MAHA POWERDYNO MSR, POWERDYNO MSR 500, POWERDYNO MSR 1000, POWERDYNO MSR 1050, POWERDYNO MSR 800 Original Operating Instructions

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MSR

Single Roller Dynamometer

Original Operating Instructions

BA053101-en

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MSR 500 MSR 800 MSR 830 MSR 850 MSR 1000 MSR 1050

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Safety .................................................................................................................. 7

Description ........................................................................................................ 12

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Contents

1.1 Introduction .............................................................................................................. 7

1.2 Symbols ................................................................................................................... 7

1.3 Intended Use ........................................................................................................... 7

1.4 Safety Instructions for Commissioning ...................................................................... 7

1.5 Safety Instructions for Operation............................................................................... 8

1.6 Safety Instructions for Servicing ................................................................................ 9

1.7 Danger Zone .......................................................................................................... 10

1.8 Safety Information about Tires ................................................................................ 10

1.9 Safety Information about the Eddy Current Brake ................................................... 11

1.10 Safety Features ...................................................................................................... 11

1.11 Accessories ........................................................................................................... 11

1.12 What to Do in the Event of an Accident .................................................................. 11

2.1 General Information ................................................................................................ 12

2.2 Specifications ......................................................................................................... 13

2.2.1 Dimensions ............................................................................................................ 13

2.2.2 Communication Desk ............................................................................................. 15

2.2.3 MSR 500/1 ............................................................................................................ 16

2.2.4 MSR 500/2 ............................................................................................................ 17

2.2.5 MSR 500/2 4WD .................................................................................................... 18

2.2.6 MSR 500/3 4WD .................................................................................................... 19

2.2.7 MSR 800 ............................................................................................................... 20

2.2.8 MSR 830 ............................................................................................................... 21

2.2.9 MSR 850 ............................................................................................................... 22

2.2.10 MSR 1000 ............................................................................................................. 23

2.2.11 MSR 1050 ............................................................................................................. 24

2.3 Main Switch ........................................................................................................... 25

2.4 Controls and Indicators .......................................................................................... 25

2.5 Emergency Stop .................................................................................................... 26

2.6 Remote Control ...................................................................................................... 27

2.7 Description of the Interface Box .............................................................................. 29

2.7.1 RPM Module (Standard) ......................................................................................... 31

2.7.2 Environmental Module (Standard) ........................................................................... 33

2.7.3 OBD Module (Optional)........................................................................................... 34

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Description of the SINAMICS Components .......................................................... 44

Transport and Storage ....................................................................................... 47

Installation and Initial Operation ........................................................................... 47

Installation ......................................................................................................... 47

Software ............................................................................................................ 51

Preparations for Testing...................................................................................... 59

2.7.4 Pressure/Temperature Module (Optional) ................................................................ 34

2.7.5 Analog Input Module (Optional) ............................................................................... 35

2.8 Analog Output Card (Optional) ................................................................................ 35

2.9 Measurement Programs ......................................................................................... 36

2.10 Calculation Basis .................................................................................................... 37

2.10.1 Road Load ............................................................................................................. 37

2.10.2 Torque ................................................................................................................... 38

2.10.3 Extrapolation of the Engine Power with Gasoline Engines ....................................... 39

2.10.4 Extrapolation of the Engine Power with Diesel Engines (Naturally Aspirated or

Supercharged) .................................................................................................................... 40

2.10.5 Extrapolation of the Engine Power with Turbodiesel Engines ................................... 41

2.10.6 Calculate Engine Factor fm ..................................................................................... 42

2.10.7 4 Wheel Drive Operation ......................................................................................... 43

3.1 Special Safety Instructions for the SINAMICS Components .................................... 44

3.2 Mains Connection for Booksize Drive Assembly ...................................................... 45

3.3 Basic Setup ........................................................................................................... 46

6.1 Requirements for the Place of Installation ............................................................... 47

6.2 Safety Measures .................................................................................................... 47

6.2.1 Heat Balance ......................................................................................................... 47

6.2.2 Exhaust Suction System ......................................................................................... 49

6.2.3 Fresh Air Supply for the Test Room ........................................................................ 50

7.1 System Requirements ............................................................................................ 51

7.2 Starting the Setup .................................................................................................. 51

7.3 Selecting the Setup Language ................................................................................ 52

7.4 Selecting the Destination Folder ............................................................................. 53

7.5 Selecting the SQL Server ....................................................................................... 53

7.6 Selecting the Dyno Type......................................................................................... 54

7.7 Selecting Features .................................................................................................. 54

7.8 Installing Drivers ..................................................................................................... 55

7.9 Finishing the Setup ................................................................................................. 55

7.10 Additional Settings under Windows 7 or higher ....................................................... 56

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Program Structure ............................................................................................. 63

Measurements ................................................................................................... 69

8.1 Switch on the Dyno ................................................................................................ 59

8.2 Drive onto Dyno and Secure Vehicle ....................................................................... 59

8.3 Connect the RPM Sensor ....................................................................................... 60

8.4 Connect Oil Temperature Probe ............................................................................. 61

8.5 Attach Exhaust Suction System .............................................................................. 61

8.6 Position Cooling Air Fan ......................................................................................... 61

8.7 Bring the Vehicle up to Operating Temperature ...................................................... 62

8.8 Vehicle Ready for Testing ....................................................................................... 62

8.9 Exit the Dynamometer ............................................................................................ 62

9.1 General Information ................................................................................................ 63

9.2 Tree Model ............................................................................................................. 64

9.3 Screen Design ........................................................................................................ 65

9.3.1 Status Line ............................................................................................................. 65

9.3.2 Main Screen ........................................................................................................... 67

9.3.3 Button Bar ............................................................................................................. 67

9.4 Starting the Program .............................................................................................. 68

9.5 End Program / Switch off Dyno .............................................................................. 68

10.1 Load Simulation ..................................................................................................... 69

10.1.1 Identical Functions ................................................................................................. 69

10.1.2 Constant Traction................................................................................................... 74

10.1.3 Constant Speed ..................................................................................................... 76

10.1.4 Driving Simulation ................................................................................................... 77

10.1.5 Constant Engine RPM ............................................................................................ 79

10.1.6 Standstill ................................................................................................................ 79

10.1.7 Drive Dyno ............................................................................................................. 80

10.2 Measure Engine Power .......................................................................................... 80

10.2.1 Display Last Measurement ..................................................................................... 80

10.2.2 Continuous Measurement ...................................................................................... 81

10.2.3 Discrete Measurement ........................................................................................... 84

10.3 Engine Flexibility Test ............................................................................................. 86

10.4 Speedometer Check .............................................................................................. 87

10.4.1 Vehicle Speed ........................................................................................................ 87

10.4.2 Mileage .................................................................................................................. 89

10.5 Load Adaption (Optional) ........................................................................................ 89

10.5.1 Coefficient Adaption based on ECE ........................................................................ 90

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Settings ............................................................................................................. 93

Diagnosis / Service ........................................................................................... 112

Maintenance .................................................................................................... 117

10.5.2 Coefficient Adaption based on SAE J2264 ............................................................. 91

10.6 Lug-Down Test (Option) ......................................................................................... 92

11.1 Database ............................................................................................................... 93

11.1.1 Identical Functions ................................................................................................. 93

11.1.2 Performance Curves .............................................................................................. 96

11.1.3 Time Diagram ....................................................................................................... 100

11.1.4 Vehicle Data ......................................................................................................... 101

11.1.5 Load simulation profile.......................................................................................... 102

11.1.6 Driving Cycle Data ................................................................................................ 104

11.2 Vehicle Data ......................................................................................................... 105

11.3 RPM Setting ......................................................................................................... 106

11.3.1 Driving Trial .......................................................................................................... 107

11.4 Special Settings ................................................................................................... 108

11.5 Select Dyno Type ................................................................................................. 109

11.6 Units .................................................................................................................... 109

11.7 Language ............................................................................................................. 110

11.8 Device / Interfaces................................................................................................ 110

11.8.1 OBD Settings (Optional) ....................................................................................... 111

12.1 Dyno Status ......................................................................................................... 112

12.2 Driver’s Aid Setup (Optional) ................................................................................. 112

12.2.1 Test Driving Cycle ................................................................................................ 113

12.2.2 Edit Profile ............................................................................................................ 114

12.2.3 New Profile........................................................................................................... 114

12.2.4 Delete Profile ........................................................................................................ 115

12.3 Backup/Restore Database ................................................................................... 115

12.3.1 Backup Database ................................................................................................ 115

12.3.2 Restore Database ................................................................................................ 115

12.3.3 Delete Table ......................................................................................................... 116

12.3.4 Delete Database ................................................................................................... 116

13.1 Important Information ........................................................................................... 117

13.2 Annual Inspection ................................................................................................. 117

13.3 Maintenance by the Operator ............................................................................... 117

13.3.1 Roller Set ............................................................................................................. 117

13.3.2 Eddy Current Brake .............................................................................................. 117

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Dismantling ...................................................................................................... 119

Disposal .......................................................................................................... 119

Diagnosis of SINAMICS Components ................................................................ 120

Company Information ....................................................................................... 125

13.3.3 Bearing Positions ................................................................................................. 118

13.4 Troubleshooting ................................................................................................... 118

13.5 Care Instructions .................................................................................................. 119

13.6 Spare Parts .......................................................................................................... 119

16.1 LEDs after the Control Unit has booted ................................................................ 120

16.2 Smart Line Module 16kW and 36kW .................................................................... 122

16.3 Single Motor Module / Double Motor Module ....................................................... 123

16.4 Sensor Module Cabinet 30 (SMC30) .................................................................... 124

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Safety

1.1

Introduction

1.2

Symbols

1.3

Intended Use

1.4

Safety Instructions for Commissioning

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Thoroughly read this manual before operating the equipment and comply with the instructions. Always display the manual in a conspicuous location.

Personal injury and property damage incurred due to non-compliance with these safety

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instructions are not covered by the product liability regulations.

Important safety instructions. Failure to comply with instructions could result in personal injury or property damage.

Important information.

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This dynamometer is to be used exclusively for the performance testing of motor vehicles. It is not suitable for brake testing or noise detection. Observe the rated axle load.

The equipment may not be modified without the express written consent of the manufacturer. In

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case of non-compliance the declaration of conformity becomes void.

Any use other than described is inappropriate.

• Only authorized service technicians may install and commission the test stand.

• The test stand may not be installed and operated in fire-endangered operation facilities, outside

or in damp rooms (e.g. wash halls).

• Mount components of the vehicle fixing unit in advance on a suitable lift on the test stand.

• Warning stickers must be attached by the operator:

– Hearing damage due to high noise level. Wear hearing protection. – Severe eye injuries due to flying particles. Wear protective goggles! Operator is responsible.

• Wear personal protective clothing as required or as regulated by law. The personal protective

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clothing must meet the safety-technical regulations for the respective work application.

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1.5

Safety Instructions for Operation

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• The dynamometer may only be used and operated exclusively for its intended purpose and only

within its performance limits.

• The dynamometer may only be operated by trained personnel. Dynamometer and working area

must be kept clean.

• The dynamometer may only be operated by persons who are physically and mentally fit. These

persons should be well rested and not under the influence of alcohol, drugs or medication.

• When not in use the system must be switched off and the main switch protected against re-

start.

• No persons may be in the danger zone of the dynamometer. Rotating or moving parts are dan-

gerous.

• Pay close attention to accident prevention regulations.

• Never climb on roller sets and lifting bar even when locked.

• Avoid unnecessary strain on vehicle and test stand. Drive the vehicle slowly onto the test stand.

• Damage to low lying vehicles is not covered by the warranty.

• Regularly check the tightness of the cover plate attachment screws.

• No persons may be in the pit with dynamometers in conjunction with a working pit while a vehi-

cle with rotating wheels is on the roller set.

• Wear personal protective clothing. If necessary wear protective goggles. Particles ejected from

rotating vehicle wheels can cause severe injuries. Wear tightly fitting working clothes and bind long hair together. Clothing or hair can get caught and pulled into machinery.

• Danger of hearing damage due to high noise level! Use hearing protection approved up to

120 dB(A). Noise levels over 110 dB(A) can be reached during vehicle testing. The operator is responsible for determining the noise level in vehicle and test room. When necessary, wear suitable hearing protection. The operator must attach warning stickers.

• Danger of carbon monoxide poisoning by poisonous vehicle exhaust. The test stand may only

be operated if the room in which the test stand is installed has sufficient exhaust suction and ventilation including the appropriate warning system.

• Avoid steering movement during the vehicle test. These cause certain forces to act on the vehi-

cle fixing in particular on the attachment units on the test vehicle. Vehicle doors and windows must be closed during the test drive.

• Before exiting the vehicle, put the vehicle into idle and/or put the gear to NEUTRAL. If neces-

sary decelerate the vehicle in a controlled manner avoiding steering movements. Wait until vehicle and rollers have stopped moving before exiting the vehicle. Danger of body parts and clothing being pulled into rotating rollers and vehicle wheels.

