APPLICATIONSYSTEMS

A-2/6, 5 Acre, Kothari Compound,

Tikuji Ni Wadi Road, Chitalsar - Manpada, ISO 9001:2015 Certified
THANE. PIN 400 607. (Maharashtra) INDIA.
TEL. No: 8080442054, Mob.No.9323724866
Email: [email protected]
[email protected]
Website: www.applicationsystem.net
www.dynamometerdyno.com

USER MANUAL
FOR
EDDY CURRENT DYNAMOMETER
WED 373S

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IMPORTANT FORMULAS:-
Power Conversion 1 HP = 0.746 kW
(HP to kW)
Example:-
50 HP = (50 * 0.746)
= 37.3 kW

Torque Calculation(Nm) 𝐏𝐨𝐰𝐞𝐫(𝐤𝐖)∗𝟗𝟓𝟒𝟗

Torque =
𝐑𝐏𝐌

Example:-For 50Hp Motor ( 2 Pole)

I. 50 HP = (50 * 0.746)
= 37.3 KW
37.3∗9549
II. Torque =
3000
= 118.72 Nm
Dynamometer Calibration
Torque (Nm) = Weight * Centre Distance * 9.81

Example:-

20 Kg X 0.5 Mtr X 9.81 =98.1Nm

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INDEX
Page
Content
No.

SAFETY INFORMATION 04

INTRODUCTION 06

SCOPE OF SUPPLY 05

MANUAL DYNAMOMETER FRON PANEL CONTROLS 08

INSTALLATION AND COMMISIONING PROCEDURE OF EDDY CURRENT

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DYNAMOMETER

CALIBRATION OF TORQUE SENSOR 11

COMPONENTS OF EDDY CURRENT DYNAMOMETER 12

WIRING DIAGRAM 14

MAINTENANCE 15

SAFETY PRECAUTIONS 16

TROUBLE SHOOTING 17

PREVENTIVE MAINTENANCE 19

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Safety Information

1.1 Warning, Cautions and Notes

A warning contains information which is essential for avoiding a safety hazard.

A caution contains information which is necessary for avoiding a risk of damage to the
product or other equipment.

1.2 Important Safety information

Safety information contain mechanical and electrical both during running the test.
Mechanical includes any loose bolt or coupling guard in not mounted or coupling grub screws
not tightened properly or shafts are not co-centred properly with respect to each other.
Electrical includes earthing and neutral is not proper, connections not done proper/ loose
connection.

1.3 Responsibility
It is responsibility of the installer to ensure that the equipment is installed correctly
regarding all instruction given in this guide. They must give due consideration to the safety of
the complete system, to avoid of injury to both in normal operation and in the event of a fault
or of reasonably foreseeable misuse. The manufacturer accepts no liability for any
consequences resulting from inappropriate, negligent, or incorrect installation of the
equipment.

1.4 Electrical Hazards

The voltages used in the control panel can cause severe electrical shock and could be
dangerous, extreme care is necessary at all time. Hazardous voltage may be present in any of
the following location,
• AC and DC supply cables and connections.
• Output cables and connections.
• Many internal parts of the Panel.

The supply must be disconnected before access to any electrical connection.

1.5 Stored Electrical Charge

The system contains many capacitors which stores charge and could not be touched
before checking.

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1.6 Mechanical Hazards

The Systems is designed for high-speed running hence proper care should be taken
before starting the dynamometer or system. All fasteners should be checked properly before
running.

Imp Note: -It is advised not to connect internet to the Testing system as it would corrupt the
testing software. Also do not connect any external virus containing devices to the system as
this could also harm the software.

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Introduction:
This manual is presented as a guide in installing, commissioning, operation and
maintenance of Eddy current Dynamometer Water Cooled, Model APPSYS WED-373S
and associated Dynamometer manual control Systems.

Scope of Supply:
1) Eddy current Dynamometer, Water Cooled, Model: APPSYS WED - 373 S having Water
pressure switch, torque calibration arms, speed sensor, reaction type torque sensor,
mounted on a fabricated base table.
2) Manual Dynamometer Controller to control Dynamometer loading Torque & Indicate
Torque & Speed on Digital Indicators.
3) Cable loom with Connector - Cable between Controls & Dynamometer 6 meters.

