769 V24 Connection Cable 9-pin
732 56 Coupling
a27 Pushbutton to display torque limit (|MMAX|) 732 58 Coupling Guard
When operated switchover occurs between the torque limit and 732 57 Shaft End Guard
the momentary torque. If the torque limit is being displayed, the
732 804 Squirrel-cage Motor 230 / 400 V,
display flashes. This value can now be changed using the in-
cremental control knob. class 1.0
If the display flashes, max. limit switch off (machine torque >
set torque limit) is performed at the value now shown in the
display. The DUT sheds its load: M = 0.
a28 Pushbutton to display speed limit nSTOP
When operated switchover occurs between stop speed and
current speed. If the stop speed is displayed, the display
flashes. This value can now be changed using the incremental
control knob.
a29 3-digit 7-segment display to indicate the torque
a30 4-digit 7-segment display for the indication of the speed
and error codes.
To acknowledge error see RESET (a8)!

3(b) Drive and brake unit

b1 Shaft with coupling

Mechanical connection between the D&B unit and the DUT
using flexible rubber coupling elements.

b2 25 pole data connector

to be connected to the control unit (a)

b3 7 pole connector
to connect the power cord to the control unit (a)

4 Experiment setup
 Seite 6/7

characteristics after the RESET button (a8) is pressed.

If the DUT is overheated, this device should not be
5 Putting the system into operation switched off but operated at no-load. The fan provides
Here we shall describe recording of a load characteristic and for faster cooling of the machine.
the determination of rating plate data of the machine under test 2. The torque limit has been exceeded. This is indicated
as a representative example. by the flashing of |MMAX|. Switch off occurs when the
If during the experiment procedure you deem it necessary to momentary torque value exceeds the value of the
immediately switch off the set operating state, this is possible at torque limit. The momentary limit value causing switch
any time with M = 0. The machine-generator set then comes to off flashes for a period of approx. 7 seconds in the
a standstill or continues to run at no-load. display. Thereafter the momentary measurement
values for torque and speed are displayed.
If you switch off the device you have to activate M = 0 first to
bring the motor-generator set to a standstill or no-load If the operating modes automatic recording of load
operation. Subsequently the mains switch of the control unit characteristics (a6.1) or run-up characteristics (a6.2) are active,
can be turned off. the speed control loop is switched on. The possibility exists to
vary the setpoint value for this using the incremental control
Couple the DUT and the D & B Unit, see Fig. 4.1: knob. This way any given speed can be set.
The recording of the load characteristic (a6.1) always begins at
the momentary setpoint speed and ends at the stop speed.
Afterwards the motor-generator set is unloaded and proceeds
to run at no-load.
For the recording of the run-up characteristic (a6.2) the braking
is always applied to motor-generator set until the stop speed is
reached. Subsequently it is accelerated until the speed is
reached which was in the display at the start.
As a result it is also possible to record the characteristic when
the DUT is in generator operation. For this the machine under
test is driven manually to the desired generator operating point
and then the automatic recording of the characteristic is
started.
ATTENTION: If the DUT is driven in generator operation, its
power supply must be energy recovery proof. Most DC voltage
sources are not energy recovery proof! If this is true for the
DUT it may not be operated in the generator mode.
To protect the power source of the DUT the control unit can be
switched to 2-quadrant operation (a2) which is the default
Fig. 4.1: Experiment setup for recording characteristics setting after switching on the unit. An error message ERR 1 is
then indicated, if the machine under test goes into generator
operation.
Set the INTERN / EXTERN switch (a12) to INTERN.
Switch on the control unit while pressing the START button
Determining the rating plate data
(a3). All of the LEDs light up for approx. 4 seconds and
The data on the rating plate of the three-phase asynchronous
8.8
8.8 8. is shown in the display. Also dut no is displayed in
8.8 machine with squirrel-cage rotor are applicable for nominal
(a29). motor operation. Nominal motor operation is achieved, if the
Afterwards the displays shows 0 rpm and OFF Nm. machine delivers its nominal torque to the shaft, i. e. the
D & B Unit has to load the motor with nominal torque:
Now switch on the voltage supply connected to (a10) for the
DUT. The motor-generator set rotates. The momentary speed
is indicated in the display. This amounts to approx. 1480 rpm. 732 804 Class 1.0
Now press the M = 0 pushbutton (a4): the torque display shows ∆/Y 230 / 400 V 2,65 / 4,6 A
0 Nm. 1 kW S1 cos φ 0.83
Then select the operating mode automatic recording of the load 1410 rpm 50 Hz
characteristic (a6.1).
I.Kl. F IP 20
Set the stop speed to –300 rpm with the aid of the pushbutton
(a28) and the incremental control knob (a21). Now set the
momentary rotation speed to 1600 rpm. By pressing the Rating plate of asynchronous motor with squirrel cage rotor
START button (a3) the device begins with the automatic
recording of the load characteristic for the three-phase
asynchronous motor with squirrel-cage rotor, i. e. braking
proceeds until the stop speed is reached. After completion of
the characteristic recording the stop speed is flashed for
approx. 7 seconds in the display. Afterwards the D & B Unit is
synchronized again to the machine under test.
If the characteristic is not recorded completely this can be due
to the following causes:
1. There is an ERROR message displayed (see the
equipment description 2 below). After eliminating the
error, e. g. the overheated components have cooled
off the device is ready to resume recording of

