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©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:________________________________________ ____ ___ __________
#
Page 3
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
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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
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Model 224 Above Ground Eddy Current Brake Installation and User Guide
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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
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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
Page 7
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
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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
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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.
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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
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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
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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
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Model 224 Above Ground Eddy Current Brake Installation and User Guide
load cell
Figure 1-2: Optimal Brake Cooling
Page 13
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
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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
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Model 224 Above Ground Eddy Current Brake Installation and User Guide
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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
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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
Page 17
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
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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
Page 19
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
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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
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Model 224 Above Ground Eddy Current Brake Installation and User Guide
driveline assembly
yoke
Page 21
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
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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
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Model 224 Above Ground Eddy Current Brake Installation and User Guide
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EDDY CURRENT BRAKE INSTALLATION
Eddy Current Brake Installation
3 Install the Theta Controller using four 8-32 x 3/8-inch screws.
theta controller
Figure 1-15: Install the Theta Controller
4 Install the two cable routing channels using three screws each.
cable routing
channels
Figure 1-16: Install Cable Routing Channels
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CHAPTER 1
Eddy Current Brake Installation
cable routing channels
(not visible)
Figure 1-17: Eddy Current Brake on Right Side of Dyno
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Model 224 Above Ground Eddy Current Brake Installation and User Guide
Page 25
ROUTING THE BRAKE CABLES
Refer to Figure 1-18 on page 1-22 for cable routing location information.
1 Before routing the cables, remove the two cable pass through covers (just above
the Theta Controller) and the cable pass through cover on the bottom of the side
panel. Remove the two screws securing each cable pass through cover. Set the
screws and covers aside.
2 Route the temperature sensor cable from the eddy current brake through the
panel opening closest to the dyno and over to the Breakout board.
For more information on wiring the Breakout board refer to page 1-23.
3 Route the speed pick-up cable from the Breakout board through the panel
opening closest to the dyno and over to the pick-up card.
4 Route the 25-pin cable from the Breakout board through the panel opening
closest to the dyno, along the inside of the panel using a cable routing channel
(not used by the input power cable), out through the bottom panel opening, and
to the dyno electronics.
5 Route the brake power cable from the eddy current brake through the panel
opening furthest from the dyno and over to the Theta Controller (underneath).
6 Route the input power cable from the Theta Controller through the panel
opening furthest from the dyno, along the inside of the panel using the cable
routing channel (not used by the 25-pin cable), out through the bottom panel
opening, and to your power source.
7 Route the control cable from the Theta Controller to the Breakout board.
8 Slide the brake power cable and the input power cable into a double cable pass
through. Secure the cable pass through to the panel using the two screws
removed earlier.
9 Slide the temperature sensor, speed pick-up, and 25-pin cables into a single cable
pass through. Secure the cable pass through to the panel using the two screws
removed earlier.
EDDY CURRENT BRAKE INSTALLATION
Eddy Current Brake Installation
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CHAPTER 1
Eddy Current Brake Installation
10 Do not install the cable pass through cover on the bottom of the side panel until
you have routed the load cell cable. Refer to page 2-3.
25-pin cable
input power
cable
temperature
sensor cable
double cable
speed pick-up
cable
theta controller
Figure 1-18: Routing the Cables
pass through
input power
cable
single cable
pass through
breakout board
control cable
brake power cable
1-22
Model 224 Above Ground Eddy Current Brake Installation and User Guide
Page 27
WIRING THE BREAKOUT BOARD
Refer to Figure 1-19 on page 1-24 for Breakout board location information.
1 Attach the temperature sensor cable to the Breakout board. The temperature
sensor cable has five wires which connect to the wiring block labeled TEMP. This
cable was routed to the Breakout board on page 1-21.
• Green wire connects to G1 • White wire connects to W1
• Black wire connects to B1 • Red wire connects to R1
EDDY CURRENT BRAKE INSTALLATION
Eddy Current Brake Installation
• Ground (shield) wire connects to S1
2 Attach the control cable to the Breakout board. The control cable has five wires
which connect to the wiring block labeled LOAD CONTROL. This cable was
routed to the Breakout board on page 1-21.
• Black wire connects to V- • Red wire connects to V+
• White wire connects to O+ • Green wire connects to O-
• Ground (shield) wire connects to SH
3 Attach the speed pick-up cable to the Breakout board. The control cable has four
wires which connect to the wiring block labeled DRUM 1. This cable was routed
to the Breakout board on page 1-21.
• Re d wire connects to R1 • Black wire connects to B1
• White wire connects to W1 • Ground (shield) wire connects to S1
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CHAPTER 1
Eddy Current Brake Installation
4 Verify jumpers J1 and J2 are set for the eddy current brake as shown in
Figure 1-19.