Dynamometer Specifications:
When properly installed and operated within the limits specified, Dynamometers are
expected to provide long trouble-free service life.
Model APPSYS WED 373S
Max. Torque (Nm) 1780 Nm
Min Torque (Nm) 50Nm
Maximum Torque at speed range(R / Min) 810 to 2000 RPM
Max permissible speed (6000RPM) 6000RPM
Reaction Torque Sensor Specifications Strain Gauge type-10 V DC excitation.
350 Ω 2mV/V output,
Non – Linearity < ±0.1% FSO,
Hysteresis < ±0.1% FSO,
Non-Repeatability < ±0.1% FSO,
Temperature Effect on Output < 0.0015% FSO/ºC,
Temperature Effect on Zero < 0.0020% FSO/ºC,
Speed measurement precision ± 0.2 FS %, 1RPM resolution
Torque measurement precision (F. S.) ± 0.2 FS %, 0.1Nm resolution
Coil Excitation Volts DC 90 V DC
Coil Current Amps Max 5 Amps
Torque Sensing Reaction type, Force Sensor
Form of Torque Sensor Full Bridge, Strain Gauge type. 10 V DC
Excitation. 2mV/V output.
The direction of rotation Bi directional, Clockwise & anti -clockwise
Cooling Water Flow required. 12500 LPH at 1-2 bar pressure

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Mechanical Dimensions:-
• Overall Size: 820 mm x 1340mm x 1200 mm
• Centre Height: 700 mm
• Inlet Piping: 1.5”
• Outlet Piping: 1.5”
• Calibration Arm Length from centre: 750 mm
• Cooling Water Requirement (Dynamometer Inlet) Pressure: 1.0-2.0 bars
• Temperature: Less than 60°C.
• Cooling Water Flow (Dynamometer Inlet): 12500 LPH
• Type of Lubrication: Grease

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Electrical:
• Supply Voltage:240 volts ± 10% AC, 50 Hz
• Separate Earth should be given to the system.
• Maximum Excitation: Internally set in the instrument depending on the capacity of Eddy
current dynamometer.S Generally, 3 To 5 Amps D.C.
• RPM: This is displayed by a 4 digit display. This displays dynamometer rpm.
Accuracy: ± 1 rpm.
• Torque: 4 &1/2 digit display. (4 digit torque. ½ digit for clockwise or anticlockwise
rotation display)

Manual Dynamometer Front Panel Controls:

01. Torque Load/Unload Switch:

Torque Load / Unload switch is used to provide excitation signal / voltage to
dynamometer for loading motor. To load motor keep switch in LOAD position.
In load position controller will provide excitation signal to dynamometer for loading. To
stop loading keep switch in UNLOAD position.

02. Digital Torque Meter:

Digital Torque meter will show torque applied to motor under test.

03. Digital Rpm Meter

Digital RPM meter will show RPM of motor under test.

04. Percentage Meter

Excitation percentage Meter will show percentage of excitation supply given to
dynamometer.

05. Reset Switch

Reset switch is used to Reset Water Pressure Error & Temperature Error.
Water Pressure Error. Water pressure switch is supplied with dynamometer and
connected at Water Inlet to check if water supplied for cooling of Dynamometer is at 0.5
to 1 bar. If Same is not maintained WP led on controller will glow and excitation to
dynamometer is stopped. In this case, increase Water Pressure and Press Reset switch
to start Test again.

06. Torque Loading Potentiometer (Set)

10 turn helical potentiometer to load torque on Device under test. It shows the no of
turn of potentiometer. Rotate this knob clockwise to load Device under test.

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07. Manual Mode – M

Manual mode to operate dynamometer in as per your standard procedure / loading
torque as per your requirement. In this excitation current delivered by CONTROLLER is
independent of the dynamometer speed. It means Torque is independent of speed and
there no relation between Torque & speed. The torque of the Dynamometer can be
varied with the help of potentiometer provided on the face control.

08. Constant Torque Mode – T

The PID Card constantly tracks the actual torque input with the value set by the
potentiometer and adjusts the Dynamometer Current to maintain the desired Torque.
By pressing this button, you could set the value of Torque by using the potentiometer
(Set Torque Pot) say 20 Nm. The Dynamometer will constantly load the test System for
20 Nm irrespective of the speed. Use the dial on Set Torque Pot to apply constant
Torque.

09. Constant Speed Mode – N

In this mode Speed is kept CONSTANT with variable Torque.
The PID Card constantly tracks the actual Speed input with the value set by the
potentiometer and adjusts the Dynamometer Current to maintain the desired Speed
within control limits. The Dynamometer Speed remains Constant irrespective of the
Torque loading. Use the dial on Set Torque Pot to apply constant speed the dial
displays ‘0’ to ‘10’ corresponding to RPM ‘0’ to ‘Max Speed’ with a multiplication factor
M = ‘Max Speed / 10’.
If the RPM meter doesn’t show the set Speed as desired by you, use the RPM error
preset (RP error) as shown in dynamometer card.

