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Scientific Solutions Electric Motor Tester (ELMO)

This document describes Scientific Solutions' Elmo test system.


Contents:

Description
Components

System Hardware Connections
LabRack Computer System - Keyboard, Monitor, Mouse and Power
LabRack Computer System to MCU
MCU to DCU

Device Connections

U/D Connection
DCU connections for Electric Window Motors
Standard Motor Connection
Smart Motor Connection
T Connection & Temperature Probes

Voltage Input Connection


System Power Up

Status Lights

Software Introduction

Annual Calibration & Licensing Requirements
Part Numbers
Specifications

Software License
Document Notice
Limited Warranty
Trademark Notification




Description:

The Scientific Solutions Elmo test system is designed for the durability testing of electric motors and systems. The Elmo system incorporates a modular design for ease of expansion. The system contains software and programmable hardware to control electric window motor UP/DOWN position, detect stall over-current conditions and monitor failures. It consists of a self-contained computer incorporating a Scientific Solutions data acquisition system that connects to a Master Control Unit (MCU). The MCU has one connector for cabling back to the computer and four additional connectors for cabling to Device Control Units (DCU). Each DCU can control up to four devices. A fully configured system, can simultaneously test 16 electric window motors, i.e. four "virtual" cars.

Components:

The Scientific Solutions Electric Motor Tester consists of a LabRack Computer System, a LabRack Master Control Unit and from one to four Device Control Units and the Elmo software. The following table describes these various components:

LabRack Computer System:


The LabRack Computer System contains the Scientific Solutions LabMaster data acquisition system. This is the brains of the tester and is responsible for the control signals and the monitoring and acquiring of the data. The LabRack Computer System runs the system software which includes a graphical user interface for easy test configuration. The LabRack Computer System is housed in a rackmount unit (4U or 2U).

The LabRack Computer System directly connects to the Master Control Unit with a single high-density cable.


LabRack Computer System

Master Control Unit: (MCU)

The Master Control Unit (MCU) decodes the signals from the computer system and creates individual interfaces for connecting up to four Device Control Units (DCU). The MCU has logic to determine the quantity of DCUs attached and reports this back to the computer system so the control software can automatically determine the test matrix.

The Master Control Unit has five connections on the back; one for connection to the computer system (as previously described), and four for connection to the individual DCUs.



LabRack MCU

Cable Connection: LabRack Computer System and Master Control Unit:

The LabRack Computer System and the Master Control Unit are generally supplied as a set, since each test system requires one of each. Also supplied with this set is a cable that is used to connect the two units.


cable, 68pin computer - MCU

Device Control Unit: (DCU)

The Device Control Unit (DCU) contains the necessary high current outputs and associated control logic to directly control four devices.

The back of the DCU has a single connection to connect to one of the four connections on the back of the MCU.

The front of the DCU has four sets of connections labeled Device #1, Device #2, Device #3 and Device #4. It also has an additional set of connections labeled Voltage Input.

The DCU requires an external voltage source (not included with the system) to be connected to the Voltage Input connector. Under software control, the DCU switches the externally supplied voltage to the four Device connections.




LabRack WCU

Cable Connection: Master Control Unit to Device Control Unit:

Each test set up can consist of from one to four Device Control Units. Each DCU is supplied with a cable that is used to connect the DCU to the MCU.


cable, 25pin MCU - WCU

Elmo Software:


The Elmo software that is used to control the system is pre-loaded on the LabRack Computer System. It is graphical software that allows the user to configure, monitor and collect results from a test.




System Connections:

The following procedure should be used to connect the various system components.


LabRack Computer - Monitor, Keyboard, Mouse and Power

Connect a monitor, keyboard and mouse to the LabRack Computer System. You can also connect the power cable to the Computer System and the monitor. Be sure that the Computer System and monitor are powered-off before connecting the additional components.
Computer Connections


LabRack Computer System to MCU

Connect the Computer System to the MCU with the supplied cable. Note that this cable contains a high-density pin connector on each end. These connectors are designed for only one correct alignment. Make sure the cable connections and the connections on the back of the Computer System and the MCU are properly aligned before trying to make the connection. Be careful not to bend any of the pins. After the connections are properly made, use the thumb screws to secure the connectors on the back of the Computer System and the MCU.
Cable 68pin to Computer

Cable 68pin to MCU

Cable 68pin to Computer and MCU




MCU to DCU

Connect the MCU to the DCUs. Each DCU is supplied with a cable for this connection. The MCU can accommodate from one to four DCUs. Connect the first DCU to the "Device Control Unit 1" connection. If you are using a second, third or fourth DCU unit, then connect these to the corresponding Device Unit connection. Do not skip DCU connections - start with number 1 for the first, 2 for the second, 3 for the third and so on. These connectors are designed for only one correct alignment. Make sure the cable connections and the connections on the back of the MCU and DCU are properly aligned before trying to make this connection. Be careful not to bend any of the pins. After the connections are properly made, use the thumb screws to secure the connectors on the back of the MCU and DCU.
Cable 25pin to MCU

Cable 25pin to WCU

Cable 25pin to MCU and WCU


Device Connections.

