RIT MULTIDISCIPLINARY SENIOR DESIGN 2010

Standard Operating Procedure

Baja Water Propulsion Test Stand

This SOP specifies how to assemble, use, troubleshoot, and disassemble the water propulsion system test stand.

Test Stand Assembly

Tools Needed:

(2) ¾” socket wrenches

Pieces Needed:

(1) front piece and (1) back piece with plywood

attached (Front piece has the electric box on it)

(2) side pieces with plywood attached

(5) cross pieces: (4) side pieces and (1) center

(center piece has 2 bolt holes)

(4) pieces of flat stock (two sides, two fronts)

(8) lid brackets

Liner

(12) 5 ½ inch bolts, with two washers each and one nut each

(12) 3 inch bolts with nuts

(6) 3½ inch bolts

NOTE: Pictures not to scale

Assembly Procedure:

1. Assemble one side piece and the front piece by matching the colored dots. Ensure

the dots face to the outside of the frame.

2. Bolt two pieces together using the three 5 ½ inch bolts and two washers. Place

one washer under the head of the bolt, slide the bolt through the two frame pieces

with the head of the bolt on the outside of the frame, place another washer before

the nut and screw on the nut. Do not fully tighten the nuts.

3. Bolt the back piece onto the same side piece using three 5 ½ inch bolts. Ensure

the colored dots match and are facing the outside of the frame.

4. Lay the five cross-pieces on the floor in between the front and back side pieces,

matching the colored dots on each cross-piece with the colored dots on the

plywood. Make sure the tabs of the cross-pieces are facing the center cross piece

(to the right if on the left side of center and to the left if on the right side of center)

and the center piece is in the middle.

Tabs Center piece

Cross-piece dots

5. Bolt the five cross pieces in place on both sides using the 3½ inch bolts. The

bolts should go through the frame, plywood, and tab on the cross-piece. Hand

tighten the nuts until both sides of the cross-pieces are bolted in, then go back

through and tighten all the nuts.

6. Place bottom piece of plywood on top of the cross pieces in the assembled frame.

To do this, stand the plywood up on the long side and slide it into the frame.

Then, stand at the open end of the frame and slowly let it down until it rests on the

cross-pieces. Be sure that the bottom piece is clear of all debris that could poke a

hole in the liner.

7. Bolt the other side frame piece to the front and back frame pieces using the 5 ½

inch bolts. Ensure the colored dots match up and are facing the outside.

8. Tighten all frame nuts with ¾ inch socket and wrench.

9. Bolt the four pieces of flat stock onto the frame, attaching them to the horizontal

bars that are about 6 inches from the top of the frame. Line the flat stock up with

the holes in the frame using the six 3 inch bolts, but leave the nuts off the bolts.

Ensure the colored dots on the flat stock match the ones on the frame.

10. Place the liner in the frame and attach it to each side by sliding the top edge of the

liner over the flat stock. Run the bolts through the holes on the front and back of

the liner. Slide one lid bracket onto the end of each of the three front and back

frame bolts and one onto the bolt at the center of each side frame before screwing

on the nut. Ensure the lid brackets with colored dots on them are placed on the

side frame pieces. Tighten all the nuts and ensure the lid brackets are oriented

with the ledge facing the top of the frame. Be sure not to over-tighten, though, as

it may rip the liner.

11. Slide both sides of the lid onto the tank and ensure the two pieces interlock

correctly.

Troubleshooting:

Holes don‟t line up:

Ensure colored dots are facing outside of frame

Ensure the frame is on semi-level ground

Ensure all frame pieces are oriented the correct way

Bolt is too short:

Ensure the right bolt is being used

Liner falls down:

Ensure top of liner is fixed under flat stock

Drive System Assembly

Tools Needed:

½” and 11/16” wrenches

Assembly Procedure:

1. Insert u-shaped metal brackets into holes located at ends of tank. Match the

colored dot on each bracket to the dot on the tank (dots circled in picture). Adjust

nuts to even height on all brackets. Set pins aside.