The air brake will be activated when the dyno electronics power is turned off or
when the red button on the pendant is lit. The eddy current brake is used for load
control.
temp
jumpers
J1 and J2
load control
Figure 1-19: Wire the Breakout Board
speed pick-up
1-24
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SECURING THE BRAKE TO THE DYNO ROOM FLOOR
1 Install the foot to the left and right panels using one 1/2-13 x 1.25-inch flange bolt
and one 1/2-13-inch nylock nut (not visible).
2 Install the Red Head Anchors. Refer to Appendix A for Red Head Anchor
installation instructions.
foot
EDDY CURRENT BRAKE INSTALLATION
Eddy Current Brake Installation
foot
install red head anchor
bolt
(nut not visible)
Figure 1-20: Secure the Brake to the Dyno Room Floor
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Page 31
T
ORQUE
M
C HAPTER
2
ODULE INSTALLATION
The Torque Module, when added to Dynojet's market leading i nertia dynamometer,
results in a complete vehicle performance test.
This chapter provides instructions for installing and using the Torque Module with
WinPEP 7. To ensure safety and accuracy in the procedures, perform the procedures
as they are described.
This chapter is divided into the following categories:
• Load Cell Installation, page 2-2
• Torque Module Installation, page 2-4
• Load Cell Calibration, page 2-10
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CHAPTER 2
Load Cell Installation
LOAD CELL INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This section describes how to install the load cell.
PARTS LIST
The following table lists all of the parts included in the Torque Module Installation kit
(P/N 73920007). 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.
part number description quantity
35430899 Weight, 25 lb 4
61319001 Calibration Arm Assembly 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
Torque Module Sub-Assembly
or
Torque Module High Resolution Sub-Assembly
1
INSTALLING THE LOAD CELL
1 Verify the main dyno power is disconnected.
2 Remove the two bolts and nuts securing the existing bar on the eddy current
brake and remove the bar. Set the bolts and nuts aside.
3 Verify the eyelets on the load cell are spaced the same as the bar removed earlier.
Adjust the load cell spacing by loosening the lock nut and turning the eyelet.
bar
distance must be
the same
Figure 2-1: Verify Load Cell Spacing
eyelet
lock nut
2-2
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TORQUE MODULE INSTALLATION
Load Cell Installation
4 Secure the load cell to the mounting bracket using the two bolts and nuts
removed earlier.
5 Route the load cell cable out through the bottom panel opening. Make sure the
load cell cable is clear of any power cable or hot or rotating objects.
6 Slide the input power cable (routed on page 1-22) into one side of the double
cable pass through removed earlier.
7 Slide the 25-pin cable and load cell cable through the other side of the double
cable pass through cover.
8 Secure the cable pass through cover to the panel using the two screws removed
earlier.
load cell cable
dyno
load cell and 25-
pin cable on left,
input power cable
on right
route cables through
cable pass through
Figure 2-2: Install the Load Cell
install the load cell
(the brake is not
shown for clarity)
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CHAPTER 2
Torque Module Installation
TORQUE MODULE INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This section describes how to access the dyno electronics, install the Torque Module,
route the load cell cable, and install the side and top brake covers.
ACCESSING THE DYNO ELECTRONICS
You will need to access your dyno electronics in order to add the torque module. Use
the following steps to access the dyno electronics.
1 Remove the eight screws securing the cover and lift the cover off.
2 Add the torque module to the top of the dyno electronics. Refer to “Installing the
Torque Module” on page 2-5.
3 Leave the dyno electronics enclosure out. You will need to route the load cell
cable to the Torque Module later.
dyno electronics
Figure 2-3: Inside the Electronics Enclosure
2-4
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INSTALLING THE TORQUE MODULE
1 Verify the main dyno power is disconnected.
2 Turn off the main power switch on the CPU Module on the dyno electronics and
unplug the power cord.
3 Remove the dust cover from the existing top module.
TORQUE MODULE INSTALLATION
Torque Module Installation
dust cover
power cord
input
power switch
Figure 2-4: Remove Dust Cover
4 Loosen the top right screw on the back of the existing top module.
5 Plug the Torque Module into the existing top module. Place the dust cover,
removed in step 3, on the Torque Module.
6 Secure the grounding strap on the back of the Torque Module to the existing top
module.
grounding strap
Figure 2-5: Secure Grounding Strap
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CHAPTER 2
Torque Module Installation
7 Secure the Torque Module to the dyno electronics with the plastic tie straps (one
on each side).
Note: Do not attach the load cell cable at this time.
torque module
tie strap
green LED light
load cell cable and port
do not attach at this time
Figure 2-6: Attach Torque Module
2-6
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ROUTING THE LOAD CELL CABLE
1 Route the load cell cable from the cable pass through on the eddy current brake
to the dyno electronics.