• Keep dyno surface clean and dry. Danger of slipping when surface is wet, oily or icy! Do not

place any objects (tools, material etc.) on the dynamometer. Wear protective shoes with antislip soles and steel toe caps to avoid slipping and mechanical injuries. Parts which protrude more than 20 mm out of the floor are to be marked with black-yellow tape.

• In addition to the danger zone, the operator is responsible for confining the area of the test

room in which no persons are allowed during testing with a safety catch device or a cell wall. Mark the danger zone (roller width + 1100 mm) on both sides behind the vehicle up to cell wall/safety catch device.

• Danger of accident due to vehicle fixing fracturing! Do a visual check for damage to the vehicle

fixing before each use. Never start the test operation without suitable and correctly installed vehicle fixing. Lower lifting bar before fixing the vehicle. Fix the test vehicle at the back and front side to the dynamometer and secure against lateral break out and swinging movements. The vehicle fixing must be adjusted to the vehicle being tested and may only be used within its stat-

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1.6

Safety Instructions for Servicing

ed purpose and performance limits. Installation of the vehicle fixing exclusively by skilled, trained personell. Inspect attachment units on the test vehicle for strength. Pay attention to manufacturer’s information and/or load capacity. Pull on the parking brake and raise the lifting bar before removing the vehicle fixing. The use of unsuitable vehicle fixing, in particular external vehicle

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fixing increases the danger of injuries and can impair safety.

• Service work may only be carried out by authorized service technicians.

• The operating mode selection switch must be put in the correct position with repair, mainte-

nance and set-up work. Remove the key to protect against unauthorized usage.

• The safety devices must be set by authorized service technicians.

• The safety devices may not be replaced or circumvented.

• Wear tight-fitting safety gloves when doing setup work to reduce the danger of pinching. Wear

a protective helmet when doing service work in the test stand pit to avoid impact injuries.

• Life-threatening electrical voltage! Only authorized electricians are allowed to work on the

electrical parts of the equipment based on valid electro-technical rules and guidelines. Before doing any work on the test stand electrics switch off all voltage and secure against re-starting. Test for absence of voltage! Cabinet contains components with storage charge. After switching off all voltages life-threatening voltage can still be present for at least 5 minutes! Check for discharge before starting work! Lock circuit box and store key securely. Hand out key only if needed to authorized electricians.

• Errors and deviations from normal operating conditions are to be inspected only by trained skil-

led workers who are authorized to do this kind of work. Circuits which are fed by an uninterruptible power supply are still under voltage even after the test stand has been switched off from the mains connection. The control has circuits which are tapped before the mains disconnection device of the test stand and are not voltage-free after switch off using the mains disconnection. All equipment which are connected before the mains disconnection device are wired with the colors YELLOW or ORANGE. Pay attention to calibration instructions.

• Use suitable lifting device with sufficient load capacity to open heavy test stand components.

The heaviest components can weigh up to 300 kg. Removal only by qualified skilled personnel. Adhere to all valid safety regulations and relevant work protection guidelines. Lift test stand components only on the designated lifting points.

• Use suitable lifting device with sufficient load capacity for removal and transport of heavy test

stand components. The heaviest components can weigh up to 300 kg. Removal and transport only by qualified skilled personnel. Adhere to all valid safety regulations and relevant work pro-

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tection guidelines. Lift test stand components only on the designated lifting points.

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1.7

Danger Zone

1.8

Safety Information about Tires

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During dynamometer operation no persons are allowed to stay in the danger zone. See illustration

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for minimum distance.

MSR 500 MSR 500 4WD

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MSR 800 MSR 1000 4WD

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• Check tire pressure and do a visual check of the tires for any signs of damage.

• To avoid tire damage we recommend that test tires be used during the performance test.

• No vehicles should be tested which have snow tires, racing tires or retreaded tires!

• Pay attention that the fastest permissible speed for the tires is not exceeded!

• Check the alignment weights on the rims to make sure they are tight before testing.

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1.9

Safety Information about the Eddy Current Brake

1.10

Safety Features

Lockable Main Switch

Pit Safety (optional)

Warning and Information Labels

1.11

Accessories

1.12

What to Do in the Event of an Accident

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• Pay attention to tire size! No test should be done with tires under 12”!

The eddy current brake can heat up significantly during long lasting usage. The brake rotors may become red hot. After a long lasting measurement under load, the eddy current brake should continue to be rotated without load by the vehicle at a speed of approx. 50 – 80 km/h. The rotating rotors suck cooled air from the side and throw it radially off. The eddy current brake is

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thereby effectively cooled preventing heat build-up at the rotors damaging the coil insulation.

The safety features must be checked regularly by an authorized service technician. Pay attention to statutory requirements. The dyno shall not be operated with defective safety features.

Serves as a normal On and Off switch and as an emergency switch. The switch can be protected against unauthorized usage by locking with a padlock.

Light barrier or infrared movement sensor. Issues audible and visual signals in the event that persons are in the working pit.

Warning and information labels are attached to the dyno. The labels shall not be changed or removed. Defective warning and information labels must be replaced.

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The equipment shall be operated only with accessories which have been approved or permitted by

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MAHA.

• The injured person is to be removed from the danger area. Find out where dressing and band-

ages are kept. Seek first-aid.

• Provide first-aid (stop bleeding, immobilise injured limbs), report the accident and seal off the

accident site.

• Immediately report any accident to your supervisor. Make sure a record is kept of every occa-

sion first-aid is provided, e.g. in an accident book.

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• Remain calm and answer any questions that may arise.

BA053101-en

Description

2.1

General Information

RPM module

Environmental module

Analog module

OBD module

Pressure/Temperature module

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Pos: 38 /Techn ische Dok ument atio n/Le istun gsmess tec hnik/ PO WERDYN O/0 5310 1 MS R/BA/I nha lt: 0 531 Bes chr eibun g Al lgem eines @ 14\mod_1241595173293_75.docx @ 371141 @ @ 1

The single roller dynamometer MSR consists of:

• A communication desk with PC, monitor, keyboard and wheel mouse (depending on ver-

sion)

• A remote control

• One or two roller sets

Optionally available are:

• A cooling air fan which is connected to the communication desk and is operated via the radio

remote control.

• An interface box via which the following modules can be connected:

Acquisition of engine RPM via Trigger tongs (Otto engine), Piezo clamp sensor (Diesel engine), TDC-sensor (manufacturer-specific, upon request), Diagnostic plug (manufacturer-specific, upon request), Oil temperature probe (up to max. 180°C) and much more.

Acquisition of ambient temperature, intake air temperature, air pressure and humidity, fuel temperature

Acquisition of analog signals

Aquisition of OBD data

Recording of 2 temperatures and 2 pressures each

• To determine performance data of DIN 70020, EWG 80/1269, ISO 1585, SAE J1349 or JIS

D1001 a barometer and a humidity sensor are installed in the interface box (Graphic package is

(*)

prerequisite)

• MAHA emission testers, gasoline (MGT5) and diesel (MDO2 and MDO2 LON) which can be

connected to the dyno

• DIN A4 ink jet printer, color

• Fuel consumption device for gasoline and diesel engines. (Krupp/AIC)

• Analog output card to process measured variables as analog signal

(e.g. display of issued variables on an external analog instrument

(*) These options are not connected to the interface box but separately on the dyno.

Pos: 39 /-----For ma t-----/MA N UEL LER UMB RUC H Se ite num br uch @ 0\m od_1134403577687_0.docx @ 1277 @ @ 1

(*)

BA053101-en

2.2

Specifications

2.2.1

Dimensions

MSR 500

Pos: 40 /Technische Dokument ation/Alle Gerät e/Übersc hriften/Üb erschriften 1. 1/T/Übers chrift 1.1: Technis che Daten @ 7\mod _1 184075526343_75.docx @ 99711 @ 2 @ 1

Pos: 41 /Technische Dokument ation/Alle Gerät e/Übersc hriften/Üb erschriften 1. 1.1/A/Übers chrift 1.1.1 : Abmessunge n @ 14\mod_1241595523910_75.docx @ 371167 @ 3 @ 1

Pos: 42 /Technische Dokume ntatio n/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 Abmessungen (Bilder) MSR 500 @ 23\mod_12983 909 220 89_0.d ocx @ 978 971 @ @ 1

Pos: 43 /Tec hn isch e Dokumentation/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 Abmessungen (Bilder) MSR 1000 @ 14\mod_1241595624149_0.docx @ 371193 @ @ 1

BA053101-en

MSR 1000

Pos: 44 /Technische Dokument ation/Alle Gerät e/Übersc hriften/Üb erschriften 1. 1.1/K/Über schrift 1. 1.1: Komm un ika tions pu lt @ 13\m od_1 23417 52964 30_7 5.docx @ 3354 86 @ 3 @ 1

BA053101-en

2.2.2

Communication Desk

Pos: 45 /Techn ische Dok ument atio n/Le istun gsmess tec hnik/ PO WERDYN O/0 5310 1 MS R/BA/I nha lt: 0 531 K ommun ika tions pult ( Bild er) @ 23\mod_1296722871974_0.docx @ 969333 @ @ 1

Pos: 46 /Techn ische Dok ument atio n/Le istun gsmess tec hnik/ PO WERDYNO/053101 MSR/BA/Inhalt: 0531 Kommunikationspult (Text) @ 23\mod_1297151385424_75.docx @ 971753 @ @ 1

Communication desk, Version A .................................................................... 670 x 1400 x 800 mm

Pos: 47 /-----For mat -----/MAN UE LLE R UM BR UCH Se iten umb ruc h @ 0\mod_1134403577687_0.docx @ 1277 @ @ 1

Communication desk, Version B (available from March 2011) ........................ 350 x 1230 x 860 mm

BA053101-en

2.2.3

MSR 500/1

1-Axle Roller Set with 1 Eddy Current Brake and 1 Electric Motor

Pos: 48 /Technische Dokume ntatio n/Alle Geräte/ Übersc hriften/ Überschr iften 1.1. 1/M/Über schrift 1.1.1: MSR 5 00/1 @ 24\m od_13 05615 9950 73_0.d ocx @ 1 00740 1 @ 3 @ 1

Pos: 49 /Tec hn isch e Do kum ent atio n/Le ist un gsmes s techn ik/ PO WER DYNO /05 310 1 MS R/B A/In ha lt: 0 531 MSR 5 00/1 ( Bi ld) @ 23\ mod_1296463645669_0.docx @ 968263 @ @ 1

Pos: 50 /Techn ische Dok ument atio n/Le istun gsmess tec hnik/ PO WERDYN O/0 5310 1 MS R/BA /In ha lt: 0 531 MSR 500/ 1 ( Tex t) @ 22\m od_1295432174832_75.docx @ 963400 @ @ 1

Roller diameter 504 mm / 20"

Rolling circumference 1583 mm

Roller length 750 mm

Track width (min….max.) 700…2200 mm

Roller wall thickness 12 mm

Total weight of Roller set 1630 kg

Mech. inertia weight approx. 280 kg

Permissible axle load 2500 kg

Maximum speed 300 km/h

Motor power 22 kW

Wheel power stat. / dyn. 260 / 1000 kW

Const. tractive force 7000 N

Fuse with / without drive 63 / 16 A

Supply voltage 3 x 400 + N + PE

Pos: 51 /Technische Dokume ntatio n/Alle Geräte/ Übersc hriften/ Überschr iften 1.1. 1/M/Über schrift 1.1.1: MSR 5 00/2 @ 24\m od_13 05616 1336 11_0.d ocx @ 1 00743 1 @ 3 @ 1

BA053101-en

2.2.4

MSR 500/2

1-Axle Roller Set with 2 Eddy Current Brakes and 1 Electric Motor

Pos: 52 /Tec hn isch e Do kum ent atio n/Le ist un gsmes s techn ik/ PO WER DYNO /05 310 1 MS R/B A/In ha lt: 0 531 MSR 5 00/2 ( Bi ld) @ 23\ mod_1296464800590_0.docx @ 968323 @ @ 1

Pos: 53 /Techn ische Dok ument atio n/Le istun gsmess tec hnik/ PO WERDYN O/0 5310 1 MS R/BA/ In halt: 0 531 MSR 500/ 2 ( Tex t) @ 22\m od_1295432706059_75.docx @ 963460 @ @ 1

Roller diameter 504 mm / 20"

Rolling circumference 1583 mm

Roller length 750 mm

Track width (min….max.) 700…2200 mm

Roller wall thickness 12 mm

Total weight of Roller set 1940 kg

Mech. inertia weight approx. 305 kg

Permissible axle load 2500 kg

Maximum speed 300 km/h

Motor power 22 kW

Wheel power stat. / dyn. approx. 520 / 2000 kW (Peak)

Tractive force approx. 14000 N

Fuse with / without drive 63 / 40 A

Supply voltage 3 x 400 + N + PE

Pos: 54 /-----For ma t-----/MA N UEL LER UMB RUC H Se ite num br uch @ 0\m od_1134403577687_0.docx @ 1277 @ @ 1

