©1993-2008 Dynojet Research, Inc. All Rights Reserved.
Installation Guide for In Ground Model 224 Automotive Dynamometers.
This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet,
and all rights are reserved. This manual, and the software described in it, is furnished
under license and may only be used or copied in accordance with the terms of such
license. This manual is furnished for informational use only, is subject to change without
notice, and should not be construed as a commitment by Dynojet. Dynojet assumes no
responsibility or liability for any error or inaccuracies that may appear in this manual.
Except as permitted by such license, no part of this manual may be reproduced, stored in
a retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
recording, or otherwise, without the prior written permission of Dynojet.
The Dynojet logo is a trademark of Dynojet Research, Inc.
Any trademarks, trade names, service marks, or service names owned or registered by any
other company and used in this guide are the property of their respective companies.
Dynojet Research, Inc., 2191 Mendenhall Drive, North Las Vegas, Nevada 89081, USA.
Printed in USA.
Part Number: 98210100 Version 4 (04/2008)
RECORD
Dynamometer Number: ____________________________________________________
#
T
ABLE OF
C
ONTENTS
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Chapter 1 Specifications and Operating Requirements
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Your Dyno Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Dynamometer Specifications and Requirements . . . . . . . . . . . . . . . . . . . .1-5
Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Computer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Fire Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Ground Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Phone and Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Tie-Down Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Model 224 In Ground Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Dyno Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Pit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
224 Pit Requirements and Specifications . . . . . . . . . . . . . . . . . . . . . . . . .1-11
In Ground Model 224 Automotive Dynamometer Installation Guide
i
TABLE OF CONTENTS
Chapter 2 Installation
Unpacking and Inspecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Anchoring the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Connecting the Dyno Electronics and Shop Air . . . . . . . . . . . . . . . . . . . . .2-7
Aligning the Optical Pickup Card Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Wiring the Breakout Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Pit Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Installing the Pit Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Ground Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Chapter 3 Basic Dyno Operation
Loading the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Connecting the RPM Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
RPM Pickup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Connecting the Secondary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . .3-5
Connecting the Primary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Pre-Run Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
After Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Things to Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Verifying the SAAR Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Maintaining the SAAR Brake Shoe Clearance . . . . . . . . . . . . . . . . . . . . . . 3-12
Appendix A Red Head Anchor Installation
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Appendix B Torque Values
Standard Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Grade 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Metric Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Grade 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Grade 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i
ii
In Ground Model 224 Automotive Dynamometer Installation Guide
W
ARNINGS
Disclaimers
Dynojet Research, Inc. (Dynojet) makes no representation or warranties with respect to the contents
hereof and specifically disclaims any implied warranties of merchantability for any particular purpose.
Dynojet reserves the right to revise this publication and to make changes from time to time in the
content hereof without obligation of Dynojet to notify any person of such revision or changes.
Dynojet is not responsible for false operation due to unexpected dynamometer operation such as may
be caused by static, software bugs, hardware failure, etc.
Dynojet is not responsible for damage resulting from improper installation of the dynamometer or
from improper service rendered to the dynamometer. Dynojet is not responsible for damage incurred
due to alteration of the dynamometer or components, use of unapproved parts, or abuse to the
dynamometer.
Do not connect or disconnect cables or components on the dynamometer with the power on.
Always wear protective clothing, ear protection, and eye protection (goggles, safety glasses) when
using and servicing the dynamometer.
Equipment Power Requirements
The dynamometer has specific power requirements. Connecting the dynamometer to the incorrect
voltage will void the dynamometer warranty. Installation may require a licensed electrician.
Potentially Lethal Voltages
Components attached to and within the dynamometer operate with potentially lethal voltages. To
provide the greatest assurance of safety, the AC power cord(s) must be disconnected from the power
source before servicing electrical components or wiring. Disconnect all power cords before servicing
electrical components for the greatest assurance of safety.
In Ground Model 224 Automotive Dynamometer Installation Guide
iii
WARN IN GS
Electrostatic Discharge Precautions
Electrostatic Discharge
Electrostatic Discharge (ESD), or static shock, can damage electronic components within the
dynamometer. The damage may occur at the time of an ESD occurrence, or the shock may degrade
the component, resulting in a premature component failure later. To avoid ESD damage, always
practice good ESD control precautions when servicing the dynamometer. Dynojet designs its
dyn amo me ter s t o be ver y t ole ran t o f st ati c sh oc ks by the users, but the electronics are vulnerable when
the electronics are exposed. ESD occurs as a result of a difference of potential between two objects
when the two objects touch. Damage occurs as a result of the energy released when the discharge
(touch) occurs. The difference of potential can accumulate by as simple an action as a user moving
across carpet or a seat. If that person’s energy is discharged directly to the electronics, the electronics
can be damaged.