Make sure the load cell cable is clear of any power cables or hot or rotating
objects.
2 Route the load cell cable through the cable clamp on the back of the dyno
electronics enclosure.
2a Loosen the two screws and lift the clamp up to slide the load cell cable
through.
2b Secure the clamp with the two screws.
3 Attach the 9-pin connector on the load cell cable to the front of the Torque
Module and tighten down the screws.
4 Attach the power cord to the dyno electronics and turn the power switch on.
cable clamp
TORQUE MODULE INSTALLATION
Torque Module Installation
torque module
load cell cable
Figure 2-7: Route the Load Cell Cable to the Torque Module
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CHAPTER 2
Torque Module Installation
5 The green LED light on the Torque Module should now be on.
6 Replace the dyno electronics cover.
torque module
tie strap
green LED light
load cell cable and port
do not attach at this time
Figure 2-8: Attach Torque Module and Load Cell Cable
2-8
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Page 39
INSTALLING THE SIDE AND TOP COVERS
1 Install the brake side cover using ten 1/4-20 x 3/4-inch button head flange screws.
side cover
TORQUE MODULE INSTALLATION
Torque Module Installation
Figure 2-9: Install the Side Cover
2 Install the brake top cover using six 1/4-20 x 3/4-inch button head flange screws.
top cover
Figure 2-10: Install the Top Cover
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CHAPTER 2
Load Cell Calibration
LOAD CELL CALIBRATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This section provides instructions for using the Torque Module with WinPEP 7. The
Torque Module must be calibrated prior to use. Follow the directio ns on the scr een
exactly. Failure to perform the directions accurately will result in improper torque
values.
1 Verify you are in the MakeRun screen.
2 Verify you are connected to the dyno electronics.
Note: For more information on connecting to the dyno electronics, refer to the
WinPEP 7 User Guide (on your WinPEP CD or at
www.dynojet.com/manuals.shtml) or the WinPEP 7 Online Help.
3Select Tools
Note: Before proceeding, be sure the eddy current brake is free and clear of any
obstructions. There should not be anything resting on the eddy current brake or
the dynamometer drum during this procedure.
4Click Next to perform the Zero Calibration.
The Calibration window will appear. The hardware is now zeroing out the torque
cell. If the unit does not calibrate, recheck the setup and retry.
MakeRun Options Torque Cell Calibration.
Figure 2-11: Zero Calibration Window
2-10
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TORQUE MODULE INSTALLATION
Load Cell Calibration
Once the Zero Calibration is complete, the Calibration Mass window will appear.
5 Enter the Torque Module calibration value. Refer to Figure 2-13.
Note: You must perform this step the first time you calibrate the load cell.
Or
If you are only performing a Zero Calibration, click Finish.
bolt pattern closest to
the end of the
calibration arm
Figure 2-12: Calibration Mass Window
Enter the calibration number stamped near the bolt pattern at the end of the
calibration arm. If you do not have enough room to use the bolt pattern closest to
the end of the calibration arm, use the number stamped near the bolt pattern in
the center of the arm.
Note: Dynojet recommends you secure the calibration arm using the bolt pattern
closest to the end of the arm unless space constraints in your dyno room do not
allow you to.
bolt pattern near the
center of the
calibration arm
Figure 2-13: Calibration Arm Number
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CHAPTER 2
Load Cell Calibration
6Click Next to continue.
7 Install the calibration arm and weights. Refer to step 8 and
The Span Calibration window will appear.
Figure 2-15 on page 2-13.
Figure 2-14: Span Calibration Window
2-12
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TORQUE MODULE INSTALLATION
Load Cell Calibration
8 Install the calibration arm and weights using the bolts at the end of the calibration
arm.
Note: If you do not have enough room to use the bolt pattern closest to the end
of the calibration arm, use the bolt pattern in the center of the arm. Refer to
Figure 2-16 on page 2-14.
8a Secure the calibration arm to the eddy current brake by tightening the bolt
using the handle.
8b Gently place the weights on the calibration arm.
Note: Verify the calibration arm is not contacting the cover.
The calibration weights are very heavy. The weights must be set on the arm
gently or you will damage the load cell.
secure arm to brake by
tightening handle
weight support
pin
weights
Figure 2-15: Install Calibration Arm and Weights Using the Bolt Pattern Closest to the End
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CHAPTER 2
Load Cell Calibration
If you do not have enough room to use the bolt pattern closest to the end of the
calibration arm, use the bolt pattern in the center of the arm as shown in
Figure 2-16.
secure arm to brake by
tightening handle
weight support
pin
weights
Figure 2-16: Install Calibration Arm and Weights Using the Bolt Pattern in the Center
2-14
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TORQUE MODULE INSTALLATION
Load Cell Calibration
While installing the calibration weights, you should notice the Torque Gauge on the
DynoTrac Window moving from 0 to about 500 foot-pounds.