2. With one person on each yellow handle, lift the drive assembly onto the top of the

tank. Set the assembly into the brackets located on the tank ends. Secure the

assembly with the pins provided. Level the assembly by adjusting the height of

the brackets with the screws underneath. Once level, tighten the bolts.

3. Attach cross member on top of tank and under drive assembly (picture). Attach

drive assembly to cross member with U-bolts provided.

4. Standing behind tank, firmly take hold of rope (left picture). Remove chain from

handle, and gently lower arm assembly. Do not allow arm to swing freely into

drive position. Have another person insert retaining pin. Right picture shows

retaining pin in place.

5. Ensure coupling vane passes through hall sensor gap without interference,

position indicated in picture. Adjust hall sensor/coupling position if necessary.

6. Attach load cell to vertical holder behind the drive carriage (location shown in left

picture). Attach cable between the load cell and the drive carriage. Ensure cable

length does not restrict motion of drive carriage. If cable length restricts motion

of carriage, (i.e. cable pulls carriage to back of aluminum rails) adjust position of

hook (shown in right picture).

7. Remove stops on aluminum rails. Continue with electronics assembly.

8. When testing is complete, replace stops on aluminum rails. Raise wheel with

lever and secure with chain.

Troubleshooting:

Holes on drive assembly do not line up with holes on brackets (step 2):

Ensure frame assembly is square

Temperature differences may cause frame and/or drive assembly to

deform. Allow all parts to settle at same temperature

Hall sensor vane interferes with hall sensor:

Stop motor

Adjust position of vane collar and/or hall sensor.

Vibration causes excess movement in structure (shaking):

Ensure U-bolts on cross member and lock nuts on end brackets are tight.

Electronics Attachment

Initial Checklist:

Make sure all electronics are not powered before attempting to connect wires.

Make sure all wires are well secured. In other words, make sure there are no lose

wires or that no wires become lose when pulled with moderate force.

KBCC-225 requires single phase 230V ± 15% and is rated for 25A

Pieces Needed:

NEMA12 JIC Screw Cover Wall Mount enclosure with subpanel:

KBCC-225 Motor controller:

Signal electronics box:

LSB300 (Load Cell):

Honeywell 4AV16F Hall Sensor:

Connecting/Disconnecting the Motor:

Caution: Exert caution when opening the NEMA12 JIC Screw Cover Wall Mount

enclosure, as there are short wires connected from the KBCC-225 Motor Controller

to the enclosure cover. Pulling hard could cause damage to the Motor Controller.

1. Unscrew the NEMA12 JIC enclosure cover by removing the four screws in each

cover of the cover. Slowly remove cover from the enclosure. Cover can be moved

downwards for easier access to the inside of the enclosure.

2. Route the four-wire bundle from the motor through the hole on the left side of the

electronics enclosure. The bundle should contain four wires. On the motor

controller, the thicker wires labeled A1 and A2 connect to terminals A1 and A2,

respectively. The thinner wires labeled F+ and F- connect to terminals F+ and F-,

respectively.

3. Replace enclosure cover.

Signal Electronics Connection:

1. Connect the side labeled EL on cable PD2 to the power connector as labeled on

the signal electronics box. It can only be connected in a specific orientation.

2. Connect the wires labeled 'Hall Sensor' to the hall sensor mounted on the shaft of

the motor.

3. Connect the load cell cable from the load cell on the top of the frame to the

connection labeled 'Load Cell' on the signal electronics box.

4. USB connections are labeled 'Hall Sensor' and 'Load Cell'. Connect USB cables to

these locations to hook these parts up to the computer.

5. Mount the small signal electronics box to the velcro located next to the large

power electronics enclosure.

Troubleshooting:

Wheel spins the opposite way than desired:

Switch wires connected to terminals A1 and A2 on motor controller.