10. Null Switch.

This switch is used while calibrating Dynamometer. In calibration process after
hanging weights on calibration arms used this switch to make torque 0.0 on Torque
Meter on Controller.

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INSTALLATION AND COMMISIONING PROCEDURE OF EDDY

CURRENT DYNAMOMETER

1) Install EDDY CURRENT Dynamometer, Connect water supply, through pump, to Water
Inlet (pressure switches side). Please ensure that water flow quantity is as suggested to you
earlier. In case Water flow rate is less, Dynamometer will get excessively heated up &
damage internal parts. Please ensure good, filtered water is circulated in Dynamometer
Otherwise water path in Dynamometer will get blocked & Dynamometer will get excessive
heated up. (Water pressure switch is supplied along with Dynamometer. Make sure the
water pressure is maintained at 1-2 bar pressure.)
2) Ensure that Dynamometer shaft is free to rotate by hand. Ensure that no metallic rubbing
noise coming out from Dynamometer when rotated.
3) Please mount calibrating Arms on both sides of Dynamometer with bolts.
4) Connect Dynamometer Shaft to the engine through coupling/ cardan shaft.
5) Please ensure position of Infra-Red Speed Sensor such that toothed wheel is in sensing
slot & not touching slot at any sides. (On non-driving side of Dynamometer).
6) Observe for metallic rubbing noise from Dynamometer, Coupling, and Cardan shaft. If
noise is excessive, please inform us.
7) Make sure that the reaction type loadcell is mounted perpendicular to the base table. If
the load cell is at an angle, it will show deviated results.

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COMMISIONING PROCEDURE FOR PANEL

.
1) Connect Dynamometer Controller Connectors (pre-wired) as per DYNO CONTROLLER
CONNECTORS supplies
2) Please connect three pin Plug to 220 V AC, Single Phase supply, as per Dynamometer-
Panel Wiring Diagram.pdf. Keep Mode Selector Switch to MANUAL Mode & ensure
TORQUE Potentiometer (Knob) at Zero position.
3) Switch ON Single Phase supply to Panel.
4) Observe all Torque Indicator & Speed Indicator will show some value.
5) If Ok, Proceed for Dynamometer calibration.
6) Ensure DIGITAL TORQUE INDICATOR shows 000 reading. If indicator shows some
reading, adjust NULL preset on Dynamometer Control card by small screw driver.

CALIBRATION OF TORQUE SENSOR

1) Ensure DIGITAL TORQUE INDICATOR shows 000 reading. If indicator shows some
reading, adjust NULL preset on Dynamometer Control Card by small screw driver.
2) Measure distance in Meters from Dynamometer Shaft Center, to Calibration arm bolt
where weight is to be hang.
3) Keep a known weight of say 1 Kg on the calibration arm. Hence Torque is Weight (Kg) X
Distance (Meter) X 9.81 to indicate Torque in Nm.
4) Example if 1 Kg weight is hanged on Torque Calibration arm bolt & distance is 0.5meters.
Then Torque is 1 Kg X 0.5 Mtr X 9.81 = 4.905 Nm.
5) Set the torque obtain in step 3 i.e. 4.9 Nm by using SPAN preset on Dynamometer Control
Card, by opening the front panel of Manual Controller. Manual Controller is below Monitor
having, Torque, Speed, and Temp Controllers.
6) Remove the weight and check the Torque indicator it will show the ‘0’ value.
7) Repeat the above step until you achieve maximum repeatability.

PROCEDURE OF CONSTANT TORQUE

1) Keep Motor / Dynamometer rotating at some speed. SPEED INDICATOR will indicate
Motor speed in RPM.
2) Keep LOAD ON / OFF Selector Switch to ON side.
3) Increase TORQUE by TORQUE Potentiometer on face of control panel.
4) Increase TORQUE TO DESIRED LEVEL.
5) Reduce TORQUE to ZERO by Potentiometer.

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PROCEDURE OF CONSTANT SPEED

6) Now, put Mode selector switch to CONSTANT- SPEED Mode.