Note: The Torque Gauge may or may not be in this range.
• If the torque cell has been previously calibrated incorrectly or has not been
calibrated for a while, the gauge may show values out of this range until
calibration is complete.
• If you use the bolt pattern in the center of the calibration arm, the gauge will
show values around 250-260 foot-pounds.
Note: Let the torque gauge needle stabilize before clicking Next.
9From the Span Calibration window (Figure 2-14), click Next to continue.
At this point, the value on the gauge should match the value on the calibration
arm.
10 Remove the calibration arm and weights and click Finish.
Figure 2-17: Calibration Is Complete Window
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Page 47
B
ASIC
D
YNAMOMETER
C HAPTER
O
PERATION
3
The Dynojet dynamometer (dyno) gives state of the art technology, durability, and
accuracy that you need. Dynojet’s advanced engineering delivers the precise
horsepower measurements a technician needs to make quick and accurate
evaluations of engine performance and drive train problems.
This chapter will walk you through loading and preparing your dynamometer and
includes instructions for basic dyno operation. For more detailed instructions, refer
to the WinPEP 7 User Guide. This manual can be found on your WinPEP CD or at
www.dynojet.com/manuals.shtml.
This chapter is divided into the following categories:
•Loading the Car, page 3-2
• Connecting the RPM Pickup, page 3-5
•Pre-Run Inspection, page 3-8
• Making a Test Run, page 3-10
Model 224 Above Ground Eddy Current Brake Installation and User Guide
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CHAPTER 3
Loading the Car
LOADING THE CAR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use the following steps to load a car on the dyno.
Note: For more information about lift operation , refer to the instructions
included with the lift.
1 Verify the dyno electronics power is on and connected to your computer.
2 Make sure you are in the MakeRun screen.
3 Set the dyno brake on by pressing the red button on the hand held pendant.
4 For four or all wheel drive vehicles, measure the wheel base on the vehicle and
adjust the 224-4WD dyno to the dimension before driving the vehicle on the
dyno.
5 Drive the vehicle onto the dyno and align the vehicle straight with the dyno.
6 Stop the vehicle when the drive axle(s) is centered on the drum(s).
rear or front wheel
drive vehicles
center drive axle on dyno drum
four or all wheel
drive vehicles
adjust wheel base of
224-4wd dyno
center drive axle on both dyno drums
Figure 3-1: Center the Drive Axle(s) on the Drum(s)
3-2
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BASIC DYNAMOMETER OPERATION
Loading the Car
7 When the vehicle is positioned properly on the dyno, shut the engine off.
• If the vehicle has an automatic transmission, place it in park.
• If the vehicle has a manual transmission, place it in gear.
8 Set the vehicle’s emergency brake.
9 Secure the non-drive wheels using the provided tire chocks. Do not use tire
chocks for four wheel drive vehicles.
10 Attach the tie-down straps.
Rear Wheel Drive
• Attach two tie-down straps from secure anchor points to the rear of the
vehicle. Attach additional tie-down straps from the rear of the vehicle as shown
in Figure 3-2.
• Attach two tie-down straps from secure anchor points to the front of the
vehicle.
Front Wheel Drive
• Attach two tie-down straps from secure anchor points to the rear of the
vehicle.
• Attach two tie-down straps from secure anchor points to the front of the
vehicle. Attach additional tie-down straps across the front of the vehicle to
form a crisscross.
Four Wheel (All Wheel) Drive
• Attach two tie-down straps from secure anchor points to the rear of the
vehicle. If the vehicle is equipped with a rear steering system, attach additional
tie-down straps across the rear of the vehicle to form a crisscross.
• Attach two tie-down straps from secure anchor points to the front of the
vehicle. Attach additional tie-down straps across the front of the vehicle to
form a crisscross.
rear wheel drive
Figure 3-2: Attach Tie-down Straps
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front wheel drive
four wheel drive
3-3
Page 50
CHAPTER 3
Loading the Car
11 Tighten the tie-down straps evenly making sure that the drive wheels remain
centered on the drum.
The tie-down straps should always be connected to the vehicle’s solid axle or
the suspension control arms. Factory tie-down hooks connected to the
vehicle’s frame may be used on the end opposite the drive wheels (for
example: the front end of a rear driven vehicle).
12 Release the brake on the vehicle and the dyno.
13 Start the vehicle and put the transmission into first gear or drive.
14 Press the accelerator pedal so the drums begin turning slowly. While the drums
are slowly turning, get a feel for the stability of the vehicle. Stop the drum with the
dyno brakes.
