©2004-2005 Dynojet Research, Inc. All Rights Reserved.
Eddy Current Brake Installation and User Guide For Model 224 Above Ground
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 manu al ma y be repr oduced, sto red 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 89031, USA.
Printed in USA.
Part Number: 98215100 Version 3 (03/05)
RECORD
Dynamometer Number: ____________________________________________________
Eddy Current Brake
(Retarder) Number:________________________________________ ____ ___ __________
#
T
ABLE OF
C
ONTENTS
Chapter 1 Eddy Current Brake Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Power Requirements and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Replacing the Power Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Eddy Current Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Before Installing the Eddy Current Brake: Verify Optimal Brake Cooling . . .1-8
Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Removing the Rear Deck Support Brace . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
Installing the Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
Installing the Spline Shaft and Driveline Assembly . . . . . . . . . . . . . . . . . .1-15
Installing Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
Installing the Front and Rear Brake Covers and Theta Controller . . . . . . .1-18
Routing the Brake Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-21
Wiring the Breakout Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-23
Securing the Brake to the Dyno Room Floor . . . . . . . . . . . . . . . . . . . . . .1-25
Chapter 2 Torque Module Installation
Load Cell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Installing the Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Torque Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Accessing the Dyno Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Installing the Torque Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Routing the Load Cell Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Installing the Side and Top Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Load Cell Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Model 224 Above Ground Eddy Current Brake Installation and User Guide
i
TABLE OF CONTENTS
Chapter 3 Basic Dynamometer Operation
Loading the Car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Connecting The RPM Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
RPM Pickup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Connecting the Secondary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . .3-6
Connecting The Primary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Pre-run Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
After Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Appendix A Red Head Anchor Installation
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Appendix B Power Requirements—Excluding North America
Power Requirements and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Replacing the Power Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Appendix C Installing the Adapter and Bearing—
Early Model Dynamometers
Installing the Adapter and Bearing—Early Model Dynos . . . . . . . . . . . . .C-2
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i
ii
Model 224 Above Ground Eddy Current Brake Installation and User Guide
E
DDY
C
URRENT
C HAPTER
B
RAKE INSTALLATION
1
This document provides instructions for installing the eddy current brake (retarder)
to the Dynojet model 224 above ground automotive dynamometer (dyno). This
document also provides instructions for installing and calibrating the load cell and
basic dynamometer operation. To ensure safety and accuracy in the procedures,
perform the procedures as they are described.
Document Part Number: 98215100
Version 3
Last Updated: 03-10-05
This chapter is divided into the following categories:
•Introduction, page 1-2
• Power Requirements and Installation, page 1-5
• Eddy Current Brake Installation, page 1-8
Model 224 Above Ground Eddy Current Brake Installation and User Guide
1-1
CHAPTER 1
Introduction
INTRODUCTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before installing your eddy current brake, please take a moment to read this guide for
installation instructions and other important information.
This guide is designed to be a reference tool in your everyday work and includes the
following chapters and information:
EDDY CURRENT BRAKE INSTALLATION
This chapter describes the procedures for installing the eddy current brake.
TORQUE MODULE INSTALLATION
This chapter describes the procedures for installing the torque module and load cell
along with load cell calibration.
BASIC DYNO OPERATION
This chapter describes basic dyno operating procedures.
RED HEAD INSTALLATION
This appendix describes the procedures for installing the Red Head anchors.
POWER REQUIREMENTS—EXCLUDING NORTH AMERICA
This appendix describes the power requirements and installation instructions for all
locations excluding North America.
INSTALLING THE ADAPTER AND BEARING—EARLY MODEL DYNOS
This appendix describes the procedures for installing the adapter and bearing needed
for early model dynos.
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Model 224 Above Ground Eddy Current Brake Installation and User Guide
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.
EDDY CURRENT BRAKE INSTALLATION
Introduction
Bold
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, 3D visualizations, and press releases
about our latest product line.
Highlights items you can select on in the software
interface, including buttons and menus.
The arrow indicates a menu choice. For example,
“select File
then select the Open choice on the File menu.”