The Device Control Unit has four sections;

DCU Showing all four Device Connections


Each section has a U, D and T connector.

DCU Connection U/D/T

U/D Connection:
Direction: Output from the DCU
Description: The voltage that is applied to the Voltage Input terminals on the front of the DCU are available on the U/D output connections under control of the software. The software controls the on/off condition of the U/D voltage and also the polarity of the U/D outputs.

DCU Connections for Electric Window Motors
The design of the Elmo system makes it idea for testing Electric Window Motors. A single DCU can control either Standard Motors or Smart Motors. You can run a test with a mix of both Standard and Smart Motors - you just have to connect each motor type to a different DCU. For example, if a test requires 1 Standard Motor and 1 Smart Motor, then you would need 2 DCUs' - one for connection to the Standard Motor and one for connection of the Smart Motor. Since each Elmo system can have up to 4 DCUs, there is quite a bit of versatility in the testing of electric window motors.

The following charts indicate the correct connections to make for each type of motor. The last two columns of the charts indicate the voltage that will be present on the U/D terminals corresponding to the window direction (UP or DN).

Standard Motor Connection

Standard
Motor #

Motor
Connection

Device #

DCU
Terminal

Voltage
UP

Voltage
DN

1

UP control

Device # 1

U

+V

GND

1

DOWN control

Device # 1

D

GND

+V

2

UP control

Device # 2

U

+V

GND

2

DOWN control

Device # 2

D

GND

+V

3

UP control

Device # 3

U

+V

GND

3

DOWN control

Device # 4

D

GND

+V

4

UP control

Device # 4

U

+V

GND

4

DOWN control

Device # 4

D

GND

+V

Since each Standard Motor requires one Device section, a DCU can control up to 4 Standard Motors.
A system with four DCUs can therefore test up to 16 Standard Motors.
Note: If the wiring is reversed, then the window direction will be opposite to what is expected.

Smart Motor Connection

Smart
Motor #

Motor
Signal

Device #

DCU
Terminal

Voltage
UP

Voltage
DN

1

UP control

Device # 1

U

+V

float

1

DOWN control

Device # 1

D

float

+V

1

+V power

Device # 2

D

+V

+V

1

Ground

Device # 2

U

GND

GND

2

UP control

Device # 3

U

+V

float

2

DOWN control

Device # 4

D

float

+V

2

+V power

Device # 4

D

+V

+V

2

Ground

Device # 4

U

GND

GND

Since each Smart Motor requires two Device sections, a DCU can control up to 2 Smart Motors.
A system with four DCUs can therefore test up to 8 Smart Motors.
Note: If the wiring is reversed, then the motors will not operate properly.

T Connection:
Direction: Input to the DCU
Description: This input terminal is used for connection to a Scientific Solutions Temperature probe. A temperature probe allows the system to make temperature measurements. The T connector is a 3.5mm Stereo Jack. The temperature probe can typically make measurements from -40 Celsius to +125 Celsius (refer to the specification section of this document).

The temperature probe is a cylindrical device approximately 1" long and 1/3" in diameter.
It has a single 3.5mm Stereo Plug connection.
Temperature Probe
You can insert the temperature probe directly into the front of the DCU unit to verify its operation. To remotely locate the temperature probe, you need to use a cable. The cable needs a 3.5mm Stereo Plug on one end and a 3.5mm Stereo Jack on the other end.


Voltage Input Connection

Connect the Voltage Input on the front of the DCU to an external voltage source. Be sure the VOLT and GROUND connections are made to the correct terminals. If you have multiple DCUs and are using one power supply to power them all, then each DCU should have a VOLT and GROUND connection back to the supply, i.e. avoid connecting to one of the DCU's and daisy-chain connecting the power to the additional DCUs and this could result in an unreliable test setup.

Voltage Connection to DCU

Note: The external power supply must have sufficient capabilities to provide enough electrical current to sustain the stalling of the window motors. Each window motor can require up to 25 amps of stall current. If four windows are tested one-at-a-time (i.e. they are not all stalling in the UP or DN condition at the same time, but are staggered during the test) then an external 25 amp supply is sufficient. However, if four windows are simultaneously tested (that is the all stall at the same time), then the external voltage should be able to supply 100 amps of current (25 amps per stall x 4 stalls). A fully configured system with four DCUs requires (25 amps / motor) * (4 motors / dcu) * (4 dcu / mcu) = 400 amps of +Voltage.