15 Check all the straps and ensure the vehicle is tracking straight on the dyno.
3-4
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BASIC DYNAMOMETER OPERATION
CONNECTING THE RPM PICKUP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Your Dynojet dynamometer includes a primary wire inductive pickup and two
secondary wire inductive pickups. These small “clothespin like” inductive pickups are
used to sense RPM. An RPM pickup is required if you want to view torque graphs.
Generally you will use one secondary wire inductive pickup on a spark plug wire.
Vehicles with wasted spark ignition systems may require two secondary inductive
pickups. On a wasted spark ignition, typically one coil will be connected to two spark
plug wires. Attach one secondary pickup to each of these wires. If the pickups are
connected to two plug wires that do not fire at the same time, an erratic RPM readout
may occur. The primary wire ind uctive pickup senses RPM pulses from the coil.
Although this pickup location generally works better, it is harder to find the correct
location to connect the RPM pickup.
Note: If a pickup is not being used, disconnect it from the dyno electronics to
prevent any stray pick up of signals.
The optional Optical Sensor is useful on diesel powered vehicles, MSD ignitions, and
other high RFI ignition systems. For more detailed information on the Optical Sensor,
refer to the Optical RPM Sensor Installation Guide (P/N 98295109).
Connecting The RPM Pickup
Inductive pickups are very fragile. The ferrite core can easily be damaged and
is not covered under warranty. Dr opp ing, snapping, vibration, and heat can all
damage the ferrite core.
The dyno electronics RPM module contains the electronics that sense the RPM pulses.
An auto-gain circuit looks at only the peak voltage of the vehicle’s spark, ignoring the
lower voltages to help reduce electronic noise problems. Wasted spark ignition
systems will produce a lower voltage level on the exhaust stroke than the
compression stroke. By definition of the auto-gain circuit, lower voltage spark levels
will be ignored, missing every other spark the vehicle would produce.
RPM PICKUP DESCRIPTIONS
RPM pickup description
Secondaries (Non- wasted spark system) Use one secondary pickup. Unplug the other pickup from the RPM
module and set the degrees between plug fires to 720° in WinPEP.
Secondaries (Wasted spark ignition
system)
Primary pickup Attach the primary wire pickup to the primary side of the coil. Set
Optional Optical RPM Sensor Attach the sensor wire to the RPM module, also be sure to plug in
Use two secondary pickups. Attach one pickup on each spark plug
wire on the same coil and set the degrees between plug fires to
360° in WinPEP.
the degrees between plug fires by taking 720/number of cylinders.
For example, the number of degrees between plug fires on a V-8
engine with a single coil is 720/8=90 degrees.
the small power lead into the CPU module. The other end of the
wire attaches to the Optical Sensor. Set the degrees between plug
fires to 360° in WinPEP. Refer to the Optical RPM Sensor
Installation Guide (P/N 98295109).
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CHAPTER 3
Connecting The RPM Pickup
CONNECTING THE SECONDARY INDUCTIVE PICKUP
The secondary inductive pickup cannot be in contact with, or it’s connecting wire be
crossing, other engine electrical wires or stray RF interference may result.
1 Clip the secondary inductive pickup around one spark plug wire.
2 Route the inductive pickup cable clear of devices that produce electronic noise
(spark plug wires, coil wire, coil etc.).
Note: Inductive pickup placement is important. Position the inductive pickup so
that it is not making contact with any other spark plug wires. Separate the spark
plug wire from the spark plug wire bundle for proper operation.
Note: You must ground the vehicle to the dyno for the electronics to function
properly.
connect secondary
inductive pickup on a
single spark plug wire
automobile
distributor
Figure 3-3: Secondary Inductive Pickup
Figure 3-4: Separate Spark Plug Wire
3-6
Model 224 Above Ground Eddy Current Brake Installation and User Guide
Page 53
CONNECTING THE PRIMARY INDUCTIVE PICKUP
The primary inductive pickup cannot be in contact with, or it’s connecting wire be
crossing, other engine electrical wires or stray RF interference may result.
1 Clip the primary inductive pickup around the primary side of the coil.
2 Route the primary wire cable clear of devices that produce electronic noise.
Note: You must ground the vehicle to the dyno for the electronics to function
properly.
BASIC DYNAMOMETER OPERATION
Connecting The RPM Pickup
coil
Figure 3-5: Primary Inductive Pickup
connect primary
inductive pickup on the
negative side of the coil
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CHAPTER 3
Pre-run Inspection
PRE-RUN INSPECTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Perform a vehicle inspection before making a run.
• Check the radiator coolant and oil levels.
•Check the fuel source.
• Rotate the drum(s) and check for rocks caught in the tire tread that could fly out.
• Check the tire pressure and tire speed rating. Improperly inflated tires or
exceeding the maximum speed rating can result in premature wear or severe tire
damage. Make sure the tire has no major deficiencies (cracks in sidewalls, tread life,
etc.).