BA053101-en

2.2.5

MSR 500/2 4WD

4WD with 1 Eddy Current Brake and 1 Electric Motor per Axle

Pos: 55 /Technische Dokume ntatio n/Alle Geräte/ Übersc hriften/ Überschr iften 1.1. 1/M/Über schrift 1.1.1: MSR 5 00/2 4WD @ 24\mod_1305616199956_0.docx @ 1007461 @ 3 @ 1

Pos: 56 /Tec hn isch e Do kum ent atio n/Le ist un gsmes s techn ik/ PO WER DYNO /05 310 1 MS R/B A/In ha lt: 0 531 MSR 5 00/2 4W D (B ild) @ 23\m od_1296464625288_0.docx @ 968293 @ @ 1

Pos: 57 /Tec hn isch e Do kum ent atio n/Le ist un gsmes s techn ik/ PO WER DYNO /05 310 1 MS R/B A/In ha lt: 0 531 MSR 5 00/2 4W D (Tex t) @ 22\mod_1295435416655_75.docx @ 963520 @ @ 1

Roller diameter 504 mm / 20"

Rolling circumference 1583 mm

Roller length 750 mm

Track width (min….max.) 700…2200 mm

Roller wall thickness 12 mm

Total weight of Roller set 4130 kg

Mech. inertia weight 2 x 280 kg

Permissible axle load 2500 kg

Maximum speed 300 km/h

Maximum speed of a tracked, non-driven axle approx. 200 km/h

Motor power 2 x 22 kW

Wheel power Front axle stat. / dyn. 260 / 1000 kW (Peak)

Wheel power Rear axle stat. / dyn. 260 / 1000 kW (Peak)

Tractive force Front axle approx. 7000 N

Fuse 63 A

Supply voltage 3 x 400 + N + PE

Pos: 58 /Technische Dokume ntatio n/Alle Geräte/ Übersc hriften/ Überschr iften 1.1. 1/M/Über schrift 1.1.1: MSR 500/3 4WD @ 24\mod_1305616255864_0.docx @ 1007491 @ 3 @ 1

BA053101-en

2.2.6

MSR 500/3 4WD

4WD with 1 Eddy Current Brake FA, 2 Eddy Current Brakes RA, 1 Electric Motor per Axle

Pos: 59 /Tec hn isch e Do kum ent atio n/Le ist un gsmes s techn ik/ PO WER DYNO /05 310 1 MS R/B A/In ha lt: 0 531 MSR 5 00/3 4W D (B ild) @ 23\mod_1296464996919_0.docx @ 968353 @ @ 1

Pos: 60 /Tec hn isch e Do kum ent atio n/Le ist un gsmes s techn ik/ PO WER DYNO /05 310 1 MS R/B A/In ha lt: 0 531 MSR 5 00/3 4W D (Tex t) @ 22\mod_1295435803655_75.docx @ 963580 @ @ 1

Roller diameter 504 mm / 20"

Rolling circumference 1583 mm

Roller length 750 mm

Track width (min….max.) 700…2200 mm

Roller wall thickness 12 mm

Total weight of Roller set 4395 kg

Mech. inertia weight 1 x 280 kg / 1 x 305 kg

Permissible axle load 2500 kg

Maximum speed 300 km/h

Maximum speed of a tracked, non-driven axle approx. 200 km/h

Motor power 2 x 22 kW

Wheel power Front axle stat. / dyn. 260 / 1000 kW (Peak)

Wheel power Rear axle stat. / dyn. 520 / 1000 kW (Peak)

Tractive force Front axle approx. 7000 N

Tractive force Front axle approx. 14000 N

Fuse 63 A

Supply voltage 3 x 400 + N + PE

Pos: 61 /-----For ma t-----/MA N UEL LER UMB RUC H Se ite num br uch @ 0\m od_1134403577687_0.docx @ 1277 @ @ 1

BA053101-en

2.2.7

MSR 800

1-Axle Roller Set

Pos: 62 /Technische Dokume ntatio n/Alle Geräte/ Übersc hriften/ Überschr iften 1.1. 1/M/Über schrift 1.1.1: MSR 8 00 @ 24\mod_1306494127905_0.docx @ 1013813 @ 3 @ 1

Pos: 63 /Technische Dokumentation/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 MSR 800 (Bild) @ 23\mod_1298447556531_0.docx @ 9 790 71 @ @ 1

Pos: 64 /Technische Dokumentation/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 MSR 800 (Text) @ 14\mod_1241597479700_75.docx @ 371613 @ @ 1

Roller diameter 762 mm / 30"

Rolling circumference 2393 mm

Roller length 700 mm

Track width (min….max.) 900…2300 mm

Roller wall thickness 20 mm

Total weight of Roller set 1910 kg

Mech. inertia weight approx. 700 kg

Permissible axle load 2500 kg

Maximum speed > 300 km/h

Wheel power approx. 660 kW

Const. tractive force not available

Fuse 16 A

Pos: 65 /-----For ma t-----/MA N UEL LER UMB RUC H Se ite num br uch @ 0\m od_1134403577687_0.docx @ 1277 @ @ 1

BA053101-en

Supply voltage 230 V + N + PE

2.2.8

MSR 830

1-Axle Roller Set with 1 Eddy Current Brake

Pos: 66 /Technische Dokume ntatio n/Alle Geräte/ Übersc hriften/ Überschr iften 1.1. 1/M/Über schrift 1.1.1: MSR 8 30 @ 24\mod_1305616305111_0.docx @ 1007521 @ 3 @ 1

Pos: 67 /Technische Dokumentation/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 MSR 830 (Bild) @ 23\mod_12984482086 73_0.d ocx @ 979 137 @ @ 1

Pos: 68 /Technische Dokumentation/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 MSR 830 (Text) @ 14\mod_1241597837603_75.docx @ 371639 @ @ 1

Roller diameter 762 mm / 30"

Rolling circumference 2393 mm

Roller length 700 mm

Track width (min….max.) 900…2300 mm

Roller wall thickness 20 mm

Total weight of Roller set 2270 kg

Mech. inertia weight approx. 700 kg

Permissible axle load 2500 kg

Maximum speed > 300 km/h

Wheel power approx. 700 kW (Peak)

Tractive force approx. 8600 N

Fuse 20 A

Supply voltage 3 x 400 V + N + PE

Pos: 69 /-----For ma t-----/MA N UEL LER UMB RUC H Se ite num br uch @ 0\m od_1134403577687_0.docx @ 1277 @ @ 1

BA053101-en

2.2.9

MSR 850

1-Axle Roller Set with 2 Eddy Current Brakes

Pos: 70 /Tec hn isch e Do kumentatio n/Alle Geräte/ Überschrift en/Überschr iften 1.1. 1/M/Überschr ift 1.1.1: MSR 85 0 @ 24\mod_1306494212398_0.docx @ 1013843 @ 3 @ 1

Pos: 71 /Technische Dokumentation/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 MSR 850 (Bild) @ 23\mod_12984483036 66_ 0.d ocx @ 9 791 62 @ @ 1

Pos: 72 /Technische Dokumentation/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 MSR 850 (Text) @ 14\mod_1241598845809_75.docx @ 371695 @ @ 1

Roller diameter 762 mm / 30"

Rolling circumference 2393 mm

Roller length 700 mm

Track width (min….max.) 900…2300 mm

Roller wall thickness 20 mm

Total weight of Roller set 2630 kg

Mech. inertia weight approx. 750 kg

Permissible axle load 2500 kg

Maximum speed > 300 km/h

Wheel power approx. 1400 kW (Peak)

Tractive force approx. 17200 N

Fuse 40 A

Supply voltage 3 x 400 V + N + PE

Pos: 73 /-----For ma t-----/MA N UEL LER UMB RUC H Se ite num br uch @ 0\m od_1134403577687_0.docx @ 1277 @ @ 1

BA053101-en

2.2.10

MSR 1000

4WD with 1 Eddy Current Brake and 1 E-Machine per Axle

Pos: 74 /Technisch e Dok ument ation/Al le Gerät e/Über schrift en/Über schri ften 1. 1.1/M/ Überschr ift 1 .1.1: MSR 10 00 @ 24\ mod_1306493890113_0.docx @ 1013753 @ 3 @ 1

Pos: 75 /Techn ische Dok ument atio n/Le istun gsmess tec hnik/ PO WERDYN O/0 5310 1 MS R/BA/I nha lt: 0531 MSR 1000 (Bild) @ 23\mod_1298448477424_0.docx @ 979192 @ @ 1

Pos: 76 /Technische Dokumentation/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 MSR 1000 (Text) @ 14\mod_1241599234153_75.docx @ 371747 @ @ 1

Roller diameter 762 mm / 30"

Rolling circumference 2393 mm

Roller length 700 mm

Track width (min….max.) 900…2300 mm

Roller wall thickness 20 mm

Total weight of Roller set 5610 kg

Mech. inertia weight 2 x 700 kg

Permissible axle load 2500 kg

Maximum speed > 300 km/h

Maximum speed of a tracked, non-driven axle approx. 200 km/h

Motor power 2 x 30 kW

Wheel power Front axle approx. 700 kW (Peak)

Wheel power Rear axle approx. 700 kW (Peak)

Tractive force Front axle approx. 8600 N

Tractive force Rear axle approx. 8600 N

Fuse 63 A

Supply voltage 3 x 400 V

Pos: 77 /-----For ma t-----/MA N UEL LER UMB RUC H Se ite num br uch @ 0\m od_1134403577687_0.docx @ 1277 @ @ 1

BA053101-en

2.2.11

MSR 1050

4WD with 1 Eddy Current Brake FA, 2 Eddy Current Brakes RA, 1 Electric Motor per Axle

Pos: 78 /Technische Dokume ntatio n/Alle Geräte/ Übers ch rift en/ Über schr ift en 1.1. 1/M /Üb ersc hr ift 1 .1. 1: M SR 1 050 @ 2 4\mod_1306494009976_0.docx @ 1013783 @ 3 @ 1

Pos: 79 /Technische Dokumentation/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 MSR 1050 (Bild) @ 23\mod_1298448681304_0.docx @ 979222 @ @ 1

Pos: 80 /Technische Dokumentation/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 MSR 1050 (Text) @ 14\mod_1241599445142_75.docx @ 371773 @ @ 1

Roller diameter 762 mm / 30"

Rolling circumference 2393 mm

Roller length 700 mm

Track width (min….max.) 900…2300 mm

Roller wall thickness 20 mm

Total weight of Roller set 5970 kg

Mech. inertia weight 1 x approx. 700 kg / 1 x approx. 730 kg

Permissible axle load 2500 kg

Maximum speed > 300 km/h

Maximum speed of a tracked, non-driven axle approx. 200 km/h

Motor power 2 x 30 kW

Wheel power Front axle approx. 700 kW (Peak)

Wheel power Rear axle approx. 1400 kW (Peak)

Tractive force Front axle approx. 8600 N

Tractive force Rear axle approx. 17200 N

Fuse 63 A

Supply voltage 3 x 400 V + N + PE

Pos: 81 /-----For ma t-----/MA N UEL LER UMB RUC H Se ite num br uch @ 0\m od_1134403577687_0.docx @ 1277 @ @ 1

BA053101-en

2.3

Main Switch

2.4

Controls and Indicators

Operating Modes

Position 1: OPERATI-

Position 0: CALIBRA-

TION

Position 2:

SETUP

Pos: 82 /Technische Dok umentatio n/Alle Geräte/ Überschrift en/Überschr iften 1.1/H /Überschr ift 1.1: Hauptschal ter @ 6\mod_ 11775 92858 312_ 75.do cx @ 906 35 @ 2 @ 1

Pos: 83 /Technische Dokume ntatio n/Alle Geräte/ Inhalte/ Info!/I nhalt: I nfo - Hauptschalter @ 23\mod_1298624423518_75.docx @ 979863 @ @ 1

The main switch is located at the side wall of the communication desk.

Pos: 84 /Technische Dokume ntatio n/Alle Geräte/ Inhalte/ Inhal t: Haupts chalt er v1 - A lle Geräte @ 23\mod_1298376098685_75.docx @ 978845 @ @ 1

• Main switch in position 0: Power supply OFF

• Main switch in position 1: Power supply ON

• When in position 0, the main switch can be protected against tampering

by means of a padlock.