For more information on each individual component, refer to its datasheet.

Using the Electronics

Running the Motor:

Before running the test stand, make sure the emergency stop button is pulled out

and the potentiometer knob is turned all the way counter-clockwise.

Turn the potentiometer knob clockwise to increase the speed of the motor and

counter-clockwise to decrease the speed of the motor. The motor will stop when

the potentiometer is turned all the way counter-clockwise.

The emergency stop button is a push-pull type button. By pressing this button, the

motor will coast to a stop.

Troubleshooting:

For more information on each individual component, refer to its datasheet.

Data Acquisition

Software Preparation:

1. Use computer with Windows XP (Instacal only works on XP, not on Windows

Vista, Windows 7, or any Mac OS)

2. Install LabView v. 8.6

3. Download TracerDAQ, Instacal, and Universal Library

a. Go to www.mccdaq.com

b. Under Tech Support, click Software/Driver Downloads

c. Need to register

d. After registration, a website with the downloads opens up

e. Download MCCDAQ CD (includes all three needed components)

Test Stand Operation:

1. Open Instacal (Start All Programs Measurement & Computing Instacal)

2. Look at which board numbers are connected

3. Make sure board number 0 is the DAQ connected to the load cell and board

number 1 is connected to the hall sensor

4. Open the test stand file ‘Mini Baja Test Stand Interface.vi’

5. LabView will open

6. Make sure the board numbers found under the ‘Configurations & Log Control’

Tab correspond to the board numbers found in the TracerDAQ program

7. Set the channel below ‘Board Number (Load Cell)’ to 0

8. Set the range below ‘Board Number (Load Cell)’ to ±10V by use of the arrows

9. Set the channel below ‘Board Number (Hall Sensor)’ to 0

10. The sample rate for the load cell can be adjusted by moving the slider bar found

under the ‘Configurations & Control’ Tab

11. To ensure that the DAQs are working properly, perform a test run before using

a. Make sure the Load Cell graph changes when the string connected to the

load cell is pulled slightly

b. Move the hall sensor vane through the hall sensor and make sure it is

registered on the graph

c. If nothing changes on the graphs when these actions are performed, check

the troubleshooting section

12. Press the white arrow found at the top of the screen to start the VI

13. Data Logging:

a. Press the ‘Start DAQ’ button found in the upper left corner

b. You will be prompted to choose a file to log the data to; choose a .xls file

(only .xls files are supported, so .xlsx is not going to work)

c. To start Data Logging, press the ‘Log Data?’ button in the upper right

corner

d. When you are done logging data, press the ‘Log Data?’ button again. This

will stop the data logging.

Note: The ‘Log Data?’ button will have changed to ‘Logging…’

during the logging process

e. Data Logging can be restarted at any time as long as the ‘DAQDone’

button in the upper left corner has not been pressed

14. To stop the VI, press the ‘Done’ button in the upper left corner

15. The VI will reset after a short delay

Troubleshooting:

If a *.vi file can‟t be found when opening the „Mini Baja Test Stand

Interface.vi‟, a window will come up searching for that file:

a. Press Browse in the window

b. Click on Das16 (My computer Local Disk (C: ) Program Files

National Instruments Labview 2009 menus Universal Libraries

Das16)

c. A list will open up

d. Find the appropriate *.vi file and double click

e. The ‘Mini Baja Test Stand Interface.vi’ program will open up

f. Press Ignore on the Warning Message that will pop up

Any error messages resulting from the DAQs can be found in the

„Configuration & Log Control‟ Tab

If any of the error messages say “Background Operation already in

progress”, make sure you have the board numbers entered correctly:

a. If the board numbers are not correct, they can be easily changed in the

Instacal program

b. Open Instacal

c. Right-click on the board number

d. Change the board number to the appropriate number

If the VI does not stop when the „Done‟ button is pressed and data

logging has not been initiated:

a. Click on the ‘Start DAQ’ button .

b. Select a logging file as in the Data Logging section above. The VI should

stop shortly after.