System Power Up:

After the proper connections have been made, you should power up the computer system and the external supply voltage. The system has some inherent safety features, one of these being that the external supply voltage is not present on the motor connections until the software has initialized the system. However, caution should always be exercised and it is good practice to verify all the connections and the correct polarity of the external voltage connections before applying any power.


Status Lights:

In addition to the information provided on the computer screen by the software, lights on the various components can be used to determine the status of the equipment.

Computer System:
Green Light - indicates computer is ON
Red Light - indicates access to the internal hard disk drive
Lights - Computer

Master Control Unit:
The Master Control Unit has five LED light indications. One for System Power (Red LED) and Four for Device Control Units (Blue LED):

System Power - Indicates connection to the computer and that computer power is ON
Lights - MCU Red


Device Control Unit - Indicates connections made to DCUs. There are four lights, one for each DCU that can be connected.
Lights - MCU Blue

Device Control Unit - Unit Number:
The Device Control Unit has four Blue LED light indicators.

Unit Number
- Indicates connection to the MCU and that the software has initialized the DCU. Only one of the Unit Number lights is illuminated. The Unit Number light will only illuminate when the connections are made (DCU->MCU & MCU->Computer), power is ON, AND the software is running (which turns ON the appropriate Unit Number light). As the DCU is initialized all the lights may blink, but once the initialization is finished, only one of the four lights will be illuminated to indicate the particular Unit Number. The software can also use the Unit Number light to indicate the status of a test - refer to the software documentation for details.
DCU Front Panel LED


Software

Software Introduction:

When the test system is powered on, the computer will complete a boot-up sequence. Once this is complete, you can start the test software by selecting its icon on the computer desktop.

Once you start the software, you will need to create the test you would like to run. The software allows you to define tests with information such as the number of DCUs to use, the type of motor connected to each DCU, duration of test in cycles or time, and various measurements to make and actions to take when the measurements exceed your limits. The software allows you to save and re-load the test configuration.

Refer to the Software's on-line help for details



Annual Calibration & Licensing

The Elmo system as delivered is fully tested and calibrated. Annual calibration should be maintained for proper system operation. A label on the front of each system component indicates its serial number, calibration date, and calibration due date. The software license is also renewable on an annual basis. Scientific Solutions provides calibration of the equipment and renewal of the software license. Please contact Scientific Solutions at support@Scientific-Solutions.com to arrange for your annual calibration and software license renewal.

Part Numbers

Part Number

Description

Contents

815306

LabRack Computer System and Master Control Unit.

The LabRack Computer System and the Master Control Unit are generally supplied as a set, since each test system requires one of each


LabRack Computer System

  • Computer system
  • Operating System (Pre-loaded)
  • LabMaster PC Interface installed
  • Cable to connect PC Interface to the MCU
  • Elmo Control Software (Pre-loaded)
  • US 110v power cable (others available on request)


Master Control Unit

  • Master Control Unit

815307

Device Control Unit

  • Device Control Unit
  • Cable to connect DCU to MCU

815308

Temperature Probe

  • Temperature Probe
  • 20' Cable



Specifications

DCU:
+Voltage Input requirement


+10v to +15v, 25 Amp per active stalled device

DCU:
U/D Output Signal

Software controlled polarity
+V at 25 Amp maximum current output
or
Ground

DCU:
U/D Output Connection:


Banana Jack pair, 25A rated.

DCU:
T Input Connection:


3.5mm Stereo Jack

Temperature Probe

-40 Celsius to +125 Celsius (+/- 2 C)
-40 Fahrenheit to +257 Fahrenheit (+/- 4 F)
3.5mm Stereo Plug connector

Computer System

Universal Switching Power Supply
90-220VAC, 50/60Hz

Environmental:

Operating Temperature

0 to 70 Celsius


Storage Temperature

-25 to +85 Celsius

Relative Humidity

To 95% non-condensing

Agency Approvals

FCC Class A, CE-Mark





Software License:

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(c) 2002-2003 Scientific Solutions Incorporated. All Rights Reserved.

This manual, as well as the hardware and software described in it, is furnished under license and may only be used or copied in accordance with the terms of such license. The information in this manual is furnished for informational use only, is subject to change without notice, and should not be construed as a commitment by Scientific Solutions Incorporated. Scientific Solutions assumes no responsibility or liability for any errors or inaccuracies that may appear in this publication.

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