Pos: 85 /Technische Dokument ation/Alle Gerät e/Übersc hriften/Üb erschriften 1. 1/B/Übers chrift 1.1: Bedien - und Anz eigeelemen te @ 23\mod_ 12962 20301 443_ 75.do cx @ 9681 07 @ 2 @ 1

Pos: 86 /Technische Dokumentation/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 Bedien- und Anzeigeelemente (Bild) @ 24\m od_1305638503474_0.docx @ 1007773 @ @ 1

Pos: 87 /-----For ma t-----/MA NUEL LER UM BRUC H Zeile nscha ltun g @ 7\mod_ 1195 1389 65731_ 0.doc x @ 13217 7 @ @ 1

Pos: 88 /-----For ma t-----/MA NUEL LER UM BRUC H Zeile nscha ltun g @ 7\mod_ 1195 1389 65731_ 0.doc x @ 13217 7 @ @ 1

Pos: 89 /Techn ische Dok ument atio n/Le istun gsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 Bedien- und Anzeigeelemente (Text) @ 23\mod_1296549358503_75.docx @ 968523 @ @ 1

Locking Brake ON ON ON

Hydraulic System OFF OFF ON

Power Section of Eddy Current Brake

Motors/Converters ON OFF (Safety Stop) OFF (Safety Stop)

Operating Mode Selector Switch

Control ON/OFF

EMERGENCY STOP

ON OFF OFF

B C A D E F

OPERATION Indicator Lamp

SETUP Indicator Lamp

REMOTE CONTROL Indicator Lamp

Each time the operating mode is changed, the control is disabled and must be re-enabled using the Control ON button.

BA053101-en

Enabling / Disabling the Dynamometer

2.5

Emergency Stop

ON 1 Main switch ON. 2 Set operating mode selector switch to re-

3 Control ON.  Dyno is ready for operation.

Pos: 90 /Technische Dokume ntatio n/Alle Geräte/ Übersc hriften/ Überschr iften 1.1/N /Überschr ift 1 .1: No t-Ha lt @ 23\mod_1297171316373_75.docx @ 972449 @ 2 @ 1

Pos: 91 /Technische Dokumentation/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 Not-Halt (Bild) @ 24\mod_1305639886912_0.docx @ 1007804 @ @ 1

OFF 1 Control OFF. 2 Main switch OFF.

quired position.

 Dyno is shut down.

A B

Pos: 92 /Technische Dokumentation/Leistungsmesstechnik/POWERDYNO/053101 MSR/BA/Inhalt: 0531 Not-Halt (Text) @ 2 3\mod_1296551173826_75.docx @ 968643 @ @ 1

EMERGENCY STOP at Communication Desk

Push the mushroom button to enable the EMERGENCY STOP:

 Motor converters OFF  Power section of eddy current brake OFF  All outputs for hydraulic and pneumatic systems OFF

Pos: 93 /-----For ma t-----/MA N UEL LER UMB RUC H Se ite num br uch @ 0\m od_1134403577687_0.docx @ 1277 @ @ 1

 Program must be restarted

Portable EMERGENCY STOP for Motor-Driven Dynamometers

BA053101-en

2.6

Remote Control

PC Keyboard

1 2

4 5

6 7

Pos: 94 /Technische Dokument ation/Alle Gerät e/Übersc hriften/Üb erschriften 1. 1/F/Übers chrift 1.1: Fernbed ienung @ 7\mod_1184152042500_75.docx @ 99994 @ 2 @ 1

Pos: 95 /Tec hn isch e Do kum ent atio n/Le ist un gsmes s techn ik/ PO WER DYNO /05 230 1 L PS 30 00 R100/ BA /In hal t: 0 523 Fern bed ien ung ( Tex t) @ 13\m od_1234179191060_75.docx @ 335824 @ @ 1

The functions of the program can also be selected via the remote control. The remote control can be operated directly from the vehicle.

The signal is transmitted by radio. The receiving antenna for the signal is located in the desk. Should several dynos each with its own remote control be operated in one room, the remote

controls must be set to different channels. As soon as the remote control is switched on and radio connection to the dyno exists, the green

control lamp will light up permanently on the operation desk. The green control lamp will blink briefly each time a key is pressed.

When not in use the remote control should always be stored in the re-charging box to avoid a total discharging of the battery. The re-charging box is equipped with a "re-charge overload protection”. The re-charging time for a fully discharged battery is about 12 to 14 hours. During the re-charging procedure the red LED on the re-charging box will light up and "Battery recharging" appears on the display of the remote control.

To switch on the remote control press the ON key. The remote control has an automatic switch off (Timeout) which can be variably set. The remote control switches off when no key has been pressed during this time.

The letters on the remote control can be selected by pressing the SHIFT key. Press again to return to the normal operation mode. The display "SHIFT" appears in the window when the SHIFT key has been pressed.

Pos: 96 /Techn ische Dok ument atio n/Le istun gsmess tec hnik/ PO WERDYN O/0 523 01 L PS 300 0 R1 00/ BA/I nha lt: 052 3 Fer nbed ie nun g ( Tabe lle) @ 13\mod_1234943754775_75.docx @ 342981 @ @ 1

The remote control keyboard consists of two pads: Function key pad + Number pad.

Use this key to activate the lifting bar. It can then be operated with the cursor keys.

F3 + Cursor keys

Switch fan on / off F2

Deletes an entire line

Selection of a menu item (In combination with the function key F5 and the cursor keys target values can be increased or decreased in some menus.)

Confirmation of inputs Return

Deleting the character before the cursor position Discarding of inputs

Backspace

Switch over to letter mode

Connection for Pedal force sensor

In some menus special functions can be opened. The key assignments vary in the different menus. Four boxes with diverse functions are located on the lower screen edge in these menus. These options are select-

F5 to F8 ed with the function keys F5 to F8 on the remote control. If the button bar has further levels, these can be displayed using the cursor keys.

Use this key to activate the load simulator. It can then be operated with the cursor keys.

F4 + Cursor keys

Use this key to activate the roller set adjustment. It can then be operated with the cursor keys.

BA053101-en

Remote Control

PC Keyboard

Pos: 97 /Tec hn isch e Do kum ent atio n/Le ist un gsmes s techn ik/ PO WER DYNO /05 230 1 L PS 30 00 R100/ BA /In hal t: 0 523 Fern bed ien ung ( Bi ld) @ 13 \mod_1234876860125_0.docx @ 342615 @ @ 1

Switch on remote control

Exit a program part

Input of a comma

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BA053101-en

2.7

Description of the Interface Box

DRZ PTH OBD P2T2

A B D C H

E F I M L K J

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Pos: 100 /Te ch nisc he D ok umen tati on/ Leis tu ngsm ess tech ni k/PO WE RDYN O/0 523 01 L PS 3 000 R10 0/B A/ Inh alt: 052 3 Sc hni ttst elle nbox ( Text 1) @ 13\m od_1234179543447_75.docx @ 335902 @ @ 1

The Interface Box records engine RPM, environmental data, OBD data, temperature, pressure and analog signals. This is done via modules. A maximum of 4 modules can be installed in the interface box.

Additional modules can be installed in a second interface box which is connected parallel and, if desired, adapted to customer requirements.

As standard equipment, the interface box 1 has an RPM and an environmental module.

Dimensions (H x W x L) Weight

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approx. 120 x 170 x 160 mm approx. 1.0 kg

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BA053101-en

DRZ

PTH

OBD (Option)

P2T2 (Option)

Display the Interface Box Assignment

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Piezo clamp, TDC sensor Light barrier

Oil temperature probe

Trigger tongs

Fuel temperature

Intake air temperature

Atmospheric pressure

Humidity sensor

OBD

Pressure 1

Pressure 2

Temperature 1

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1 The assignment of the interface box appears using the keys <SHIFT> + <F1> . 2 Use <CONTINUE> or <RETURN> to exit this screen.

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Temperature 2

BA053101-en

2.7.1

RPM Module (Standard)

Trigger Tongs

(D)

Piezo Clamp

(A)

(B)

Clamp W

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The RPM module is used to record the RPM and oil temperature (Plug-in card CAN DRZ). The following RPM sensors/sources can be used:

The RPM signal is picked up at the ignition cable (spark plug or distributor ignition coil) with the trigger tongs. The trigger tongs should be placed as close as possible to the spark plug and as far as possible from the next ignition cable. The trigger tongs take up the high voltage signal inductively which is conducted from the distributor to any random cylinder. The pulse is relayed from the trigger tongs to the test box where it is converted to an RPM signal.

Attachment: Position

on the interface box.

Piezo clamp is only used with diesel engines. The piezo clamp consists of a piezo element which recognizes pressure differences at the lead-in and then converts them into electric pulses. It is important that the piezo clamp which is used is suitable for only one diameter of the fuel line and should only be placed at a straight section of the line at any cylinder (attach ground clamp on the same injection line).

Attachment: Position

on the interface box.

The alternator RPM is ascertained through the clamp W. The number of pulses per rotation at the alternator (proportional to the crank shaft RPM) should be known or must be determined by an external measuring device. This is necessary because individual vehicle models have different transmissions between crank shaft and alternator. The RPM determination at the clamp W is only used with diesel engine vehicles.

BA053101-en

TDC Sensor

(A)

(B)

Light Barrier

Notes on adjusting the engine rpm via the light barrier

two

(A)

(B)

Driving Trial

The TDC sensor is always manufacturer-specific, i.e. depending on the vehicle manufacturer the corresponding diagnostic plug is used for the RPM signal pick up.

The TDC sensor offers an extremely accurate

RPM measurement. Once f rot/min

is reached, an RPM of 12000

max

-1

is displayed.

The level must be between 30 mV and 30 V so that an RPM pulse is recognized

Attachment:

• Position

on the interface box.

The light barrier is used when no direct way of determining the RPM at the engine is possible. The transmission ratio to the engine RPM must be 1:1. If the light barrier is attached to the cardan shaft, the transmission ratio must be between 0.5 and 2. The light barrier must be positioned in such a way that via a reflector which is attached either to the vibration absorber, drive belt, or cardan shaft, the RPM can be picked up free of any interference (no vibration influence etc.).

When making adjustments in the lower rpm range (drive shaft rpm < 800), we recommend using

reflectors in order to double the number of impulses generated.

When doing so, please remember the following:

• The reflectors must be systematically placed around the engine, exactly opposite one another.

Prominent points on the engine housing can be used to position the reflectors.

• When entering the gear ratio you must also double the previous value.

Attachment: Position

on the interface box.

If none of the above mentioned alternatives is available for determining an RPM measurement, a driving trial can be used to do the same. The RPM is converted from the dyno roller speed.

BA053101-en

OBD Module

Oil Temperature Probe (Optional)

(C)

2.7.2

Environmental Module (Standard)

Fuel Temperature (Optional)

Intake Air Temperature

Ambient Temperature

At the beginning of a test a pre-determined RPM value must be approached ('Test gear' / Gear transmission close to 1:1) while in a specific gear. This RPM value will be stored.

During the performance test the software will convert the roller’s current RPM into engine RPM. (Please note: The calculated RPM will only correspond if the vehicle is driven in the 'test gear'.)

Automatic transmission vehicles without converter lockup cannot use the driving trial method, because the engine RPM deviates due to converter slip.

The RPM is read from the OBD data.

Driving trials should only be done when the engine is warmed up to operational temperature. The oil temperature meter is used to determine the oil temperature and to monitor it during the testing procedure.

Oil temperature probe for car and truck, with variable length (100 to 1500 mm), with plug and 6 m supply line.

Attachment: Position

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on the interface box.

The environomental module is used to record the environmental data (Plug-in card CAN PTH).

• Fuel temperature (Optional)

• Intake air temperature

• Ambient temperature

• Air pressure

• Humidity

The fuel temperature is recorded using the interface box and the fuel consumption device and and can be used as additional information for the fuel consumption measurement.

The intake air temperature is recorded using the interface box and is used for projection of the engine performance based on DIN 70020, EWG 80/1269, ISO 1585, SAE J1349 or JIS D1001.

The ambient temperature is recorded using the interface box.

BA053101-en

Air Pressure

Humidity

2.7.3

OBD Module (Optional)

(OBD)

2.7.4

Pressure/Temperature Module (Optional)

Pressure 1 + 2

Exhaust Gas Temperature

The air pressure is recorded using the interface box and is used for projection of the engine performance based on DIN 70020, EWG 80/1269, ISO 1585, SAE J1349 or JIS D1001.

The humidity is recorded using the interface box and is used for projection of the engine performance based on DIN 70020, EWG 80/1269, ISO 1585, SAE J1349 or JIS D1001.

The current air temperature , ambient pressure and relative humidity is included in the calculation with the given standards (DIN 70020, EWG 80/1269, ISO 1585, SAE J1349 and JIS D1001)

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The OBD module is used for recording the OBD data (Plug-in card CAN OBD Module). This OBD data is different depending on the vehicle manufacturer.

Attachment:

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• Position

on the interface box (see section

The pressure/temperature module is used to record 2 temperatures and 2 pressures (Plug-in card CAN P2T2).

Pressure 1 +2 is user specific. The test range stretches from– 0.9 to + 4.0 bar and can for example be used to determine the intake pressure, turbocharger pressure, etc.

The exhaust gas temperature is used as monitor check of the combustion process and to judge its quality.

The high temperature sensor consists. of a Ni-Cr-Ni thermo element with compensation line. The measurement range stretches from 0 to 1000 °C.