LD DIDACTIC GMBH . Leyboldstrasse 1 . D-50354 Huerth . Phone +49 2233 604-0 . Fax +49 2233 604-222 . e-mail: [email protected]

by LD Didactic GmbH Printed in the Federal Republic of Germany

Technical alterations reserved
Page 7/7

6 Overview of the test machines

The following table contains the recommended values for nSTOP
and |MMAX| for various DUTs:
Machine type |MMAX| / Nm nSTOP / rpm

732 60 Compound-wound mach. 10 > 250

732 61 Shunt-wound machine 10 > 250
732 62 Series-wound machine 10 > 250

732 70 Universal motor 10 > 250

732 73 Bifilar-wound motor R - -
732 74 Capacitor motor R - -

732 804 Squirrel-cage 230/400 V - -

Fig. 5.1: Load characteristic of a three-phase asynchronous
motor with squirrel cage rotor in delta connection 732 81 Squirrel-cage 400/690 V - -
732 94 Squirrel-cage motor D - -

732 96 Squirrel-cage motor SW - -

The nominal torque is calculated out of the rating plate data as 732 98 Multifunction machine - -
follows:
733 07 Synchronous machine SC - -
MN = P / ω = P * 60 / (2 * π * n)
= 1000 W * 60 / (2 * π * 1410 rpm) = 6.77 Nm 733 15 Reluctance motor - -

Using the MODE pushbutton (a5) switch on the operating mode

automatic torque control TORQUE CONTROL (a7.3). Now with The setting of the torque limit is carried out using the
the aid of the incremental control knob (a21) you can set the pushbutton (a27). These limits are set to protect the
calculated torque below the display. DUT against overload in accordance with the table
If the correct operating point has been set, the nominal current, above. The setting should be performed before putting
nominal power factor and nominal speed can be determined for the DUT into operation.
this machine. Since the electrical power is also measured, the
efficiency of the machine can be calculated, too.
Measurement results:

Deviations of the measured results from the values specified on

the rating plate can be attributed to the machine's
manufacturing tolerances, as well as the operating
temperature. The permissible tolerances are listed in
IEC 60034-1.
The load characteristics can be recorded point-by-point in the
same manner as the rating plate data was checked. Any
random torque value can be set and the corresponding
operating values like speed, current, electrical power, power
factor and efficiency can be determined for each setting.

On the basis of the experiments performed you should also

demonstrate the operation and functionality of the control unit.
Using the representative experiments carried out here similar
procedures can be implemented to investigate any other DUTs
from the 1.0 kW machine series. Corresponding experiment
procedures can also be referred to in the experiment manuals
accompanying the respective machines, see therefore in
manuals T 10.4.x. The load simulations for fan, lifting or
winding drives permit investigations of stable operating points,
starting problems and the setting of frequency converter
parameters.