• Visually inspect the vehicle. Make sure it is in safe running order.
• Make sure ear protection and safety glasses are used when the dyno is being
operated.
• Check the tie-down straps to make sure that they are tight and secured.
• Check the drive tires to be sure that they are aligned correctly on the
dynamometer’s drums.
• Keep all rotating components clear at all times.
• Only the operator should be near the dyno or the vehicle during the test.
• Never allow any person(s) to stand behind the dyno or vehicle when it is being
operated.
• Perform any other safety inspections appropriate to running your vehicle on the
dyno.
Never allow any person(s) to stand behind the dyno or vehicle when it is being
operated. Only the operator should be near the dyno or the vehicle during the
test.
BEFORE STARTING THE ENGINE
Connect an exhaust hose or hoses (if dual exhaust) on the vehicle, make sure the
hose fits over the tail pipe, is not plugged or kinked and the hose is vented correctly
out of the dyno room.
Engine exhaust contains poisonous carbon monoxide gas. Breathing it could
cause death. Operate machine in well ventilated area.
3-8
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ENGINE WARM UP
Warm the vehicle’s engine and drivetrain before beginning testing. Consistent engine
temperatures will assure your runs are repeatable.
AFTER ENGINE WARM UP
Always leave the vehicle in park (automatic transmission) or in first gear (manual
transmission), with the engine off, and make sure the emergency brake and the dyno
brake are on when you get out of the vehicle.
• Fix any fuel, oil, or coolant leaks that may have shown up after engine warm up and
check the carburetor for leaks.
• Any loud or unusual engine noises or excessive exhaust smoke should be resolved
before continuing.
BASIC DYNAMOMETER OPERATION
Pre-run Inspection
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CHAPTER 3
Making a Test Run
MAKING A TEST RUN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dyno runs provide safe, reliable road testing right in the shop. The dyno allows you to
measure, record, and diagnose performance problems quickly. The dyno combined
with WinPEP 7 produces consistent, easily interpretable power graphs. Use the
following instructions to ensure repeatable and accurate measurements.
1 Verify the vehicle is secured properly.
2 Place the vehicle in a low gear and release the dyno brake using the hand held
pendant.
3 Slowly accelerate the vehicle to 20 m.p.h.
4 Test the tachometer operation.
4a Rev the engine. The gauges on the computer screen should be moving. If
the tachometer is moving but not registering the correct RPM values, the
number of degrees of revolution of the crank shaft (the plug fires number) is
incorrect.
4b Stop the vehicle, return to the MakeRun Configuration dialog box, and enter
the correct value for the plug firing order.
5 Press the red brake button to apply 100% braking and slow down the vehicle.
Using the vehicle’s own brakes to slow or stop the drum at speeds over 30
m.p.h. can severely over heat the brake parts. Dynojet dynamometers with the
mechanical brake, air brake, or eddy current brake accessory can be used to
slow the vehicle and drum to a full stop at any speed. The vehicle’s brakes
should be used in an emergency stop situation only.
6 Shut the engine off and put the vehicle in gear (manual transmission) or park
(automatic transmission).
7 Set the vehicle’s parking brake and leave the dyno brake on.
8 Perform a final inspection.
• Verify the drive tire’s alignment on the dyno drums.
• Make any adjustments to the tie-down straps as needed.
• Perform any other safety checks that you deem appropriate to your particular
situation.
You are now ready to make a high speed run on the dyno. Refer to your WinPEP 7
User Guide for more detailed instructions.
3-10
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R
ED
H
EAD
A PPENDIX
A
A
NCHOR INSTALLATION
This appendix contains instructions for installing the Red Head Multi-Set™II Anchors.
The anchors will be used to secure the dyno to concrete. To ensure safety and
accuracy in the procedures, perform the procedures as they are described. Be sure to
read and understand the warnings included in this appendix.
WARNINGS
Always wear safety glasses and other necessary protective devices or apparel
when installing or working with anchors.
ITW Ramset/Red Head Multi-Set II Anchors are designed to operate properly
only when installed with ITW Ramset/Red Head brand Setting Tools.
The use of a 24 to 40 ounce hammer is recommended for expanding Multi-Set II
anchors.
The use of carbide drill bits manufactured with ANSI B94. 12-77 drill bit diameter
requirements is recommended for installation of this anchor.
Not recommended for use in lightweight masonry material such as block or brick.
Use of core drills is not recommended to drill holes for use with this anchor.
Not recommended for use in new concrete which has not had sufficient time to cure.
Anchor spacing and edge distance requirements (anchor installation locations) are
the responsibility of the engineer of record.
CONTACT INFORMATION FOR ITW RAMSET/RED HEAD
Contact ITW Ramset/Red Head at 1-630-350-0370, or 1300 North Michael Drive,
Wood Dale, IL 60191.