Precautions
To protect against ESD damage, you must eliminate the difference of potential before the electronics
are handled. Touch the chassis of the dynamometer before touching any of the electronics. By touching
the chassis, you discharge any static shocks to the chassis instead of to the electronics.
If you are holding a circuit board or dynamometer component in your hand when you approach the
machine, touch the chassis of the dynamometer with your hand before installing the circuit board or
component.
When handling a circuit board or component to someone, touch that person with your hand first,
then hand them the component.
Always carry circuit boards in anti-static bags when the boards are exposed (removed from the
dynamometer).
Battery Fire and Explosion Hazards
There is a danger of explosion if the battery is incorrectly replaced. Replace only with the same or
equivalent type recommended by the manufacturer. Discard used batteries according to the
manufacturer’s instructions.
Automotive Batteries
In operation, batteries generate and release flammable hydrogen gas. They must always be assumed
to contain this gas which, if ignited by burning cigarette, naked flame or spark, may cause battery
explosion with dispersion of casing fragments and corrosive liquid electrolyte. Carefully follow
manufacturer's instructions for installation and service. Keep away all sources of gas ignition and do
not allow metallic articles to simultaneously contact the negative and positive terminals of a battery.
Do not allow the positive and negative terminals to short-circuit. The dynamometer chassis is tied to
the negative side of the battery. Do not short between the positive battery terminal or the starter
connections to the chassis. In addition, make sure metal tools such as screw drivers, wrenches, and
torque wrenches do not come in contact with the negative and positive terminals of the battery. Short
circuiting the terminals of the battery can cause burn injuries, damage to the dynamometer, or trigger
explosions.
Charging
Batteries being charged will generate and release flammable hydrogen gas. Charging space should be
ventilated. Keep battery vent caps in position. Prohibit smoking and avoid creation of flames and sparks
nearby.
Wear protective clothing, eye and face protection, when charging or handling batteries.
iv
In Ground Model 224 Automotive Dynamometer Installation Guide
WAR NIN GS
Other Potential Hazards
The AC power outlet shall be installed near the equipment and it shall be easily accessible to allow for
disconnect before service.
The dynamometer should be located in a well ventilated area. There is a carbon monoxide hazard with
all internal combustion engines. Engine exhaust contains poisonous carbon monoxide gas. Breathing
it could cause death.
Any dyno room design must incorporate sufficient exhaust extraction.
Always wear proper ear and eye protection when operating the dynamometer.
Never operate the dynamometer with the covers removed.
Never stand behind the dynamometer when in operation.
Never operate the dynamometer when there is excessive vibration or noise. Resolve these problems
before proceeding.
Never fuel the vehicle on the dynamometer unless appropriate safety measures are taken.
Verify brake operation before beginning any dynamometer testing.
Verify the vehicle is properly secured to the dynamometer.
Never operate the blowers without the guards installed.
Exercise care with any dynamometer testing; portions of the dynamometer and vehicle may become
hot.
As with any equipment using electricity and having moving parts, there are potential hazards. To use
this dynamometer safely, the operator should become familiar with the instructions for operation of
the dynamometer and always exercise care when using it.
Do not repair or replace any part of the dynamometer or attempt any servicing unless specifically
recommended in published user-repair instructions that you understand and have the skills to carry
out.
Version 4 In Ground Model 224 Automotive Dynamometer Installation Guide
v
C HAPTER
S
PECIFICATIONS AND
Thank you for purchasing Dynojet’s In Ground Model 224 Automotive Dynamometer
(dyno). Dynojet’s software and dynamometers will give you the power to get the
maximum performance out of vehicles you evaluate. Whether you are new to the
benefits of a chassis dynamometer or an experienced performance leader, the
repeatability and diagnostic tools of WinPEP 7 software and a Dynojet dynamometer
will give you the professional results you are looking for.
This document provides instructions for installing the dyno. This document will walk
you through operating requirements, installation, and basic dyno operation. To
ensure safety and accuracy in the procedures, perform the procedures as they are
described.