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"Description of the Interface Box"

BA053101-en

2.7.5

Analog Input Module (Optional)

2.8

Analog Output Card (Optional)

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The analog input module is used to record 4 analog signals (Plug-in card CAN AIN4).

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Measurement data from –10 V to +10 V or from –20 mA to +20 mA can be recorded.

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The analog output card (Plug-in card LON OUTA) is used for further processing of measured values as analog signals for an external device (e.g. analog display, digital display).

There are 4 analog outputs available from –10 V to +10 V.

The plug-in card LON OUTA is connected in the communication desk.

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BA053101-en

2.9

Measurement Programs

Load Simulation

Measure Engine Power

Extrapolation of the Engine Power (Optional)

Flexibility Test

Speedometer Test

Road Load Adaption (Optional)

Lug-Down Test (Optional)

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This dynamometer provides an exact simulation of defined road load conditions. Fuel consumption measurement and exhaust analysis, as well as serial monitoring of vehicles can

be carried out. The following operation modes can be selected for conducting the various measurement tasks:

•

The user can pre-select from various load conditions which make possible the determination of e.g. a specific engine diagnosis or vehicle climbing power. Depending upon need, various load conditions can be simulated such as constant traction, a constant speed, a constant RPM or a driving simulation.

•

Use this menu item to determine the vehicle’s engine power (continuous and discrete measurement).

•

Extrapolation of the engine power based on DIN 70020, EWG 80/1269, ISO 1585, JIS D 1001, SAE J 1349.

•

The engine flexibility can be checked using this menu item. Once the flexibility test has been called up the vehicle weight and road load must be entered as in the road load simulation test.

•

The vehicle’s speedometer can be tested using this menu item. The speed can be tested as well.

•

Various dyno coefficients can be determined using this menu item. The iterative coefficient adaption can be done based on ECE or SAE J2264 standard.

•

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Use this menu item to do a diesel exhaust measurement under full load.

BA053101-en

2.10

Calculation Basis

2.10.1

Road Load

m a

3,6

ref

Roll

2 ref

Flex

3 ref

Air

⋅+

⋅

⋅⋅

Air resistance power P-Air [kW]

v ) v (v A c 0,5 P

0FrontWAir

⋅+⋅⋅⋅⋅=

Flex power P-Flex [kW]

v g m P

wFlex

⋅⋅⋅=

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Equation

with

• v

• v Driving speed

• P

• a.m Vehicle mass

The air resistance power is proportional to the surface of the vehicle front and air resistance coefficient c

with e.g.

• Air density r (rho)

Reference speed for resistance performance values - normally 90 km/h.

ref

Air resistance performance [kW]

air

Flex performance [kW]

flex

Roll resistance performance [kW]

Roll

= 1.1 kg/m

• air resistance coefficient

• Front surface

(VEH-width x Height)

• Driving speed

• Head wind speed

results:

• P

= 0,5 · 1,1 · 0,38 · 2,5 · 252 · 25

air

Front

v = 90 km/h = 25 m/s

= 0.38

= 1.7 m · 1.47m = 2.5 m2

= 0 m/s

= 8.164 kW at 90 km/h

Flex power or resistance is defined as the power loss which occurs due to the flexing of the tire on the road surface and/or roller.

Generally speaking the flex power does not have a relevant influence on the test results due to the minimal flex resistance coefficient.

BA053101-en

Roller Resistance Power P-Roll [kW]

rRoll

⋅⋅

⋅

Mass m = Vehicle mass [kg]

[N] a m F ⋅=

2.10.2

Torque

[U/min]

9549 [kW] P

⋅

The rolling resistance power arises from tire and road surface deformation as a function of speed:

with e.g.

• Roll resistance coefficient of the tires

• Vehicle mass

• Gravitation constant

• Driving speed

= 0.012

m = 950 kg

g = 9.81 m/s

v = 90 km/h = 25 m/s

the result is:

• P

= 0.012 · 950 · 9.81 · 25

Roll

= 2.79 kW

Since this value only represents a small fraction of the total Road Load it is entered as a fixed standard value on our dynamometers: for steel belted radial tires approx. 2.5 kW, for winter tires approx. 3.75 kW.

Setting of the vehicle mass, the aerodynamic drag power and the rolling resistance power is absolutely necessary for Road Load simulation and stop watch tests, in order to simulate the vehicle under the correct Road Loads.

This value is needed in order to attain a proportional traction F via the eddy-current brake from the vehicle determined acceleration.

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Equation

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BA053101-en

2.10.3

Extrapolation of the Engine Power with Gasoline Engines

⇒

293

[K] T

[mbar]

1013

 



 



⋅

⇒

[

]

6,0

1,2

298

[K]

mbarp

990

 



 



⋅



 





 



⇒

[ ]

6,0

1,2

298

[K] T

mbarp

990

 



 



⋅



 





 



⇒

[ ]

6,0

1,2

298

[K] T

mbarp

990

 



 



⋅



 





 



⇒

[ ]

6,0

1,2

298

[K] T

mbarp

990

 



 



⋅



 





 



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• DIN 70020

• EEC 80/1269

• ISO 1585

• SAE J1349

• JIS D1001

with

• Ka correction factor

• p Atmospheric pressure at the dyno in mbar (1 mbar = 0.001 bar)

• T Air temperature at the dyno in Kelvin (0°C = 273 K)

e.g.

• ambient air pressure p = 936 mbar

• ambient temperature T = 17°C = 290K

• based on DIN 70200 the result is: Ka = 1.07671

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BA053101-en

2.10.4

Extrapolation of the Engine Power with Diesel Engines (Naturally Aspirated or Supercharged)

⇒

[ ]

5,0

293

[K] T

mbarp

1013

 



 



⋅=

⇒

[ ]



 





 



 



 



⋅=

7,0

298

[K] T

mbarp

990

⇒

[ ]



 





 



 



 



⋅=

7,0

298

[K] T

mbarp

990

⇒

[ ]



 





 



 



 



⋅=

7,0

298

[K] T

mbarp

990

⇒

[

]



 





 



 



 



⋅=

7,0

298

[K]

mbarp

990

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• DIN 70020

• EEC 80/1269

• ISO 1585

• SAE J1349

• JIS D1001

with

• fm Engine factor (Standard = 0.3)

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BA053101-en

2.10.5

Extrapolation of the Engine Power with Turbodiesel Engines

⇒

[ ]

5,0

293

[K] T

mbarp

1013

 



 



⋅=

⇒

[ ]



 





 



 



 



⋅



 





 



5,1

0,7

298

[K] T

mbarp

990

⇒

[ ]



 





 



 



 



⋅



 





 



2,1

0,7

298

[K] T

mbarp

990

⇒

[ ]



 





 



 



 



⋅



 





 



5,1

0,7

298

[K] T

mbar

990

⇒

[ ]



 





 



 



 



⋅



 





 



5,1

0,7

298

[K] T

mbarp

990

⇒

[ ]



 





 



 



 



⋅



 





 



7,0

0,7

298

[K]

mbar

990

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• DIN 70020

• EEC 80/1269

• ISO 1585

• SAE J1349

• JIS D1001

with fm Engine factor (Standard = 0.3)

The extrapolation formula for Turbodiesel engines in the ISO 1585 only applies to air cooled charge-air coolers. The following equation applies to water cooled charge-air coolers:

• ISO 1585

(water cooled)

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BA053101-en

2.10.6

Calculate Engine Factor fm

652,37 ≤≤

14,1.036,0 −=

2,37<

2,0=fm

65>

6540

≤≤

14,1

.036,

0 −=

3,0=fm

65>

2,1=fm

r =

q⋅= .120000

q⋅= .60000

Pos: 143 /Technische Dokum entati on/Alle G eräte/ Übers chrifte n/Über schrifte n 1.1.1/M /Üb erschr ift 1. 1.1: Mot orfak tor fm be rechne n @ 13\mod_1234268542057_75.docx @ 337401 @ 3 @ 1

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In most cases fm = 0.3 applies but this value can be changed. The following equations are used:

Engine factor fm based on ISO 1585:

Engine factor fm based on EWG 80/1269, SAE J1349 and JIS D1001:

Pressure behavior of the supercharging:

Specific fuel consumption based on SAE J1349:

4-Takt Motoren

2-Takt Motoren

with

• fm Engine factor

• r Pressure behavior of the supercharging

• q Specific fuel consumption based on SAE J1349

Absolute boost pressure

• p

Absolute pressure in front of the compressor

• p

• F Fuel flow (mg/s)

• D Cubic capacity volume

• n Engine RPM

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BA053101-en

2.10.7

4 Wheel Drive Operation

Traction Regulation

h-Stv-St

v-St

⋅

n n

h-Stv-St

h-St

⋅

RPM Regulation

n n

h-Stv-St

v-St

⋅

n n

h-Stv-St

h-St

⋅

Road Load Simulation

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The traction target value is divided in the front and rear as a function of the support roller RPM.

with

• Fx

• n

• Fx

The variable (control of the eddy current brake) is divided between the front and rear axle. This happens again as a function of the support roller RPM.

Traction front

Traction rear

Support roller RPM front

St-v

Support roller RPM rear

St-h

Traction total

with

• y

• n

• y

Variable front

Variable rear

Support roller RPM front

St-v

Support roller RPM rear

St-h

Variable total

The traction target value which is calculated from the individual Road Loads, is divided between

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the front and rear axle as with the normal traction regulation.

BA053101-en

Description of the SINAMICS Components

3.1

Special Safety Instructions for the SINAMICS Components

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Commissioning shall not start until you have ensured that the machine in which the components described here are to be installed complies with Directive 2006/42/EC.

SINAMICS S equipment must only be commissioned by suitably qualified personnel. The personnel must take into account the information provided in the technical customer docu-

mentation for the product, and be familiar with and observe the specified danger and warning notices.

When electrical equipment and motors are operated, the electrical circuits automatically conduct a dangerous voltage.

Dangerous mechanical movements may occur in the system during operation. All work on the electrical system must be performed after the system has been switched off and

disconnected from the power supply. SINAMICS S equipment with three-phase motors may only be connected to the line system via

residual current devices (RCDs) if compatibility of the SINAMICS equipment with the RCD has been ensured as specified in EN 50178, Subsection 5.2.11.2.

Correct and safe operation of SINAMICS S equipment assumes correct transportation, storage, setup, and installation, as well as careful operation and maintenance.

The details in the catalogs and proposals also apply to the design of special equipment versions. In addition to the danger and warning information provided in the technical customer documenta-

tion, the applicable national, local, and system-specific regulations and requirements must be taken into account.

Only protective extra-low voltages (PELVs) that comply with EN 60204-1 must be connected to all connections and terminals between 0 and 48 V.

A hazardous voltage will be present in the component for a further 5 minutes after the system has been shutdown. Work cannot be carried out until this time has elapsed.

Before starting work, you should also measure the voltage after the 5 minutes have elapsed. The voltage can be measured on DC link terminals DCP and DCN. The clearances above, below, and in front of the component, which are specified in the dimension

drawings, must be observed. The DC link discharge time hazard warning must be affixed to the component, in the local lan-

guage. In a supply system without regenerative capability (e.g. diesel generator), the regenerative feed-

back capability of the Active Line Module must be deactivated via a parameter (see Description of Functions). The braking energy must then be dissipated via an additional Braking Module with a braking resistor in the drive line-up.

BA053101-en

Operating the equipment in the immediate vicinity (< 1.5 m) of mobile telephones with a transmitter

3.2

Mains Connection for Booksize Drive Assembly

C D E F G

As part of routine tests, SINAMICS equipment with three-phase motors will undergo a voltage test in accordance with EN 50178. Before the voltage test is performed on the electrical equipment of industrial machines to EN 60204-1, Section 19.4, all connectors of SINAMICS equipment must be disconnected/unplugged to prevent the equipment from being damaged.

Motors must be connected in accordance with the circuit diagram provided. They must not be connected directly to the three-phase supply because this will damage them.

power of > 1 W may lead to incorrect operation.

When operated in dry operating areas, SINAMICS equipment with three-phase motors conforms to low-voltage Directive 73/23/EEC.

DINAMICS equipment with three-phase motors conforms to EMC Directive 89/336/EEC in the configurations specified in the associated EC Certificate of Conformity.

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The mains connection for the SINAMICS Booksize drive assembly consists of a mains line filter and a mains line choke:

Supply Line from MSR Desk

Fuse

Contactor

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Mains Line Filter

Mains Line Choke

SINAMICS S120

Motor

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BA053101-en

3.3

Basic Setup

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See the enclosed circuit diagram for details.

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BA053101-en

Transport and Storage

Installation and Initial Operation

Installation

6.1

Requirements for the Place of Installation

6.2

Safety Measures

6.2.1

Heat Balance

29 % =

Engine power (mechanical) Degree of effectiveness over the entire RPM range

23 % =

Heat flow over the engine block surface and engine components.

