PowerLink GW series Eddy Current Dynamometer User Manual XiangYi (Hong Kong) Power Testing Instrument Co. Ltd. 0
GW Series Eddy Current Dynamometer User Manual Transport, Storage, use of environmental requirements The transportation and storage of the GW Series Eddy Current Dynamometer needs to meet the following conditions. Running condition Storage - with protective cover Transport - protective package Air 0 ~ 40, no freeze, the 0 ~ 50 0 ~ 50 temperature air temperature between 40 ~ 50 Relative humidity 5-85% Maximum 85% Maximum 85% No condensation. In the presence of corrosive gas, the maximum allowed relative humidity of 60% Pollution No conductive dust is allowed, the cooling water should not contain any impurities Level Vibration Maximum 1mm (0.04in.) (5-13.2Hz), Max 7m / s 2 (23ft / s 2) (13.2-100Hz) sinusoidal vibration Maximum 1mm (0.04in.) (5-13.2Hz), Max 7m / s 2 (23ft / s 2) (13.2-100Hz) sinusoidal vibration Maximum 1mm (0.04in.) (5-13.2Hz), Max 7m / s 2 (23ft / s 2) (13.2-100Hz) sinusoidal vibration Engine ± 0.02mm max alignment Impaction Not allowed Maximum 100m/s2 (330ft / s 2) 11ms Maximum 100m/s2 (330ft / s 2) 11ms Free-falling Not allowed Not allowed Not allowed Security Fast Fuse Lifting Using the lifting holes on the base, no touching or hitting to the torque and pressure sensors 1
Installation and calibration of dynamometer 1. In order to ensure the linkage between dynamometer and tested machinery (especially engines)is the stable, reliable, dynamometer and the tester machine should be installed in the same iron base platform. The concrete foundation shall be strong enough to withstand both static load and dynamic loading. The horizontal level of the platform to the floor surface shall be within 0.05mm / m. While the Dynamometer working, no axial force is permitted. Therefore, the dynamometer shall adopt a flexible coupling or an universal joint. The shaft alignment must be well aligned. After installation, use anchor bolts or pressure plate to fasten the dynamometer platform, and then to remove the fixed angel plate from the dynamometer. 2. Cooling water is essential for the dynamometer. During installation, the required size of the water pipe shall be connected to the Dynamometer s inlet and outlet, sufficient water flow, check whether there is a leakage in the water supply systems, and also check the water pressure, water flow achieve to the required value and the cooling water alarm system is working properly. To ensure normal the continuous running of the dynamometer, it is recommended to add G1 coolant to prevent the cumulating of dirt after long period of usage. The dirt inside the water will affect the cooling efficiency and resulted in damaging the dynamometer. Inlet filter shall be installed and must be cleaned regularly to prevent the entering of foreign particles. cooling water shall be clean fresh water. 3. Properly connect the control cables, excitation cables and the cables for the pressure sensors and torque sensor to the dynamometer control panels (FC2010 or CGK-type eddy current dynamometer controller). The pin connection for the GW6-25 Eddy Current Dynamomter: The excitation socket: Pin 1 and Pin 4 are connected to water pressure switch Pin 2(+) and Pin 3(-) are connected to excitation power Torque, speed socket are: Pin 1: + V voltage input for the bridge Pin 2: + positive torque output signal Pin 3: -V voltage input for the bridge Pin 4: - negative torque output signal Pin 5: GND Pin 6: ZS + speed signal output Pin 7: ZS-speed signal output GW40 to the GW450 (GWD same) terminal box wiring connections from left to right: 2
Pin no. 1 2 3 4 5 6 7 8 9 10 11 12 Symbol V+ Out V- Out- GND Zs+ Zs- K1 K2 DL+ DL- + Definition Positive Electricity Source Positive output Negative Electricity Source Negative Output Ground Speed + Speed Water Pressure switch Water Pressure switch Empty pin Excitation power source + Excitation power source - Pin 1 and Pin 7 are connected to corresponding pin of the secondary instrument. Pin 8 and 9 are connected to secondary instrument P20 socket s Pin1 and 4 Pin 11 and 12 are connected to secondary instrument P20 socket s Pin 2 and 3 Platform foundation The Dynamometer shall be installed as in Figure 2 (for reference). In order to maintain a stable and reliable connection with the engine and the dynamometer, the testing kit is recommended to install on the same platform. The concrete foundation shall be strong enough to withstand the static and dynamic load. The horizontal level of the platform shall be checked properly. 3