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APPENDIXA
Installation
INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use the table below to determine the catalog number, drill bit size, minimum hole
depth, and setting tool catalog number.
setting tool
catalog number drill bit size minimum hole depth
Carbon Steel
RM-38/RL-38 (9.5 mm)
Use the following instructions to install the Red Head anchors.
1 Drill the hole in the concrete the same outside diameter as the anchor being used
to any depth exceeding minimum embedment.
1/2-inch 1 5/8-inch (41.2 mm) RT-138
catalog number
Figure A-1: Red Head Anchor—Drill the Hole
2 Insert the anchor.
anchor
Figure A-2: Red Head Anchor—Insert the Anchor
A-2
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RED HEAD ANCHOR INSTALLATION
Installation
3 Using a hammer, drive the anchor flush with the surface of the concrete, or below
the surface if the hole depth exceeds minimum embedment.
Figure A-3: Red Head Anchor—Drive the Anchor Flush
4 Using a hammer, expand the anchor with the setting tool. The anchor is properly
expanded when the shoulder of the setting tool is flush with the top of the
anchor.
Note: Use only Ramset/Red Head setting tools to insure proper installtion.
setting tool
Figure A-4: Red Head Anchor—Expand the Anchor
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Page 61
A PPENDIX
P
OWER
This appendix contains the power requirements and inst ruc tio ns fo r all lo cations
excluding North America brake installations. Refer to page 1-5 for power
requirements and instructions for North America and Japan. To ensure safety and
accuracy in the procedures, perform the procedures as they are described.
R
EQUIREMENTS
—E
N
ORTH
XCLUDING
A
MERICA
B
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APPENDIXB
Power Requirements and Installation
POWER REQUIREMENTS AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The eddy current brake (excluding North America and Japan) 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 eddy current brake requires a dedicated 240V AC 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 dedicated wall receptacle is a three-pin IEC grounded 30A type and must be
wired in accordance with local building codes and requirements. Installation may
require a licensed electrician to conform to applicable safety standards.
If you are installing your brake in a location other than North America or Japan
and the brake is not equipped with a three pin IEC grounded plug, contact
Dynojet before attempting to connect the brake.
Local and national electrical codes will require that the box containing the receptacle
is grounded.
• This circuit should have a dedicated 30A double pole circuit breaker.
• The brake should be the only device connected to this circuit.
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POWER REQUIREMENTS—EXCLUDING NORTH AMERICA
INSTALLING THE WALL RECEPTACLE
The wall receptacle is a single 240 volt 30A dedicated circuit with a ground.
The cable carrying the power to this receptacle should be 4.0 mm
larger. Check with local building codes for th e correct size.
1 Connect one of the 240V legs to the N terminal (white).
2 Connect the other 240V leg to the L terminal (no color).
3 Connect the ground conductor to the green terminal.
Power Requirements and Installation
2
(ten gauge) or
L terminal
N terminal
(white)
Figure B-1: Wiring the Wall Receptacle
ground terminal
(green)
Version 3 Model 224 Above Ground Eddy Current Brake Installation and User Guide
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APPENDIXB
Power Requirements and Installation
TESTING FOR CORRECT VOLTAGES
You must test the receptacle for proper voltages before the dyno is connected to the
outlet.
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
1 3 220V to 250V
2box<5V
3
1
2
Figure B-2: Testing the Wall Receptacle
B-4
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POWER REQUIREMENTS—EXCLUDING NORTH AMERICA
REPLACING THE POWER PLUG
Use the following instructions to replace the plug and socket.
The plug and socket configuration must be rated for at least 240VAC 30A and have a
minimum of three conductors.
The power cord that attaches to the dyno 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 Cut off the black wire.
4 Refer to the previous table for testing and probe the new connections as follows:
• blue wire as location #1
• brown wire as location #3
• green/yellow wire as location #2
HARD WIRING TO THE BUILDING
Power Requirements and Installation
Use the following instructions to wire the brake directly to the building.
The brake must connect to a two pole disconnect switch to allow the removal of all
power to the brake 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 brake 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 Cut off the black wire.
4 Refer to the previous table for testing and probe the new connections as follows:
• blue wire as location #1
• brown wire as location #3
• green/yellow wire as location #2
Version 3 Model 224 Above Ground Eddy Current Brake Installation and User Guide
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Page 67
I
NSTALLING THE
E
ARLY
This appendix contains instructions for installing the adapter and bearing on early
model dynamometers (dynos); this includes dynos with serial numbers between
2240088 and 2240120. To ensure safety and accuracy in the procedures, perform the
procedures as they are described.