20 % =

Coolant heat flow (is transmitted via the vehicle cooler)

14 % =

Heat flow via the surface of the vehicle exhaust system

14 % =

Heat flow of the exhaust

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Check package to ensure it is complete, in accordance with the order confirmation. Report any transport damage to the carrier immediately.

During loading, unloading and transport always use suitable lifting equipment, material handling equipment (e.g. cranes, forklifts, etc.) and the right load handling attachments and slings. Always ensure that the parts to be transported are suspended or loaded properly so that they cannot fall, taking into account size, weight and the centre of gravity.

Store the packages in a covered area, protected from direct sunlight, at a low humidity and with temperatures between 0...40 °C (32…104 °F). Do not stack packages.

When unpacking, take care to avoid any possibility of injury or damage. Keep at a safe distance

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when opening the package strapping, do not allow any parts to fall out.

Installation and initial operation of the equipment may be done only by authorized and trained

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service technicians provided by the manufacturer, licensed dealers or service partners.

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The room in which the dyno is to be operated must satisfy all official regulations for the operation of equipment in the workplace.

An adequate fresh-air supply and an exhaust shaft should also be available.

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The following technical safety precautions must be observed by the customer at all times. Disregarding these precautions can be life-threatening even for those who enter the room for only

a very short period.

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Rough calculation for diesel and Otto engines The available energy in fuel is taken as standard. This is specified as fuel power with 100 % and is

divided as follows:

Heat volume in the test room P

+ P2 + P3 + P4

BA053101-en

Engine power

Heat flow surface engine block

0.8

Coolant heat flow

0.7

Heat flow vehicle exhaust system

0.5

Example 1

Engine power

= 100 kW

Heat flow surface engine block

0.8 x 100

= 80 kW

Coolant heat flow

0.7 x 100

= 70 kW

Heat flow vehicle exhaust system

0.5 x 100

= 50 kW

Heat burden on the room

= 300 kW

Example 2

Heat flow surface engnine block

0,8 x 100

= 80 kW

Heat flow vehicle exhaust system

0,5 x 100

= 50 kW

Heat burden on the room

= 200 kW

MAHA Experiences

: Is converted to heat by the air cooled eddy current brake and normally emitted into the test room.

: This energy is suctioned out with the exhaust suction system and does not contribute to heat volume in the test room.

Generally speaking the engine power to be measured is known. If this is specified with 1, the following factors are given:

The heat volume in test room is then: 1 + 0.8 + 0.7 + 0.5 = 3 This means that the energy quantity of the engine power multiplied by 3 is the volume of heat

energy in the test room.

Separate suction of the heat energy P1 converted by the eddy current brake can considerably lower the burden on the room.

The heat volume in the test room would then be: + 0.8 + 0.7 + 0.5 = 2 This means that the energy quantity of the engine power multiplied by 2 is the volume of heat

energy in the test room.

• Time period

• Ventilation concept criteria

Cooling air is of special importance as modern engine management systems are equipped with control systems which reduce the engine power when intake temperatures are too high. The full engine power is however to be measured on the dyno.

Do not fall below the following values when testing vehicles under full load:

- Air power > 25 000m³/h

- Flow speed > 90 km/h

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- Securing of under body flow (catalytic converter)

P3 Coolant heat flow 0,7 x 100 = 70 kW

An LPS 3000 performance test takes, on the average: CAR 1.5 minutes TRUCK 3 – 4 minutes A short working break follows (vehicle change, set up work, etc.)

The following points must be considered for the ventilation concept:

- Engine power

- Frequency of measurements

- Room temperature increase allowed by operator

- Room size

- Energy storage volume of the walls

BA053101-en

6.2.2

Exhaust Suction System

0.0363

1.2

Vh x n x

0.0363

1,2

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The exhaust quantity depends upon the test vehicle.The factors which are most influential are the engine cubic capacity and RPM as well as the combustion process (spark or compression ignition).

As a safety precaution it is recommended that a CO warning device be installed in the test room.

Equation for dimensioning of exhaust suction systems (see also TRGS 554, section 4.7.4.3, paragraph 2).

V = necessary suction volume flow (m³/h)

= cubic capacity of the test vehicle (l)

n = engine speed of the test vehicle (rpm)

0.0363 = approximate value

1.2 = fresh air share of 20 % Experimental values based on BG-BIA / ASA-recommendations *:

Service/Repair

350…450 m³/h 700…1200 m³/h 700…1200 m³/h 1700…2800 m³/h

Car workshop

x n x

Car workshop

Test room + AU

Truck workshop

Service/Repair

Truck workshop

Test room + Emission test

Hose ∅ Hose ∅ Hose ∅ Hose ∅

100 mm 150 mm 125 – 150 mm 200 mm

* Measurement point: Interface recording element-exhaust hose Pay attention to temperature consistency. The respective exhaust suction system must be

adapted to the needs of the operator. It is recommended that the exhaust suction system not be combined with a welding smoke

suction system and then connected to a ventilator. It is possible that a combustible or explosive mixture may be created based (see ZH 1/454 vehicle maintenance guideline).

Example for calculation based on the equation V =

Example 1 Example 2 Car with 3.0 liter cubic capacity, service work

with average speed of 3000 rpm

TRUCK 12.0 Liter cubic capacity, service work

with average speed of 1500 rpm V = 3.0 x 3000 x 0. 0363 x 1.2 V = 12.0 x 1500 x 0. 0363 x 1.2 V = 392.04 m³/h V = 784.08 m³/h

The exhaust discharge for the auto exhaust can be done with suction hoses (air flow rate > 3000 m³/h) or with suction flaps (air flow rate approx. 10000 m³/h) .

BA053101-en

Vt =

Vh x (t in °C:273 Kelvin) x λ

6.2.3

Fresh Air Supply for the Test Room

Example for calulation at dynamometers

= Supply degree of 0.85 (without Turbocharger)…approx. 1.9 (depending on engine and

manufacturer)

Example 1 Example 2 Car dyno,

Engine 5.547 liter, Engine speed 5000 rpm, Temperature 500°C, λ = 1.0

Vt = 5.547 x 5000 x 0. 0363 x 1.2 x 500/273 x 1.0

Vt = 2212.71 m³/h Vt = 5029.49 m³/h

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According to currently effective regulations in the Federal Republic of Germany, the air must be renewed 10 to 15 times per hour in closed testing rooms with a surface area up to 100 m².

The air must be renewed 5 to 8 times per hour in rooms over 100 m². An air throughput of approx. 5000 m³/h is required for a surface area of 100 m².

Truck dyno,

Engine 18.273 liter,

Engine speed 2300 rpm,

Temperature 500 °C,

λ = 1.5

Vt = 18.273 x 2300 x 0,.0363 x 1.2 x 500/273

x 1.5

An inadequate fresh-air supply increases the burden on the test personnel and distorts the test results.

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BA053101-en

Software

7.1

System Requirements

7.2

Starting the Setup

Auto-

run.exe

EUROSYSTEM\ Setup.exe

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OS ............Win XP with SP 2; Win Vista (32 Bit) for ES v7.00.015 or later; Win 7 for ES v7.10.001 or later

CPU .......................................................... > 1.6 GHz; recommended: Intel or similar AMD products

HDD .......................................................................................................... 1 GB free memory space

Graphics card ........................................ Resolution 1024 x 768 with 24 bit color depth (True Color)

RAM ............................................................................... Win XP: 512 MB; Win Vista or Win 7: 1 GB

Drives ............................................................................................................................... DVD-ROM

Interfaces ......................................................................................................... 2 free USB interfaces

• If using Win 7, please read section

stalling the application software!

• All passwords and administrator rights must be available at the time of the installation.

• If the tester is used with multiple work stations, a TCP/IP network must be available.

• For external devices with RS232 connectors an RS 232 interface must be available.

• PC speciality stores offer a wide range of USB-to-RS232 adapters. There is, however, no

standard guarantee that every adapter will function on the RS232 interfaces. For this reason, MAHA offers adapters with the order number (VZ 910140) which have been tested on MAHA products.

• When replacing old computers with PC-LON cards (ISA slot), be aware that new computers no

longer have ISA slots. For new computers that means that a LON-USB card (VZ 912033) is needed for the connection to the test lane.

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1 Insert the CD in the

disk drive.

⇒ Installation starts

automatically. If not, start

Additional Settings under Windows 7

before in-

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from the CD.

2 To start the setup

click the equipment type being used.

BA053101-en

7.3

Selecting the Setup Language

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1 Choose a setup

language. German and English are available.

2 Confirm with

<Next>.

⇒ The InstallShield

Wizard appears.

3 Confirm with

<Next>.

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7.4

Selecting the Destination Folder

7.5

Selecting the SQL Server

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1 Choose the default

destination folder or click <Browse> to select a different folder.

2 Confirm with

<Next>.

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1 Select the SQL

server.

2 Confirm with

<Next>.

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7.6

Selecting the Dyno Type

7.7

Selecting Features

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1 Choose the dyno

type.

2 Confirm with

<Next>.

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1 Mark the check-

boxes of the features you want to install.

2 Confirm with

<Next>.

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7.8

Installing Drivers

7.9

Finishing the Setup

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1 Install the required

drivers.

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 When this window

appears, the installation has been successfully completed.

1 Click <Finish> to

exit the InstallShield Wizard.

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7.10

Additional Settings under Windows 7 or higher

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Prior to installation disable the Windows Update function:

• Control Panel

• System

• Advanced system

settings

• Hardware

• Device Installation

Settings ►

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After inserting the EUROSYSTEM CD "AutoRun" is started. Use this program to install your version of EUROSYSTEM.

Click the equipment being used (

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Provided the User Account Control is enabled, this Windows confirmation prompt appears.

Confirm with "Yes“.

Do the software installation as described above, starting with step "Selecting the Setup Language".

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After the installation process has been successfully completed, assign the user rights for the directory. To do this, open the installation directory, usually located at: C:\Programs\MAHA\ [Equipment type], then right-click the folder. In the object menu, select "Properties“ (

In this dialog window, click tab "Security“ and then button "Edit“ (

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Confirm the assignment with "OK“. The new permissions will now be applied.

Now the user rights can be assigned.

Mark entry "Benutzer" (German for "User“) (

) and tick the "Allow" checkbox next to the "Full control" permission. (

Preparations for Testing

8.1

Switch on the Dyno

8.2

Drive onto Dyno and Secure Vehicle

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1 Switch on the main switch at the communication desk. 2 Turn the Operating mode switch to position 2 "Setup". 3 Push the Control ON button.

See also section "Description / Controls and Indicators".

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Risk of injury by flying particles!

• Before driving onto the rollers, remove all particles such as gravel etc. from the tires.

• Check the balancing weights on the rims for tight fit.

• Wear protective glasses.

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1 Block the rollers. 2 Position the front axle in the center on top of the front roller set. 3 Put on the parking brake. 4 Fix the vehicle at the front with tightening straps, and with chains at the rear. The anchoring

should be tight, but not pull down the vehicle. 5 Release the parking brake and shift to idle position. 6 Move the rear roller set until the rear axle also sits centered on the top. 7 Retighten the vehicle fixing again.

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8 Release the roller blocking.

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Never

8.3

Connect the RPM Sensor

Life-threatening injuries possible if vehicle breaks loose from fixing!

• No persons shall be in the test room during vehicle testing! Danger!

• Fix the test vehicle before each test at the rear and front onto the dyno with the proper (MAHA-)

vehicle fixing. Usage of a different fixing attachment can affect safety and cause personal injury.

MAHA accepts no liability for the resulting damage.

• The vehicle must be fixed in such a way that the vehicle cannot laterally break away and that no

swinging movements are created!

• Safeguard that the vehicle mass cannot be moved on the rollers!

• Make sure that the vehicle fixing is suitable for the vehicle being tested.

• Only skilled, trained personnel shall install the vehicle fixing.

• Always install the vehicle fixing completely and properly and check its proper functioning before

test start.

• Check the orderly condition and suitable rigidity of the vehicle’s attachment unit before every

vehicle fixing procedure (e.g. towing hooks, trailer coupling, towing attachment)!

• Fasten the chains and straps to suitable points at the vehicle chassis or suspension.

• If using tightening straps for anchoring pay close attention that the loose ends do not get close

to the tires or rollers. This is especially important when the fan is switched on!

• Check the tightening straps for damage before each measurement.

•

start the test operation without suitable and complete vehicle fixing!

• Visually check the vehicle for leakage: Fuel system, drive train, engine, water, exhaust.

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1 Connect the RPM sensor in the engine compartment. The procedure depends upon the type of

sensor. Please pay attention to the detailed description of the various RPM sensors in section

"Description / Interface Box"

Set the RPM sensor using the selection list in window "RPM Sensor" in the menu "RPM

Settings". 2 Connect the RPM sensor to the interface box.

Other data sensors which may be needed during the test should be connected according to

the interface assignment plan for the interface box. Connect all needed sensors to the vehicle.

Use the menu "RPM Settings" to check whether all connected measurement sensors are

functioning correctly.