The Water Supply System Only small part of the heat generated from the dynamometer is absorbed by the metal part of the dynamometer. Most of the heat was concentrated on the inner coils of the field excitation. From the GW Eddy Current Dynamometer structure diagram, there are many cooling vanes inside the excitation coils for heat exchange purpose. The chilled water absorbed the heat and return to the reservoir/water tower for cooling. The cooling water is recycled water. The water inlet and outlet shall be properly installed. It is recommended to install a manual valve to control the water. The piping arrangement for the Dynamometer is shown as below figure. Schematic diagram of the dynamometer water supply system Cooling water is the very important for the dynamometer. Right size of water pipe must be connected to water inlet and outlet. The inlet water pressure must be 0 ~ 0.1Mpa. The water flow must be checked and no leaking in water supply system is permitted. It is also required to check the water pressure, water flow achieved required value. Perform the function check water alarms. Electrical contacts for water pressure must be normal closed contacts. The contact points are connected to Pin 1 and 4 of the field excitation power socket. The contact closed when the water pressure dropped below 0.02Mpa and the opened when the water pressure above 0.02MPa. To ensure normal running of the dynamometer, it is recommended to add G1 coolant into the water system to prevent cumulating of the dirt and debris. Water 4
filter shall be installed to prevent the ingress of foreign particle. Cooling water shall be fresh water. The water flow for the Eddy current dynamometer 5
The calibration of the Dynamometer The dynamometer shall be tested before usage and after the installation. In order to ensure the accuracy, it is recommended to calibrate the dynamometer at every six months. If any abnormalities found, re-calibrate the dynamometer. The factory shall provide the calibration device, which includes a calibration arm and a set of counter weights (the counter weight is according to the Class 4, GB standard). Users may follow the below steps to calibrate the dynamometer. 拉压力传感器 Dynamometer with calibration arm and counter weight 1. Figure 6 shows the dynamometer with calibration arm and counter weights. 2. Refer to "CGK eddy current dynamometer control device" or "FC2010 Measurement and Control" manual to connect the control cables. 3. Set the zero point before adding the counter weight (Please refer to the manual) 4. Add full scale of counter weight to the calibration arm tray 5. Set the full-scale of the instrument (see manual) 6. Remove all counter weight from the tray to check the zero point. 7. Add a counter weight to the tray, check and compare the torque display value with the counter weight value. 8. Gradually add the counter weight to full scale and compare the torque display value with the actual weight. 9. Gradually reduce the weight to zero and compare the torque display value with the actual weight. The error of the torque display value with the actual counter weight shall not be greater than 0.2~0.4% of the F/S of the testing dynamometer. 10. Remove the calibration arm and the counter weights after calibration. Open the water inlet valve and set zero point again before usage. If the calibration accuracy cannot meet the required level, please refer to the manual "dynamometer care and maintenance" section. 6
The commissioning of the Dynamometer Before turning on the dynamometer, please check the connection of dynamometer and the tested engine are properly installed aligned. The accuracy is no more than ± 0.02mm. Check all fastening bolts of coupling are tightened, the safety cover is installed. After checking, please follow the below steps to operate the dynamometer: 1. Set the dynamometer control panel (e.g. FC2000 or CGK series engine automatic measurement system) at constant current and constant torque modes. Set the value at zero before starting the tested engine/machine. 2. Open the water inlet valve, the cooling water will flow through the inlet valve and pressure switch before entering into the dynamometer cooling room. When the water pressure below the 0.02Mpa, the excitation current is prohibit to entering into excitation coil. Thus the dynamometer will not absorb any power. 3. When changing the mode of control and the value of the FC2000 or CGK series engine control unit, the loading of the dynamometer will change according to the change in excitation current. The dynamometer will act as a load and at the same time to act the load measurement device. 4. When the increase the loading of the dynamometer, particular shall be paid attention to the water temperature. The outlet water must not exceed 55. If the water temperature exceeded 55, increase the flow rate or the pressure of the water to reduce the water temperature. 5. After the test, set the exciting current to zero, and then shut down tested engine/machine. Close water valves and shut down water supply system. 7