7) Increase Potentiometer to some value; say 1.00 reading on Potentiometer, In this case
Motor Speed will be limited to approx. 1500 RPM. Even if Motor speed is raised up,
Dynamometer will not allow going beyond 1500 RPM, but TORQUE Value will Increase
will raise Motor Speed, TORQUE Potentiometer works as SET SPEED potentiometer in
this mode.
8) Now, Reduce TORQUE Potentiometer to 0.00 ( Zero) value

COMPONENTS OF EDDY CURRENT DYNAMOMETER

a) Eddy Current Dynamometer

b) Reaction Type Torque Sensor (S Type Load Cell)

c) RPM Sensor

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d) RPM Sensor guard

e) Inlet & Outlet Pipe Line

f) Pressure Switch

g) Cable conduit with connectors on both side.

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Wiring diagram:

Dynamometer card

• Null preset: It works same as that null preset present on the control panel. From this we
can set the torque to zero for initial condition or start up.
• Span preset: from this we can set the tension during calibration.
• RPM preset: from this we can synchronies the rated RPM during RPM calibration.
• Nm error preset: From this we can adjust the Nm during constant Torque mode.
This is PID tuning set up. Do not change it.
• Rp error preset: From this we can adjust the RPM during constant Speed mode.
This is PID tuning set up. Do not change it.
• Trans preset: This is an RPM interlock. (In this case it is not used)

Following are the controller connection diagram shows the details:

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J15
J12
EXT SW
GND 1
C-T SW
DIN TORQ
C-N SW
D5V
DISP M SW
D0V
EXT L LED
LOAD SW
C-T L LED
10V
C-N L LED
POT SET POT LOAD UNLOAD SW
ML LED
8
GND
SW COM
GND

J13 J14

NC 1 COIL% RPM PULS O/P

GND EXT SW ON D/O
MITE RESET RPM 0-10V A/O
RESET TORQ 0-10V A/O
WPL EXT POT A/I
DRPM WP WATER FIOW D/O
D+V GND
8 RPM
GND GND

MAINTENANCE

The following periodic maintenance should be performed to prevent interruption in the

service.
1) Inspect the control cabinets and covers for tightness.
2) Check the electrical equipment and terminal strips for firm electrical connections and
cleanliness. If excessive dust or dirt has accumulated, then
⇒ Turn OFF all input power.
⇒ Use a vacuum or low-pressure clean air to remove dust and dirt on the components and
housings.
3) Check the bearing noise and bearing temperatures. The permissible temperature rise of
the bearings, over the ambient is less than 70°C. If the said limits are exceeded, the
Probable causes are:
• Deterioration and caking of the grease.

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• Undue stresses on bearings due to improper alignment in coupling.

4) In the dynamometer grease packed sealed bearings are used. It is suggested to replace
these bearings once in every two years, as recommended by bearing manufacturers.

SAFETY PRECAUTIONS
• Make sure that dynamometer and electronic products are earth grounded, to ensure
personal safety and proper operation.
• Check line voltage before operating the Dynamometer.
• Make sure that dynamometers and motors/Engine under test are equipped with appropriate
safety guards.
• Check all the alignments before running the dynamometer (mainly in rotating part e.g.
Coupling or Cardan shaft)
• There is a 60 toothed RPM sensor star is mounted on the dynamometer, please keep covering
on it else it can damage the operator.
• The mechanical energy developed by the engine/motor under test, during braking is
converted into heat which is dissipated by water in the dynamometer so don’t operate the
dynamometer without water or it can damage the internal parts
• The temperature of the dynamometer body should not exceed 55 degree, accordingly
maintain the inlet water temperature (try to maintain it below room temperature of the inlet)
• High Precaution should be taken of the load cell as it is highly sensitive, try to avoid
hammering on it else it can be damaged.

TOUBLESHOOTING
Sr.
Faults Reason of Fault Fixing
No.

1. Mechanical • This can be due to miss-alignment in • Align the couplings

vibration the couplings. properly.
• Coupling Grub screws nottightened • Tight the coupling Grub
properly. Screws.
• Motor Mounting Bolts not tightened • Tight the motor mounting
properly. bolts
2. Motor Over • Motor would be Jam. • Check whether motor
current shaft is jam, it should be
freely rotated by hand.
• Motor coil winding would be short. • Do the megger testing of
• Dynamometer would be in the load the motor.
condition. • Initially unload the
dynamometer.