Automatic transmission vehicles without converter lockup cannot use the driving trial method, because the engine RPM deviates due to converter slip.

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8.4

Connect Oil Temperature Probe

8.5

Attach Exhaust Suction System

8.6

Position Cooling Air Fan

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1 Remove the oil dipstick from the engine. 2 Adjust the length of the oil temperature probe to the length of the original dipstick by using the

cone plug.

Risk of damage! Incorrect length adjustment of the oil temperature probe can lead to engine damage!

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3 Replace the oil dipstick with the oil temperature probe. Close the opening with the cone plug.

Danger of poisoning by exhaust gases in the test room!

• Use an exhaust suction system.

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1 Place the exhaust suction system close to the exhaust pipe and switch it on.

Risk of damage! A certain distance should be maintained from the vehicle because of possible heat accumulation in

the exhaust suction unit which may cause damage to vehicle or paint.

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1 Position the cooling air fan in front of the vehicle’s radiator. 2 To make sure that the fan remains in place during operation, use the fixing levers on the casters

of the fan. 3 Switch on the air cooling fan.

Risk of damage! Cables and tightening straps can get between tires and rollers due to the air flow.

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8.7

Bring the Vehicle up to Operating Temperature

8.8

Vehicle Ready for Testing

Always

Do not

8.9

Exit the Dynamometer

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This can be done using the load simulation, e.g. with a constant traction (see section

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Simulation"

The vehicle is ready for testing when all the preparation steps for testing have been completed.

Life-threatening injuries possible by rotating dyno rollers!

•

being pulled into the rotating rollers!

• Safeguard that the operating personnel is informed when someone is underneath the dyno.

Danger for those who are under the dyno without the knowledge of the operating personnel!

• If this safety system has been bypassed, the service personnel is responsible for establishing

necessary and suitable safety measures (e.g. signs which indicate that service work is being done).

• Make sure that all keys for bypassing safety systems are only available to specially trained ser-

vice personnel.

•

"Load

keep body parts and clothing far away from rotating rollers, as there is danger of these

leave the keys in the key switch during normal test operation.

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Risk of hearing damage due to high noise level!

• Use ear protection which is approved for up to 120 dB(A).

Noise levels of over 100 dB(A) are possible during vehicle testing.

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1 Block the rollers. 2 Remove the roller adjustment device from the rear axle in a backward direction. 3 Shift into 1st gear and put on the parking brake. 4 Loosen the tightening straps at the front axle. 5 Then loosen the tightening straps at the rear axle. 6 Remove all tightening straps. 7 Release parking brake and shift into idle.

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8 Drive vehicle off dyno.

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Program Structure

9.1

General Information

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The program is menu-oriented. Data or instructions can be entered via the PC keyboard. The remote control is used for the setup operation, for e.g. wheelbase setting, starting and stopping of the pre-selected driving cycle.

The main menu is divided into several sub-menus which can be selected as follows:

• Wheel mouse: with mouse click

• Keyboard: Select with the Cursor keys and open with the <ENTER> key.

During the program procedure follow the instructions in the status line.

The following is described in the instructions:

• Program structure

• Starting the program

• Operation and explanation of the main screen and button strip

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• End program / Switch off dyno

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9.2

Tree Model

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9.3

Screen Design

9.3.1

Status Line

Symbol

Description

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Generally the screen is divided up into the following areas:

→ Status Line

→ Main Screen

→ Button Bar

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The status line on each screen continuously informs the operator about the current status of the program, guides through the program with short information and provides information about the keys to be used. Further, malfunction and error messages are displayed.

The dyno model, the operating and functional conditions of the various devices are displayed in the status line.

The various symbols are described in the following section.

Always pay close attention to the messages and instructions in the status line!

Dyno OK (green) The connection to the various dyno components (e.g. eddy current brake, interface box, etc.) are working trouble-free.

An error has occurred, but it is possible to continue (yellow).

An error has occurred, it is not possible to continue (red).

Communication status to OBD (red: communication error green: communication OK) See section

"OBD Settings"

in chapter

"Settings

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Symbol

Description

Dyno is set for CAR (green).

Fan (red: switched off green: switched on)

Pneumatic holding brake of dyno rollers. Green: Brake of drive axle(s) selected is open – rollers can rotate freely. Red: All brakes are closed – rollers are blocked. Yellow: Position of brakes is not compatible with vehicle. Click on the symbol to close the brakes: "red". Click again to open the brakes: "green".

Front Wheel Drive mode

Rear Wheel Drive mode

4 Wheel Drive mode

For setting a speed difference (3 % max.) between HA (rear wheel drive) and FA (front wheel drive)

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9.3.2

Main Screen

9.3.3

Button Bar

Example

A+B

SWITCH OVER Button

INFO Button

PRINT Button

ESCAPE Button

D C B A E

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Here menu items can be selected or measurement variables displayed.

Grey shaded boxes are not available for selection.

To select a menu item from the main screen, either

• mark it using the cursor keys / the tab key and confirm with <ENTER>, or

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• open it using a left mouse click.

Here are additional important functions. The assignment of buttons <F5> to <F8> in the button bar can vary. The individual buttons are labelled with the respective function and function key. The button assignments are explained later in the respective menu items as they appear.

The button bar assignments depend upon the screen currently active. Grey shaded buttons are not available for selection.

If the highlighted LED (A) appears in front of the arrow keys, this means the button bar has additional functions and can be "switched over" with the arrow keys (B) or wiith the <Pg ↓> or <Pg ↑> button or with the scrolling wheel of the mouse.

Use this button to display various dyno information.

Use this key or the <F12> key to start a printout.

Use this button or the <Esc> key to exit the active screen.

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9.4

Starting the Program

F8 CONTINUE

F7 UPDATE

9.5

End Program / Switch off Dyno

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1 Switch on the dyno via the main switch on the communication desk. 2 Windows is started after the PC is booted. Depending on the setting, the program is started

either automatically, or by calling up the Start group or by double clicking the icon.

 The start screen appears with the MAHA logo and version number.  The following screen appears which shows the connected PCBs.

The number of modules (PCBs) depends upon the options that have been ordered.

3 Confirm the enabling of the individual dyno components with the button

4 If desired, start a software update of the individual dyno components

using

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 After a few seconds the main menu appears.

First quit the program and then shut down the computer properly. Improper termination can cause a system crash and data loss!

1 Quit all menu items with <ESC>. 2 As soon as you are in the main menu, quit the program with <F8 EXIT>. 3 Quit Windows and shut down the computer properly.

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4 Turn off the main switch at the communication desk.

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Measurements

10.1

Load Simulation

10.1.1

Identical Functions

Button Description

Target value +/-

Target value OK

Start

Stop

Driving cycle

Evaluate

Store

Reset

Profile

Reset travel distance

Enter target value

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The Load simulation menu enables the user to preselect various load conditions which, for example, make possible targeted engine diagnosis or determination of the climbing performance of a vehicle. After selecting the menu item, the following screen appears:

• Const. traction • Const. Engine RPM • Drive dyno

• Const. speed • Standstill • Show last measurement

• Road load simulation

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LEVEL 1

LEVEL 2

• The target value can be changed and confirmed during the measure-

ment. Change the value with the +/- keys or with the remote control scroll key. If the desired value is set, it is confirmed with the <F5> key.

• The graphic recording of the measurement is started or stopped.

• A driving cycle from the database can be selected.

• The measurement evaluation is displayed.

• The measurement is stored.

LEVEL 3

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• The graphic recording of the measurement is reset to zero.

• A display profile can be selected from the database.

• The travel distance measurement is reset to zero.

• Use this button to change the current target value (e.g. Speed 50 km/h)

without having to quit the program.

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Driving Cycle (Optional)

Driving cycle

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A speed profile with fixed time and speed run can be driven on the dyno using the button

cycle

The various standard cycles are found in the directory button <F8 LOAD>.

. The required curve plot is displayed on the screen for the test driver.

Cycles.

Load the cycles from here using the

Driving

1 Use the button <F7 DRIVING CYCLE>

 The following screen appears:

2 Use the button <F8 LOAD>

 The selection screen appears. 3 Select the desired driving cycle with the cur-

sor key or the mouse and load this with

<OPEN>.

4 Start the driving cycle with the button <F6

START>. 5 The vehicle must now follow the curve plot of

the selected speed profile.

 In the enlarged cut out of the total dia-

gram (right) a green point represents the cur-

rent actual value of the vehicle. The actual

value should move along the display blue

line. In the total diagram (left) a line is shown

which represents the part of the diagram

which is currently being shown.

6 The driving cycle can be terminated with the button <F7 STOP>. 7 The driving cycle is reset to the beginning with the button <F5 RESET>.

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Evaluation / Data Logging

Scaling the Power and Load Simulation Graphs

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1 Use the button <F8 EVALUATION>.

 The following screen appears:

2 Use the drop-down menus on the right-hand side to select and save up to six test values per

diagram. The number of diagrams which can be saved is not limited. 3 Exit the measurement screen with <ESC>.

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The Power and Load Simulation graphs can be manually scaled as follows:

1 Double-click the upper left- or right-hand

corner of the diagram.  An entry field opens. 2 Enter the desired scaling value. 3 Confirm with RETURN or ENTER.

The Power values [kW] are scaled using the left-hand x-axis, the additional test values using the right-hand x-axis.

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Zoom function

Cursor function

1 Press the button <F5 CURSOR>.

Use the <F5 CURSOR OFF> to blend out the

Insert comment

Delete comment

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1 Press and hold left hand mouse key. 2 Frame the desired cutout in the diagram. 3 Release the left hand mouse key.  The diagram cutout will be enlarged by a

maximum factor of 5. 4 Use the <F6 ZOOM OUT> key to reduce the

original picture size again step by step.

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The cursor is blended in. 2 Press and hold left hand mouse key. 3 Move the cursor to the desired diagram

point.

 The measurement values are shown in the

right –hand column. 4

cursor.

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1 Press the right hand mouse key.

A window opens. 2 Enter comment. 3 Confirm with <RETURN> . 4 Press and hold right hand mouse key to

move the comment.

1 Select the desired comment with the right

hand mouse key. 2 Delete comment with <DEL> . 3 Confirm with <RETURN>.

Up to 5 comments with a max. of 40 characters can be inserted into the diagram.

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Store

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1 Use the button

<F5 STORE>.

 The following screen appears: 2 Input the vehicle data and information in the

entry boxes. 3 Use the button <F8 COMPLETE>.

 The measurement is stored.

The inserted comments are also stored in the database.

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1 Use the button <PRINT> or key <F12>.

 The following screen appears: 2 Enter the vehicle data and information in the

input boxes. 3 Using <MEASUREMENT DATA TABLE > an

additional, tabular print out of the measure-

ment data can be selected. Enter the incre-

ment. 4 Select the desired measurement data with

the <, <<, >, >> buttons.

<<, >>: Select all

<, >: Select individual 5 Use the button <F8 COMPLETE>.

 The measurement is printed out.

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10.1.2

Constant Traction

Target

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A pre-set traction value activates the eddy-current brake immediately which maintains a constant traction for the duration of the measurement.

The values to be set are oriented on

• the model and size of the test vehicle

• and on the desired inclination angle.

A steady incline (sloping surface) is simulated in this mode. It can be used, for example, to run the engine of the test vehicle up to operating temperature. The higher the value entered for the traction the larger the angle of inclination α. The simulated slope can be driven in any gear or speed. The eddy current brake effectiveness remains constant at all speeds.

1 Position the vehicle on the dyno and fix it.

2 Call up the menu LOAD SIMULATION and

then the menu point CONSTANT TRACTION

⇒ The following screen appears: 3 Enter the target value of the traction

using the digit keys. 4 Use the button <F8 CONTINUE>.

⇒ The measurement screen appears.

F-

5 Start the measurement. 6 Use the button <F6> to start or stop the

graphic recording of the measurement.

With 4-wheel drive vehicles the traction target value is divided between front and rear (depending on the vehicle-specific distribution of forces).

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Example

Calculation of the traction F

Calculation of the climbing power P

with v = km/h and the following values:

• Vehicle weight

• Angle of inclination

• Speed

• Acceleration due to

gravity

the result is:

• = 2302 N

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m = 1500 kg

= 9°

= 100 km/h

g = 9,81 m/s

and P

= 64 kW = 89 PS

= m  g  sin α

= m  g  sin α  v / 3600

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10.1.3

Constant Speed

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With the operating mode speed remains constant independent from the traction (from low to full throttle) created by the vehicle, i.e. only the the speed which was pre-set can be driven. Only the eddy current brake effectiveness increases up to full throttle but not the speed.

1 Position the vehicle on the dyno and fix it.

2 Call up the menu LOAD SIMULATION and

then the menu point CONSTANT SPEED.

 The following screen appears: 3 Enter the target value of the speed

into the entry box

4 Use the button <F8 CONTINUE>.

 The measurement screen appears.

