COLIN PAYNE-ROGERS JACOB LENNOX DR. BENJAMIN VARELA (GUIDE) COOPER CROUSE-HINDS (SPONSOR) Senior Design P13472 Final Presentation – Change of Resistance Test Stand

Project Description Prototype Change of Resistance Test Stand: measure multiple coil temperatures via 4-wire resistance measurements and a linear regression Test Control: via Labview interfaced with a PXI system including two 16-channel switches and one digital multimeter Deliverables: one relay box for metering and power control, configured NI PXI system for control and Dell Laptop as a user interface

Customer Needs, System Design Interface Relay Circuit  Operate in the VAC range  Connect using 2-Pin Amphenol cable  Select, Purchase Multimeter  Resolution of 0.01Ohm  Able to be calibrated Select, Purchase Data Acquisition System Incorporate a thermocouple  The design must comply with UL844  The multimeter is of the correct resolution and the linear regression and formula advised by the standard are the same System contained in a rolling enclosure 

Customer Needs, Labview

System Architecture

Budget - Planned AccessoryVendorPNDescriptionIndv. Cost QTY Cost PXI ChassisNI PXIe-1073 $ 1, Chassis Power CordNI $ DMMNI PXI-4065 $ 1, Relay ModuleNI PXI-2566 $ 1, Relay Terminal BlockNI TB-2666 $ System AssuranceNI $ Power Circuit RelayMcMaster7230K914PST $ $ Power Circuit Relay Allied Elec DPST $ USB DAQNI USB-6008 $ Circuit Total $ 5, Labtop $ Labview LisenceNI $ Miscellaneous Cart etc. $ 1, *Highlighted Boxes are approximate costsTotal $ 7,659.71

Budget – Actual DateVendorFaculty ReviewDescriptionAmount Budget 5, /30/2013Allied ElectronicsVarelarelays, switches /30/2013GraingerVarelavarious /31/2013Amplified PartsVarelaPower Cords /4/2013GraingerValeraterminal strip /4/2013 Wizodirect Valerasurge strip /5/2013Allied ElectronicsVarelaPower Supplies /13/2013Grainger returned items /7/2013McMasterVarelarelays /12/2013Allied ElectronicsVarelaRelays /13/2013McMasterVarelaRelays /20/2013National InstrumentsVarelaUSB DAQ /25/2013McMasterVarelascrews, HDPE /27/2013National InstrumentsValeravarious-5, /28/2013McMasterValerascrews /15/2013McMasterValerawire and screws /30/2013DellValeraComputer Balance-2,779.52

Design Summary Power Control Circuit  12 user inputs  Connection to Labview switch Measurement Control Circuit (inputs)  12 user inputs  Labview connection not shown “Splitting” Terminal Block  Split for measurement Two NI Switches  Channel connections shown “Multimeter” Terminal Block Multimeter – connections shown (hi, low, etc.)

Power Control Circuit Inputs are from the ballast. 25 and 26 are 120VAC inputs. NI Switch Connections

Measurement Control, Splitting To NI Switches Inputs 1-12 are from ballast. Connection to power and NI switching shown in the Power Control Circuit

Splitting, NI Switches To multimeter terminals From 4PST relays

NI Switches, Multimeter Terminal

System Testing Results All relay box connections active  6 “coils” (known resistors) were connected to the relay box and measured with the multimeter 4-wire measurement to ensure all connections were working properly and no internal resistance was found Labview code troubleshooting  “NaN” value removal, timing adjustments, etc. Complete ballast test at steady state using Labview to run the test and to obtain the results (see next slide)

Steady State Temperature

Successes, Incomplete, Future Work Success  Purchasing multimeter, laptop, data acquisition software  Creating Labview code  Running a successful test at 120VAC Incomplete  Rolling enclosure, Amphenol cable Future Work  Contain the test in a rolling enclosure  Run a test at 600 VAC  After double-checking code and switches to make sure Labview components will never see the volts  Convert small gaged wire connecting PXI to relay box into an Amphenol cable  Staging the ballast power with a secondary set of relays