Document Part Number: 98210100
O
PERATING
R
EQUIREMENTS
1
Versio n 4
Last Updated: 04-29-08
This chapter is divided into the following categories:
•Introduction, page 1-2
• Dyno Specifications and Requirements, page 1-5
• Model 224 In Ground Dynamometer, page 1-9
• Dyno Electronics, page 1-10
• Pit Specifications, page 1-11
In Ground Model 224 Automotive Dynamometer Installation Guide
1-1
CHAPTER 1
Introduction
INTRODUCTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thank you for purchasing a Dynojet automotive dyno. Before installing your dyno,
please take a moment to read this guide for installation instructions, dyno features,
and other important information.
This guide is designed to be a reference tool in your everyday work and includes the
following chapters and information:
SPECIFICATIONS AND OPERATING REQUIREMENTS
This chapter describes the requirements and specifications for the dyno.
INSTALLATION
This chapter describes the procedures for installing the dyno.
BASIC DYNO OPERATION
This chapter describes basic dyno operating procedures and maintenance.
RED HEAD INSTALLATION
This appendix describes the procedures for installing the Red Head anchors.
TORQUE VALUES
This appendix describes standard and metric torque values.
1-2
In Ground Model 224 Automotive Dynamometer Installation Guide
SPECIFICATIONS AND OPERATING REQUIREMENTS
CONVENTIONS USED IN THIS MANUAL
The conventions used in this manual are designed to protect both the user and the
equipment.
example of convention description
The Caution icon indicates a potential hazard to the
dynamometer equipment. Follow all procedures
exactly as they are described and use care when
performing all procedures.
The Warning icon indicates potential harm to the
person performing a procedure and/or the
dynamometer equipment.
The Record # icon reminds you to record your
RECORD
#
dynamometer and/or eddy current brake (retarder)
number on the inside cover of this manual.
Introduction
Bold Highlights items you can select on in the software
!
interface, including buttons and menus.
The arrow indicates a menu choice. For example,
“select
File !Open” means “select the File menu,
then select the
Open choice on the File menu.”
TECHNICAL SUPPORT
For assistance, please contact Dynojet Technical Support at 1-800-992-3525, or write
to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89081.
Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of
the art technical support, on-line shopping, and press releases about our latest
product lines.
Version 4 In Ground Model 224 Automotive Dynamometer Installation Guide
1-3
CHAPTER 1
Introduction
YOUR DYNO ROOM
This section is not meant to imply that a dyno room is essential to repeatable results
on a Dynojet dynamometer. However, a dyno room with an engine cooling intake fan,
exhaust extraction, and noise reduction capabilities can add a new dimension to your
shop.
A proper dyno room design will help to ensure repeatable, accurate runs. A good
dyno room should do the following:
• minimize noise
• provide a controlled environment for testing
• provide a view window (safety glass) for customers
• be designed with safety in mind
Intake Air Fan—After building your dyno room, you will need to supply an intake air
fan. The intake air fan supplies air to cool the vehicle’s engine while supplying fresh
oxygen for you and your vehicle to breathe. It is a common misconception that you
cannot tune a vehicle without a large fan simulating exact road conditions; however, a
good cooling fan is the only requirement for consistent diagnostics and tuning. The
installed fan should be 5200 CFM.
Equalizer Box—If the air flow rate coming into the dyno room is greater than the air
flow rate leaving the dyno room, the room will become pressurized. A pressurized
dyno room will make measured power misleading. To compensate, you need an
equalizer box. The equalizer box is a baffled (to reduce noise) vent to the outside of
your dyno room. The size of the equalizer box is dependent on the size of your dyno
room and the size of your fans.
Exhaust Extraction—An exhaust fan is needed to remove exhaust gasses, especially
carbon monoxide, from the dyno room. Carbon monoxide is potentially lethal to
people if not removed from the room and will affect engine power when mixed with
fresh air.
Engine exhaust contains poisonous carbon monoxide gas. Breathing it could
cause death. Operate machine in well ventilated area.
Fire Suppression—
your dyno room.
Industrial Noise Control, Inc.—Industrial Noise Control, Inc. offers a zinc-coated
steel room custom built to your specifications. This room meets all dyno room
requirements. The dyno room must be clean and dry with a comfortable room air
temperature above 32 degrees Fahrenheit (0 degrees Celsius), and have some system
of exhaust extraction.
Always have adequate fire suppression or fire extinguishers in
1-4
In Ground Model 224 Automotive Dynamometer Installation Guide
SPECIFICATIONS AND OPERATING REQUIREMENTS
Dynamometer Specifications and Requirements
DYNAMOMETER SPECIFICATIONS AND REQUIREMENTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The following specifications will help in positioning your dyno in your shop or
designing a dyno room.
CHASSIS SPECIFICATIONS
description specifications
Length
of frame 218.44 cm (86.00 in.)