A
DAPTER AND
M
ODEL
D
A PPENDIX
C
B
EARING
YNAMOMETERS
—
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APPENDIXC
Installing the Adapter and Bearing—Early Model Dynos
INSTALLING THE ADAPTER AND BEARING—EARLY MODEL DYNOS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dynos missing the bearing mounting holes, shown in Figure 1-8 on page 1-14, will
need to use the adapter (P/N 79110001) to install the bearing. This includes dynos
with serial numbers between 2240088 and 2240120.
1 Orient the bearing to the adapter as shown in Figure C-1. The arrow on the
adapter plate must point up.
2 Secure the bearing to the adapter plate using two 1/2-13 x 1.25-inch flange bolts
and two 1/2-13-inch nuts. Leave the bolts loose.
Note: The bolts are included with the eddy current brake while the nuts are
included with the adapter kit.
bearing
adapter plate
arrow
Figure C-1: Early Model Dynos—Install Bearing to Adapter
3 Secure the adapter plate to the dyno using six 1/2-13 x 3/4-inch bolts.
bolt
adapter plate
Figure C-2: Early Model Dynos—Install Adapter Plate
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INSTALLING THE ADAPTER AND BEARING— EARLY MODEL DYNAMOMETERS
Installing the Adapter and Bearing—Early Model Dynos
4 Using the template included in this appendix, drill four additional holes into the
dyno frame as shown.
Note: If you needed to use the adapter plate, you will need to drill brake
mounting holes in the dyno frame.
4a Line the template up with the existing hole on the dyno.
4b Drill two 3/8-16-inch UNC holes on each side of the dyno.
template
drill holes
existing hole
template
drill holes
existing hole
Figure C-3: Early Model Dynos—Using the Template
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Page 71
Template Placement—
Early Model Dynos
ADD 3/8-16 UNC HOLES
EXISTING HOLES
ADD 3/8-16 UNC HOLES
5 3/4"
5 3/4"
EXISTING HOLES
Template—Early Model Dynos
1 5/8"
DYNO FRAME END
Template—Early Model Dynos
EXISTING HOLE
UP
ø 5/16"
5 3/4" 5 3/4"
Page 72
I
NDEX
25-pin cable
routing 1-21
A
accessing dyno electronics 2-4
adapter plate C-2
B
bearing 1-14
retrofit C-2
brace 1-13
brake power cable 1-21
breakout board
control cable 1-23
jumpers 1-24
speed pick-up cable 1-23
temperature sensor cable 1-23
wiring 1-23
C
cable clamp 2-7
cable pass through 1-21
cable routing channels 1-19
calibration arm 2-11
number 2-11
weights 2-13
control cable
routing 1-21
wiring 1-23
conventions 1-3
covers
front and rear 1-11, 1-18
side 1-10
top 1-10
D
deck support 1-18
document part number 1-1
dyno electronics
accessing 2-4
cable clamp 2-7
E
eddy current brake
installation 1-8–1-25
optimal cooling 1-8
parts list 1-4
right side install 1-20
securing to floor 1-25
unpacking 1-9
wiring breakout board 1-23
F
front and rear covers
installing 1-18
removing 1-11
I
input power cable 1-21
installation requirements
power 1-5, B-2
K
keyed yoke 1-15, 1-16
L
load cell
installation 2-2–2-3
routing the cable 2-7
loading the car 3-2–3-4
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INDEX
M
making a test run 3-10
O
optimal brake cooling 1-8
P
parts list 2-2
power 1-5, B-2
hard wiring 1-7, B-5
installation 1-5, B-2
installing receptacle 1-5, B-3
replacing power plug 1-7, B-5
requirements 1-5, B-2
testing voltages 1-6, B-4
power requirements 1-5, B-2
pre-run inspection 3-8–3-9
R
rear deck support 1-13
brace 1-13
red head anchor
contact information A-1
installation A-2
placement 1-25
setting tool A-3
warnings A-1
routing cables
25-pin 1-21
brake power 1-21
control cable 1-21
input power cable 1-21
load cell 2-7
speed pick-up 1-21
temperature sensor 1-21
T
technical support 1-3
temperature sensor cable
routing 1-21
wiring 1-23
template C-3
testing voltages 1-6, B-4
theta controller 1-19
top cover
installing 2-9
removing 1-10
torque cell calibration 2-10–2-15
calibration arm 2-11
calibration number 2-11
calibration weights 2-13
torque gauge 2-15
torque module
installation 2-5–2-8
U
u-joint 1-15
W
WinPEP 7 2-10
wiring breakout board
control cable 1-23
jumpers 1-24
speed pick-up cable 1-23
temperature sensor cable 1-23
Z
zero calibration 2-10
S
setting tool A-3
side cover
installing 2-9
removing 1-10
speed pick-up cable
routing 1-21
wiring 1-23
spline hub 1-15
spline shaft 1-15
Index-ii
Model 224 Above Ground Eddy Current Brake Installation and User Guide
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