Open” means “select the File menu,
Version 3 Model 224 Above Ground Eddy Current Brake Installation and User Guide
1-3
CHAPTER 1
Introduction
part number description quantity
21217500 Hood, Retarder Top 1
21217501 Hood, Retarder, Side 1
21217502 Hood, Retarder, Right 1
21217503 Hood, Retarder, Left 1
21228102 Blank Pass Through Cover 3
21228105 Double Hole Pass Through Cover 2
21228506 Cable Pass Through Cover 1
21626210 Z-Bracket (cable routing channel) 2
21917100 Foot 2
32355056 Bearing-Flange, 1.75”, 2-Bolt 1
32811195 O-Ring, 7/16 x 11/16”, #-205 1
35430899 Weight, 25 lb. 4
36580804 Screw-Set, 3/8-16 x 1/2”, W/Tlok 2
36708100 Nut, 1/2-13, Nylock-Hex 2
36721100 Nut, 5/8-11 UNC, Hex 1
36801080 Bolt, 1/2-13 x 1.25”, Flange-Hex 4
36923100 Washer, 5/16”, Hardened, Flat, Stl 12
37513200 Anchor, Redhead, 3/8” 2
37518200 Installation Tool, Redhead Anchor 1
37620844 Woodruff Key, 1/2 x 2.75”, 1622-1 1
49950030 Temp Sensor, 30-500C Max 1
61319001 Calibration Arm Assembly 1
62218130 Splined Shaft Assembly 1
62240130 Driveline Assembly, 7C, 224 Retarder 1
66411004 Theta-2 Controller - 240V -20A 1
65412004 PCB, Torque Cell Rev Switch, Loaded 1
66114002
or
66104001
76950505 Torque Cell Assembly, 224 1
76950606 Cable, Input, 224 Torque Rev Sw 1
76950607 Cable, Output, 224 Torque Rev Sw 1
DM150-019-012 Bolt, 3/8-16 x 1”, Hex 10
PARTS LIST
The following table lists all of the parts included in the Eddy Current Brake
(P/N 72912001) Installation kit. Check your kit against the parts listed to make sure
you have received all of the parts. If any part is missing, contact Dynojet Technical
Support.
Torque Module Sub-Assembly
or
Torque Module High Resolution Sub-Assembly
1
1-4
Model 224 Above Ground Eddy Current Brake Installation and User Guide
EDDY CURRENT BRAKE INSTALLATION
Power Requirements and Installation
POWER REQUIREMENTS AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The following power requirements and instructions are for North America, Japan, and
locations using 60 Hz power. All other locations should refer to the instructions
found in Appendix B.
The eddy current brake requires a dedicated 240VAC single phase power outlet rated
for 30A for proper operation. Failure to follow these instructions could result in
personal injury or damage to the brake. Connecting the brake to the incorrect
voltage will void the brake warranty. Contact Dynojet with any questions.
The eddy current brake requires a dedicated wall receptacle which must be wired for
operation and is included with the brake or may be shipped in advanced in a separate
package. The brake is equipped with a twenty-five foot power cord with a twist lock
plug pre-wired on the end.
The dedicated wall receptacle is a twist lock four wire grounded 30A NEMA L14-30
type and must be wired in accordance with local building codes and requirements. If
the facility does not have 120/240 volt single phase power, and it does have 120/208
volt three phase Y power, then it is acceptable to connect the four wire receptacle
with two of the three phase lines, the neutral and the ground. With this arrangement,
there will only be 208 volts between line 1 and line 2 instead of 240 volts. This
acceptable, but performance of the eddy current brake will be reduced. In no case
shall all three phase lines be connected to the receptacle! Installation may
require a licensed electrician and must conform to UL and NEC safety standards.
Note: If you are installing your brake in North American or Japan and the brake is
not equipped with twist lock four wire grounded plug, contact Dynojet before
attempting to connect the brake.
Local and national electrical codes require a grounded receptacle box.
• This circuit should have a dedicated 30A double pole circuit breaker.
• The brake should be the only device connected to this circuit.
INSTALLING THE WALL RECEPTACLE
The wall receptacle is included with your brake and is shipped in a separate box or
may be shipped in advance in a separate package.
The wall receptacle is a single phase 240 volt 30A dedicated circuit with a neutral
connection and a ground. The neutral connection is required to split the 240 volt into
two 120 volt connections internal to the dyno.
The cable carrying the power to this receptacle should be ten gauge or larger. Check
with local building codes for the correct size.
1 Connect one of the 240V legs to the X terminal (gold co lo re d scr e w) .
2 Connect the other 240V leg to the Y terminal (gold colored screw).
3 Connect the neutral conductor to the W or WH terminal (silver screw).
4 Connect the ground conductor to the green grounding screw.
Version 3 Model 224 Above Ground Eddy Current Brake Installation and User Guide
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CHAPTER 1
Power Requirements and Installation
TESTING FOR CORRECT VOLTAGES
You must test the receptacle for proper voltages before the eddy current brake is
connected to the outlet.
If the voltage readings do not match the following table, DO NOT connect the
brake. You must have a licensed electrician correct the power connection.
Connecting the brake to the incorrect voltage can result in damage to the brake
and will void the brake warranty. Contact Dynojet with any questions.