Maintenance - Maintenance methods Cycle Scope of Inspection Point of inspection Inspection method Reference Observe and listen for Abnormal vibration any abnormal noise, and noise vibration and noise sources With a thermometer or Bearing temperature hand touching to does not exceed Daily Dynamometer Overheat check the bearings 70, the water and cooling water temperature does not temperature exceed 55 Water leak Visual inspection for water leakage Water pressure Check water pressure 0.04Mpa water using pressure gauge pressure 0.1Mpa Insulation resistance Check coil resistance Excitation coil by using insulation 10 M ohms<= Insulation resistance meter Vibration meter to measure vibration Vibration and Dynamometer body Reference Test record Every alignment Check with the dial 3 gauge months Open inlet valve and measure the pressure Pressure switch Measuring the output switch contacts Pressure switch is values working Reference setting Cable conditions is healthy Reconnect the cable Appearance and to ensure good Every Cables Any loose contacts, connections contact and cable 6 connections, rusty terminations Months Dust on the terminals Cooling water water flow Measure the flow rate by flow meter Maximum 30L/kW.h 8
- Periodic inspection methods Cycle Requirements Purpose Explain Every Filling 4g ~ 6g brand name To prevent bearing 200 Main bearing L135V grease (FAG company overheating and wear hours produced) Prevent the wear and tear of the under vibration conditions. Support Bearings Prevent wear and tear Turn bearing about 5 degrees Every 3 every 3 months. months Clean by water cleaning To prevent cooling water Cleaning the cooling water solvents or weak acid wash to blocking wash the pipes. Tightening To prevent loosen Check fasteners, re-tighten and replace if damaged Dynamometer Calibration Calibration method Every 6 Calibration arm To prevent bending Reasonable storage months Weight Prevent rusting Weight should be properly placed to avoid the collision and friction, periodic inspection. - Common problems and solutions Phenomenon Reasons Checking points Troubleshooting Use multi-meter to measure Calibration Damage of the torque and the resistance of the sensor Accuracy - Not pressure sensors bridge is balanced or not. Replace the sensors meet the Check shifting torque value. technical Observe the zero reading on Blocking of the cooling water requirements the panel while removing the piping weights from the tray. Reinstall the water piping Check by multi-meter to Short-circuited or Repair the broken cables or check for sign of loosen or termination loosen re-tighten the loose parts cable breakage Check the continuity of the Re-connect the power Cannot absorb No excitation power power cables and the cables and turn on power power position of the power switch switch Chain effect caused by voltage drop According to fault diagnostic to check the fault location Identify and eliminate the problems Coil breakage Check the resistance by a Replace the coil or send the 9
multi-meter parts back to factory for repairing Zero torque setting not correct in the control panel Re-calibration with weights Refer to the manuals for recalibration Only absorbed small power Short-circuited caused by water leakage Use Mega-meter to check the resistance between coils and insulation to the ground. Use multi-meter to check the coil resistance. Replacement of seals, drying or replacement of the coil re-assembly Ensure inlet valve is fully open, any blockage to the Dynamometer overheat Insufficient cooling water flow Water temperature too high water pipe, use pressure gauges to measure water pressure and flow meter to check the flow rate Measuring water temperature with a thermometer, water temperature not higher than 35 Open the water valve, water pipe cleaning Added more water to circulating pool or install cooling tower Dynamometer cooling water channel blocking Measure the water pressure and the flow rate Clean the water piping of the Dynamometer The prime mover or tested machine not connected to the dynamometer properly Check alignment of the installation Re=align the centerline, tolerance shall within ± 0.02mm Abnormal noise Loosen Check the tightness of the screws for shaft, driving bearings and couplings Re-tightening the loose parts Wearing of bearing Check bearing noise Replace the defective bearing 10