Height
to top of frame 58.42 cm (23.00 in.)
Width
of frame 73.66 cm (29.00 in.)
including feet 89.54 cm (35.25 in.)
including brake 96.52 cm (38.00 in.)
frame with pit covers 144.78 cm (57.00 in.)
Weight
224 dyno/crated dyno 1588 kg (3500 pounds)/ 2087 kg (4600 pounds)
Drum
diameter 60.96 cm (24.00 in.)
width 205.74 cm (81.00 in.)
Frame structural steel plate and angle
Maximum Horsepower 745.70 KW (1000 HP)
Maximum Speed 322 KPH (200 MPH)
Maximum Axle Weight 1361 kg (3000 pounds)
Remote Switches remote software control
Version 4 In Ground Model 224 Automotive Dynamometer Installation Guide
1-5
CHAPTER 1
Dynamometer Specifications and Requirements
Figure 1-1: Model 224 In Ground Dyno Dimensions
1-6
In Ground Model 224 Automotive Dynamometer Installation Guide
SPECIFICATIONS AND OPERATING REQUIREMENTS
Dynamometer Specifications and Requirements
COMPRESSED AIR
The following requirements are needed for the air brake:
• Clean and dry air, between 100-140 psi
• shut off valve
• 1/4-inch NPT pipe thread connector (to attach air to the dyno), if air hose does not
have a 3/8-inch inside diameter
COMPUTER SPECIFICATIONS
You will need to provide a computer system to run the WinPEP software. A complete
list of system requirements can be found in your WinPEP 7 User Guide. This manual is
included with your dyno and is also available on your WinPEP 7 CD.
ELECTRICAL REQUIREMENTS
description specifications
Power Requirements: 4WD electronics 110v 60Hz or 240v 50Hz
Power Requirements: dyno electronics 110v 60Hz or 240v 50Hz
Power Requirements: air pump 110v 60Hz or 240v 50Hz
Power Requirements: computer 110v 60Hz or 240v 50Hz
Power Requirements: optional eddy
current brake
240v 30amp single phase circuit for each eddy current
brake
Refer to the Eddy Current Brake Installation and User
Guide for Model 224 In Ground Automotive
Dynamometers (P/N 98215101) for more information.
Version 4 In Ground Model 224 Automotive Dynamometer Installation Guide
1-7
CHAPTER 1
Dynamometer Specifications and Requirements
ENVIRONMENTAL REQUIREMENTS
description specifications
Te mp e r at u r e
operating min./max 10°C/50°C (50°F/122°F)
storage min./max 0°C/70°C (32°F/158°F)
Humidity 0 to 95% non condensing
FIRE SUPPRESSION
Always have adequate fire suppression or fire extinguishers in your dyno room.
FORKLIFT REQUIREMENTS
You will need to provide equipment capable of lifting a minimum of 2,722 kg.
(6,000 lb.) to lift the dyno off the crate and into position in your dyno room. You will
also need a pair of straps capable of supporting 2,722 kg. (6,000 lb.) to attach to the
dyno. Dynojet recommends using two 2-inch x 6-foot single loop style straps; these
straps must be the same length.
GROUND HOOKS
Your pit cover set includes ten ground hooks. The ground hooks allow you to secure
your car in place using the tie-down straps. The layout of the ground hooks is
described in the pit dimensions (P/N 98219103) provided by your salesperson. Refer
to Appendix A for red head anchor installation instructions.
Note: You will only have the ground hooks if you ordered the Pit Cover Set.
PHONE AND INTERNET ACCESS
Dynojet recommends you have a phone close to the dyno to call for assistance in an
emergency. You may also wish to contact Dynojet to troubleshoot your dyno.
Internet access on your computer is desirable for contacting Dynojet and
downloading new information and updates.
TIE-DOWN STRAPS
Dynojet recommends using tie-down straps for securing the car on the dyno. The 224
dyno comes with an automotive tie-down package.
1-8
In Ground Model 224 Automotive Dynamometer Installation Guide
SPECIFICATIONS AND OPERATING REQUIREMENTS
Model 224 In Ground Dynamometer
MODEL 224 IN GROUND DYNAMOMETER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pickup Card
not visible from this view
Breakout Board
Pit Covers
Drum
precision balanced
and knurled
Spring Applied
Air Brake
Mounting Foot
Figure 1-2: Model 224 In Ground Dyno with the 224 Pit Cover Set
Version 4 In Ground Model 224 Automotive Dynamometer Installation Guide
1-9
Loading...