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:

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.

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.

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.

Device Connections.

The Device Control Unit has four sections;




Each section has a U, D and T connector.



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

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

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 -40º Celsius to +125º 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.

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.



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.

• Make sure your test configuration (as set up in the software) matches the capabilities of your external power supply.

• DO NOT EXCEED the Voltage Input range of the DCU of +10 volt to +15 volt

• Make sure the external supply VOLT and GROUND are made to the correct terminals on the front of the DCU.

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


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



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


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.

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

Specifications

Software License:

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