Test Stand Transportation and Storage

1. Reverse the assembly of the frame as stated in Frame Assembly Section.

2. Each of the side frame pieces and the front and back frame pieces should be

carried by two people.

3. The pieces can be transported on a dolly or in a truck to their final destination.

Ensure that the pieces do not hit any walls and are set down gently during

transportation.

4. The pieces should be stored in a dry, covered area that is not exposed to the

elements. Ensure the pieces will not fall over or be bumped when in storage so

they are not damaged.

5. Fold up the liner and make sure it is covered by one of the other frame pieces so it

does not get ripped or torn during storage.

Electronics Assembly

This should only be done if something is wrong with the electronics and they

NEED to be taken out of the small and large electronics boxes

Initial Checklist:

Make sure all electronics are not powered before attempting to connect wires.

Make sure all wires are well secured. In other words, make sure there are no loose

wires or that no wires become loose when pulled with moderate force.

KBCC-225 requires single phase 230V power ± 15%.

Be careful when opening the electronics enclosure so equipment doesn’t fall out

Pieces Needed:

Potentiometer:

ZB5AT44 Emergency Stop pushbutton (attached to enclosure cover):

ZB5AZ104 Contact Block for emergency stop button (attached to ZB5AT44):

PD-2515 Dual Output Switching Power Supply:

Four-terminal terminal block:

Power Electronics Mounting:

1. Attach the KBCC-225 Motor Controller to the larger set of four screw-holes on

the subpanel (not including the subpanel mounting holes).

2. Attach the PD-225 Power Supply to the smaller set of four screw-holes on the

subpanel.

3. Attach the Power Block to the remaining set of two screw-holes on the subpanel.

4. Connect one end of cable MC, according to the labels, to terminals L1 and L2 on

the motor controller. Connect the other end to any two separate spots on the

terminal block.

5. Connect Pin 1 and Pin 3, as labeled on cable PD1, to the same two spots on the

terminal block used in step 4. Pin 1 should be connected to the same location as

L1 and Pin 3 to the same location as L2. Connect the other end of cable PD1 to

the terminal CN1 as labeled on the PD-2515 power supply.

6. Connect the side labeled CN2 on cable PD2 to terminal CN2 as labeled on the

PD-2515 power supply. Route the power cable through the hole on the right side

of the enclosure.

7. Mount the subpanel in the enclosure using the four mounting holes located on the

corners of the subpanel.

8. Route the main power wire through the bottom hole on the enclosure.

9. If input power is balanced (i.e. both live wires are 110 V out of phase) connect

both live wires in any sequence to the terminal block location where L1 and L2

were connected. If power is not balanced (i.e. live wire is 230 V and the other is

the neutral wire) connect the live wire to the terminal block location where L1

was connected and attach the neutral wire to the terminal block location where L2

was connected.

Grounding of Power Electronics:

1. Use the remaining two free spots on the terminal block for grounding.

2. Ground connections are located near the bottom right corners of both the motor

controller and the power supply, as shown in the below figures.

Motor Controller Power Supply

3. Ground the enclosure subpanel at the hole located near the top right mounting

location of the subpanel.

4. The enclosure itself is grounded through the mounting screw located closest to the

subpanel grounding location.

Detaching Electronics Enclosure Cover:

1. Unscrew the NEMA12 JIC enclosure cover by removing the four screws in each

corner of the cover. Slowly remove cover from the enclosure.

2. Terminals 3 and 4 of the ZB5AZ104 contact block connect to terminals I1 and I2

on the motor controller, as shown by the figure below.

I1 and I2 terminals on motor controller.

3. Connect the potentiometer to terminals P1, P2, and P3 on the motor controller.

P1, P2 and P3 are labeled and are according to the figure below.

Potentiometer with terminals labeled.