Using a voltmeter that is capable of measuring AC voltage, measure between the
points listed below and verify that the correct voltages are present.
probe 1 probe 2 desired voltage measurement
2 4 216V to 260V*
1 4 108V to 130V
1 2 108V to 130V
13 <5V
3box<5V
*If using two of the three phase lines of a 120/208 V 3 phase Y system,
then expect to see 187V to 225V.
3
2
1
Figure 1-1: Dedicated Power Receptacle
1-6
Model 224 Above Ground Eddy Current Brake Installation and User Guide
4
REPLACING THE POWER PLUG
Use the following instructions to replace the four wire plug and socket.
The plug and socket configuration must be rated for at least 240VAC 30A and have a
minimum of four conductors.
The power cord that attaches to the brake has four conductors internally and their
colors are brown, blue, black, and green/yellow.
1 Connect 240VAC single phase power between the brown and the blue wire
connection points.
2 Connect the green/yellow wire to the ground connection point.
3 Wrap the black wire with the white tape to denote that it is a neutral connection
and connect it to the neutral connection point.
4 Refer to the previous table for testing and probe the new connections as follows:
• blue wire as location #2
• brown wire as location #4
• black wire as location #1
• green/yellow wire as location #3.
EDDY CURRENT BRAKE INSTALLATION
Power Requirements and Installation
HARD WIRING TO THE BUILDING
Use the following instructions to wire the dyno directly to the building.
The brake must connect to a two pole disconnect switch to allow the removal of all
power to the dyno for servicing. This box may contain fusing, circuit breakers, or the
circuit protection may be upstream in the building power system. The circuit must be
protected to 30A with slow blow fuses or time delayed circuit breakers.
The power cord that attaches to the dyno has four conductors internally and their
colors are brown, blue, black, and green/yellow.
1 Remove the brake power plug and connect 240VAC single phase between the
brown and the blue wires through the disconnect switch.
2 Connect the green/yellow wire to the ground connection.
3 Wrap the black wire with white tape to denote that it is a neutral connection and
connect it to the neutral connection.
4 Refer to the previous table for testing and probe the new connections as follows:
• blue wire as location #2
• brown wire as location #4
• black wire as location #1
• green/yellow wire as location #3
Version 3 Model 224 Above Ground Eddy Current Brake Installation and User Guide
1-7
CHAPTER 1
Eddy Current Brake Installation
EDDY CURRENT BRAKE INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This section will walk you through removing the eddy current brake from the crate,
installing the eddy current brake on model 224 automotive dynos, installing the Theta
Controller , and routing cables.
You will need to provide equipment capable of lifting the eddy current brake off the
crate and into position in your dyno room. Y ou will also need a pair of straps. Dynojet
recommends using single loop style straps.
To prevent possible injury, turn off the dyno electronics and unplug the dyno.
BEFORE INSTALLING THE EDDY CURRENT BRAKE: VERIFY OPTIMAL BRAKE COOLING
Placing the eddy current brake on the left or right side of the dyno will determine the
direction that it turns.
For optimal eddy current brake cooling, the brake should turn in the direction of the
arrows on the rotors.
When running mostly rear wheel drive cars, orient the dyno and brake so the brake is
turning in the direction of the arrows when a rear wheel drive car is on the dyno (as
shown in Figure 1-2).
Note: The dyno will function correctly for front wheel drive cars, but cooling of
the rotors will not be optimal.
The rear wheel drive example below shows the brake turning in the direction of the
arrows on the rotors. In this example, the load cell is in compression.
direction of
rotation
arrow on rotor
1-8
Model 224 Above Ground Eddy Current Brake Installation and User Guide
load cell
Figure 1-2: Optimal Brake Cooling
UNPACKING THE EDDY CURRENT BRAKE
uprights and cross
members
EDDY CURRENT BRAKE INSTALLATION
Eddy Current Brake Installation
1 Remove the top and sides of the crate.
2 Remove any hardware and parts boxes and set aside.
3 Remove the uprights and cross members off the crate.
crate top
Figure 1-3: Remove the Crate Top
remove boxes
Version 3 Model 224 Above Ground Eddy Current Brake Installation and User Guide
1-9
CHAPTER 1
Eddy Current Brake Installation
4 Remove the six screws securing the top cover to the brake. Set the screws and the
cover aside.
5 Remove the ten screws securing the side cover to the brake. Set the screws and
the cover aside.
side cover
top cover
Figure 1-4: Remove the Top and Side Covers
1-10
Model 224 Above Ground Eddy Current Brake Installation and User Guide
EDDY CURRENT BRAKE INSTALLATION
Eddy Current Brake Installation
6 Remove the five screws securing the front and rear covers. Set the screws, bolts,
and covers aside.
brake number
RECORD
Be sure you record the dynamometer and/or eddy current brake number on
the inside cover of this manual.