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3 Load is not • Dyno coil wire would be loose or • Check the wiring properly
applied to the removed. • Tighten the Grub screws
motor even • Coupling Grub screw would not be properly on the shaft.
after loading. tight hence the shaft would be
slipping in the coupling. • Select the mode i.e.M, C-
• Modes not selected. T, C-S.
• Check the water flow if
• Water Flow error. water is flowing then
check for Flow switch.
• Change the fuse.
• Fuse would have gone.
4 Load /Unload • Wiring Would be loose • Check the wiring of
toggle Switch Load/Unload toggle
Not working switch.

5 Load Cell not • Check the faults as mentioned • If Load cell is found ok
Working below. then check the wirings at
• Open the connector of Load cell and the dyno terminal.
keep controller in on position. • If we don’t get 10 VDC
• Now take multi-meter to check the across RED and BLACK
DC voltages. wire, then Load cell is
One probe of multi-meter to RED damaged and it should be
wire and other to BLACK (it should replaced with new One of
Show 10V DC). same capacity.
Now again one probe of Multi-meter • If there is no variation in
to GREEN wire and otherto WHITE it voltage across GREEN and
should show Zero VDC without WHITE after applying the
loading. force, then load –Cell is
Now holding this position, apply a damaged and to be
little Force by hand on the load cell replaced with the new of
the DC Volt should increase or same capacity.
decrease

6. Torque display • Dynamometer should be in the • Load the dynamometer

showing zero unload position. • Check the fuse& replace it
value, but not • Dynamometer Output card fuse is with the new one, then
increasing or blown. also if fuse is blown there
decreasing • Dyno coil wire would be removed. is problem in the card.
when load is Note: - There are two fuses, One for • Check whether dyno coil
Main supply and other for dynamometer wire properly connected.
applied.
card output. • Check the wiring
connection with the wiring
diagram.

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7. Torque • Load cell would not be working. • Change the load cell
display (But voltage and current would be with new one.
showing increasing and decreasing) • Check for any loose
some value, connection in PC panel.
but not • Check whether load
increasing or would be removed.
• Confirm the fault no.6
decreasing
while
applying the
load

8. RPM sensor • Dust would be there in the sensing •Clean the dust of the
not showing slot. sensor with the
pressured Air in sensing
slot.
9 % Meter is not • Replace with the new. • Replace with the new.
working
during
loading
10 WP not • Flow switch not working. • Check the flow switch
working and replace it with a new
• Relay not working one.
• Check the Relay and
replace with the new
one.
11 Mode • Dynamometer Card would not be • Contact with
selection is working. Dynamometer Supplier.
not working

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PREVENTIVE MAINTENANCE
1. Mechanical

• Keep the testing setup clean (Dust particles should not enter in rotating parts).
• Check that every fastener is tightened properly. (Brackets, Bearing Covers, Guards,
Couplings, T-Rails, etc.)
• Check whether the check nut is tightened properly.
• For checking Bearings, open the Bearing cover as shown in Fig. 1 and check whether
the grease has come out of bearings (A small amount of grease is acceptable). If the
grease discharged is in large amount, bearings need to be replaced.

BEARING COVER
CHECK NUT

Fig. 1

• Check for noise in bearings while rotating shaft with hands if any noise found bearings
might have worn out or dust particles have entered the bearings and bearings need
replacement.
• Check the bearing temperature after running the setup for 30 Mins at No Load, the
temperature should not exceed 60 deg. Celsius.
• Check for leakage and blockage if any throughout the water pipeline assembly (From
Cooling Tower to Dynamometer). If found, take corrective measures.
• Check that the Vibration pads are fastened properly with the mounting legs of
dynamometer table.
• Check whether the locked rotor test bolts are loose or not. They should be tightened
only for the Lock Rotor test.

2. Electrical

• Check if any connection wires are loose or tight (In wire loom connected to
dynamometers’ Harting connector and terminals in control panel).
• Check the input supply voltages to DC Power Supply and Control Panel.
• Check whether the earthing is properly connected to the control panel, DC power
source and the dynamometer.

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• Check load cell output voltages (between GND & +S or -S) when the load cell is kept
free on the table surface without any load. The output voltage should be 0 to 0.5 mV. If
not Loadcell should be replaced.
• Check power cables for stiffness, if these are very stiff it means that a large current is
flowing through them, (more than rated) and hence will damage the cable.

3. Electronics

• Once in 3 months open the electronics controller and panels and clean them.
• Check for heating of components or wires.
• Check all connectors for loose connections on the electronics boards and controllers.
• If any fans or filters are used on PCs, panels, or electronic controllers, clean the filters
periodically and check the fans for proper working.

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