#
front and rear covers
screw
Figure 1-5: Remove the Left and Right Covers
Version 3 Model 224 Above Ground Eddy Current Brake Installation and User Guide
1-11
CHAPTER 1
Eddy Current Brake Installation
7 Remove the four lag bolts securing the brake to the crate.
8 Place the nylon loop strap around the shaft on either side of the brake.
Dynojet recommends using single loop style straps.
9 Using a forklift, lift the eddy current brake from the crate and place the brake near
the dyno.
shaft
bolt
shaft
Figure 1-6: Remove the Brake
1-12
Model 224 Above Ground Eddy Current Brake Installation and User Guide
REMOVING THE REAR DECK SUPPORT BRACE
1 Remove the two bolts and washers securing the brace to the rear deck support
and set aside. These will be used later when installing the eddy current brake.
2 Remove the two bolts and washers securing the brace to the dyno and remove the
brace. The brace will not be used.
brace
EDDY CURRENT BRAKE INSTALLATION
Eddy Current Brake Installation
rear deck support
Figure 1-7: Remove the Brace
Version 3 Model 224 Above Ground Eddy Current Brake Installation and User Guide
1-13
CHAPTER 1
Eddy Current Brake Installation
INSTALLING THE BEARING
The eddy current brake can be installed on either side of your dyno, the installation
instructions are the same.
1 Install the bearing using two 1/2-13 x 1.25-inch flanged bolts. Leave the bolts
loose.
Note: If you are retrofitting an earl y model dyno which does not have the bearing
mounting holes, refer to the instructions in Appendix C.
bearing mounting
holes
bearing
Figure 1-8: Install the Bearing
1-14
Model 224 Above Ground Eddy Current Brake Installation and User Guide
EDDY CURRENT BRAKE INSTALLATION
INSTALLING THE SPLINE SHAFT AND DRIVELINE ASSEMBLY
1 Insert the spline shaft through the bearing and into the spline hub of drum.
Note: Make sure the short spline end faces out.
2 Push the spline shaft as far as it will go.
3 Torque the bearing mounting bolts to 57 foot-pounds.
4 Torque the two set screws on the bearing to 25 foot-pounds.
Eddy Current Brake Installation
bearing mounting
bolts
spline shaft
bearing set screws
Figure 1-9: Install Spline Shaft
5 Remove the four bolts securing the u-joint to the keyed driveline yoke. Set these
bolts aside; they will be used to secure the eddy current brake to the driveline
assembly.
6 Separate the keyed yoke from the driveline assembly. You may need to use a
screwdriver or pry bar to separate the u-joint from the yoke.
7 Place the driveline assembly on the spline shaft.
remove four bolts,
two on either side
driveline assembly
Figure 1-10: Install Driveline Assembly
Version 3 Model 224 Above Ground Eddy Current Brake Installation and User Guide
1-15
CHAPTER 1
Eddy Current Brake Installation
INSTALLING EDDY CURRENT BRAKE
1 Place the keyed yoke onto the eddy current brake shaft.
2 Line up the eddy current brake yoke with the driveline assembly.
3 Slide the brake frame towards the dyno frame until they touch. Make sure the
brake yoke is aligned with the driveline.
4 Secure the yoke to the driveline assembly using the four bolts removed earlier.
Torque the bolts to 70 foot-pounds.
Figure 1-11: Install the Brake Assembly
1-16
Model 224 Above Ground Eddy Current Brake Installation and User Guide
driveline assembly
yoke
EDDY CURRENT BRAKE INSTALLATION
Eddy Current Brake Installation
5 Secure the brake frame to the dyno using eight 3/8 x 1-inch bolts and
eight 5/16-inch hardened flat washers. Not all of the bolts and washers are visible
from this view.
6 Torque the brake yoke set screws to 25 foot-pounds.
bolts and washers
(not all visible)
Figure 1-12: Secure the Brake Frame to the Dyno
bolts and washers
(not all visible)
Figure 1-13: Eddy Current Brake on Right Side of Dyno
Version 3 Model 224 Above Ground Eddy Current Brake Installation and User Guide
1-17
CHAPTER 1
Eddy Current Brake Installation
INSTALLING THE FRONT AND REAR BRAKE COVERS AND THETA CONTROLLER
1 Install the front and rear covers to the frame using four 1/4-20 x 3/4-inch button
head flange screws and eight nuts for each cover.
2 Secure the deck support to the cover using the hardware removed earlier.
deck support
front and rear
covers
1/4-20 x 3/4-inch screws
Figure 1-14: Install the Front and Rear Covers
1-18
Model 224 Above Ground Eddy Current Brake Installation and User Guide
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