Constant Speed

via the digit keys.

the dyno is regulated in such a way that the driving

v-target

The entered speed must be higher than 7 km/h.

5 Start the measurement. 6 Use the button <F6> to start or stop the

graphic recording of the measurement.

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10.1.4

Driving Simulation

Influence of Various Factors

Load Adaption

Simulation Model

)

sin(

)(

mech

ref

3 ref

⋅⋅+

−+

⋅

gMasse

Masse

vKoeff D

Koeff C

vKoeff B

Koeff A

Exp D

ref

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The driving simulation reenacts a road drive and/or a certain load which can be set with the drive cycles based on specific drive resistances. The test stand range relates primarily to the maximum speeds of the normal statutory driving cycles from 0 km/h to max. 120 km/h and accelerations in the range of 1 m/s Large masses can be simulated during the acceleration with double and single roller dynamometers. With deceleration, that is coastdown, only the mechanically existing inertia of ca. 250…300 kg (LPS 3000); ca. 280/320 kg (MSR 500) and ca. 700 kg (MSR 1000) act per axle with the double roller set. A higher inertia is not possible with coastdown. In the cycle this results in shorter coastdown times as those given. With single dynamometers with drive the possibility arises to simulate electrically between 600…700 kg per axle due to existing drives and an acceleration (deceleration) of 1 m/s². Consequently, drive simulations in the small speed ranges are possible. Another advantage is that because of the drives the inherent dyno losses can be identified and stored at any time. The accuracy of the load is increased significantly.

The simulation on the roller set is mainly influenced by the factors rolling and flexing resistance. On/in a roller set these can be very different as opposed to the road depending on roller diameter and concept (double or single roller). Especially at low speeds < 50 km/h the flex and roll resistances of the rollers are larger than the total resistance on the road. Vehicle weight and tire pressure also play a role. These losses cannot be compensated without electric motor. Consequently, there are large deviations in the driving simulation especially in low speed range with the double roller.

Using the option "Load Adaption" the street coefficients can be adapted to the rollers. As already mentioned, an adequate adaption can only be done in conjunction with an electric motor. The MAHA MSR dynamometers with drive can conduct this kind of adaption under the above-named limits. However, these do not correspond with the industrial standards of emission dynamometers.

The operation mode vehicle-specific drive resistance characteristic including mass simulation is described by the following simulation model:

Drive Simulation (Road load simulation)

is generator- and motor-driven. The

F Tractive force target value

Koeff. A Rolling resistance coefficient (constant)

Koeff. B Flexing resistance coefficient (linear)

Koeff. C

Drag coefficient (square with n ≅ 2)

Koeff. D Drag coefficient (exponential with n being variable)

Exp. D

Exponent D (1 ≤ n ≤ 3, one decimal place)

Masse Vehicle mass

Mechanical mass

mech

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V Roller speed

dv/dt Roller acceleration

g Gravitational acceleration

α Gradient angle (±)

(Coefficients A-D refer to a reference speed of 90 km/h.)

1 Position the vehicle on the dyno and fix it.

2 Open menu LOAD SIMULATION

and then menu item DRIVING

SIMULATION.

 The following screen appears: 3 Enter the parameters using the

number keys or, if available, load

them from the database using <F6

DATABASE>. 4 Use button <F8 CONTINUE>.

 The measurement screen appears. 5 Start the measurement. 6 Use switch button <F6> to start or stop the

graphic recording of the measurement.

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When testing with electric motors, accelerations of 1…1.2 m/s axle. This corresponds with a mass of ca. 700 kg per axle.

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are possible with a non-driven

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10.1.5

Constant Engine RPM

10.1.6

Standstill

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With the operating mode engine RPM remains constant independent from the traction and speed created by the vehicle. The pre-selected target value (n-target) is regulated independent from the traction created by the vehicle up to the max. dyno motor capacity.

1 Position the vehicle on the dyno and fix it.

2 Call up the menu LOAD SIMULATION and

then the menu item CONSTANT ENGINE

RPM.

 The following screen appears: 3 Enter the target value of the engine RPM

n-target

4 Use the button<F8 CONTINUE>.

 The following screen appears

5 Start the measurement. 6 Use the button <F6> to start or stop the

graphic recording of the measurement.

Constant Engine RPM

via the digit keys.

the dyno is regulated in such a way that the

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This menu point activates the deceleration of the roller set with a defined torque of the eddy

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current brake.

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10.1.7

Drive Dyno

9864

10.2

Measure Engine Power

10.2.1

Display Last Measurement

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Function "Drive Dyno" requires that you enter a PIN code. The maximum target speed is approx. 200 km/h (depends on the vehicle's driving resistance).

Default PIN code setting:

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The vehicle’s engine power is measured using this menu point. After selecting this menu point the following selection appears. Select the individual menu points using the cursor keys or the mouse. The menu points are explained below.

• Continuous measurement

• Discrete measurement

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• Display last measurement

If the last conducted measurement is not stored and the measurement menu exited, use the item "Display last measurement" to view the measurement again. When exiting the LPS program the temporary storage (or the last measurement conducted) is deleted.

Only active with continuous and discrete measurements!

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10.2.2

Continuous Measurement

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The max. power is determined during a continous measurement and the engine power is calculated according to DIN 70020, EWG 80/1269, ISO 1585, SAE J1349 or JIS D1001 ECE, DIN, EWG or ISO (Optional), depending on which setting has been selected in category "Power Correction”. The curves for wheel, drag and engine performance are displayed graphically. If air pressure and temperature have been taken into consideration (measured) the engine performance is displayed as standard performance.

1 Position the vehicle on the dyno and fix it. 2 Open menu MEASURE ENGINE POWER and then menu item CONTINUOUS MEASUREMENT.

 The following screen appears:

3 Select the vehicle data or, if available, load these from the database with <F6 DATABASE>. 4 Use the button<F8 CONTINUE>.

5 Select the RPM source or the RPM sensor

and the appropriate box. 6 Use the button <F8 CONTINUE>.

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Continuous Measurement with Automatic Transmission and Converter Slip Measurement

7 Accelerate the vehicle gently but continuous-

ly up to the second to last gear.

As soon as the start speed is reached, the

analog display changes to green. 8 Then accelerate to full throttle. Pay attention

during the shifting phase that the vehicle is

not accelerated past 50 km/h otherwise the

test will begin before the test gear has been

reached. 9 Shortly before the max. RPM has been

reached disengage the clutch and release

the gas pedal.

Use the button <F6 LOAD> to load stored measurements and display in the background. A max. of 3 additional curves can be placed in the background.

10 After a successful measurement the engine

power and torque are displayed (if an RPM

signal is available).

The engine power accrues from the wheel

power plus the drag power, which is auto-

matically determined after the clutch is dis-

engaged. 11 To evaluate the measurement, see section

Identical Functions

mance curves

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1 Position the vehicle on the dyno and fix it. 2 Open menu MEASURE ENGINE POWER and then menu item CONTINUOUS MEASUREMENT. 3 Select the vehicle data, or, if available, load them from the database with <F6 DATABASE>. 4 Use the button <F8 CONTINUE>.

For automatic transmissions with torque converter lock-up clutches a value of 0.0 % must be entered if using manual entry.

" and section "

Perfor-

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5 Select the RPM source or the RPM sensor and the appropriate box. 6 Use the button <F8 CONTINUE>.

The driving trial makes no sense for automatic transmission vehicles without torque converter lockup clutches, because the engine RPM deviates due to the converter slip.

When accelerating pay attention that the vehicle’s "Kick-Down" is not triggered. If this is the case, the test must be cancelled and repeated.

Converter slip measurement

7 Accelerate the vehicle in the test gear (next to last gear) until the max. RPM is reached. 8 Slowly reduce the throttle once the max. RPM is reached until the message appears "Shift

gears and accelerate vehicle to XXX km/h. When this message appears, shift to the last gear

and accelerate to the target speed (the previously reached speed + 10%) . 9 Then switch to position N and release the throttle.

The message "Shift to position N" appears and shortly thereafter "Let vehicle coast down".

Let the vehicle coast down to start speed while in gear position N.

The test gear must always be the next to the last gear. The measurement starts after a preset start speed has been exceeded, which is normally set at 50 km/h for Car dynos.

10 Accelerate the vehicle in the test gear (next to last gear) again to the target speed.

The message line shows the message "Accelerate vehicle to XXX km/h ". 11 When the target speed has been reached, release the throttle and let the vehicle coast down to

standstill in test gear (not neutral). 12 After successful measurement, the engine power, wheel power, drag power and torque (if an

RPM signal is available) is shown. 13 To evaluate the measurement, see sections "

Identical Functions

" and "

Performance curves

The converter slip appears only on the printout, not on the measurement screen.

If the vehicle shifts up at the end of the measurement, this section of the diagram will be removed later. Instead, the software compares the ratio between engine rpm and speed.

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10.2.3

Discrete Measurement

Start- and End speeds

test increments and hold time

Hold time

Start-Hold time

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Discrete power measurement makes it possible to approach pre-defined points and hold them for a specified time as a function of the speed or RPM. These target points must be set before testing begins. The inspector.

constant. The hold time assures a stable test point so that for example enough time is left for a fuel consumption test to be done.

The turbo-charged engines, whose charger often has a delayed reaction.

1 Position the vehicle on the dyno and fix it.

2 Call up the menu MEASURE ENGINE POW-

ER and then the menu point DISCRETE

MEASUREMENT

 The following screen appears: 3 Select the measurement type and enter the

parameter via the digit keys into the entry

boxes. 4 Use the button<F8 CONTINUE>.

or RPM as well as the

are entered by the

is defined as the length of time which the pre-set approached RPM and/or speed is held

eases the regulation procedure. More accurate test results are supplied for

5 Select the vehicle data or, if available, load

these from the database with <F6 DATA-

BASE>. 6 Use the button <F8 CONTINUE>.

7 Select the RPM source or RPM sensor and

the appropriate box. 8 Use the button <F8 CONTINUE>.

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Accelerate slowly and consistently up to start

speed. 10 Give full throttle when the Start speed is

reached.

The dyno starts recording measurement da-

ta. The measurement should be done with-

out shifting in the next to last or last gear.

Use the button <F6 LOAD> to load stored measurements and display in the background. A max. of 3 additional curves can be placed in the background.

11 With the throttle fully depressed the first set measurement point is approached.

The eddy-current brake of the roller set maintains the vehicle or RPM speed about 5 sec. (i.e.

according to the set holding time) and stores the measurement value of this point. 12 The brake is then released and the next measurement point is approached. The inspector

maintains full throttle during the entire test time. 13 After all measurement have been taken, the information line at the bottom of the screen

indicates to the inspector that the clutch can be released: "Press clutch”.

14 To evaluate the measurement, see sections

Identical Functions

curves

" and "

Performance

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10.3

Engine Flexibility Test

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The engine flexibility can be checked using this menu point. Once the flexibility test has been called up the vehicle mass and Road Load must be entered as in the driving simulation test. Enter the start and finish speed of the test. Confirm using the <> or <Return> key and then the test can begin.

1 Position the vehicle on the dyno and fix it.

2 Call up the menu FLEXIBILITY MEASURE-

MENT.

 Following screen appears: 3 Enter the parameter in the boxes using the

digit keys or

if available, load these from the database

with the <F6 DATABASE> key. 4 Use the button<F8 CONTINUE>.

Use the cursor keys <↓> and <↑> to change between the values. Delete erroneously entered characters using the <BACKSPACE> key. Delete a complete box with the <DELETE> key.

5 Drive in desired gear and before the start

speed is reached, apply full throttle.

The test stand starts recording the time. 6 The duration of the measurement and the

measurement value are displayed.

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10.4

Speedometer Check

10.4.1

Vehicle Speed

v-act

speed

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Use this menu point to test the vehicle’s speedometer. The following functions can be checked.

• Vehicle speed

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• Mileage

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Ten freely selectable speedometer target speeds can be entered using this menu point. Each one can be approached, one after another. A basic setting is done at dyno configuration.

1 Position the vehicle on the dyno and fix it.

2 Call up the menu SPEEDOMETER TEST and

then the menu point VEHICLE SPEED.

 The following screen appears: 3 Use the key <F6 PROCESS> to change the

target speeds.

The value

the vehicle on the rollers. The target speed

speedometer. 4 Use the button<F8 CONTINUE>.

5 Accelerate the vehicle to the target speed.

Base it on the vehicle speedometer. 6 If the speed is held constant for 3 seconds,

the value is automatically taken over. Other-

wise store the measurement value with <F8

CONFIRM>. The display jumps to the next target speed. 7 Repeat the test for each target speed.

shows the current speed of

must be approached with the vehicle

Use the <F5 RETURN> to jump back to the previous target speed. Use the <F7 PASS OVER> key to jump to the next target speed.

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F6 PROCESS>:

8 When the final measurement has been com-

pleted a tabular listing of the target and actu-

al speeds will appear as well as a graphic

display of the measurement values with the

relative and absolute deviation. 9 Use the button <PRINT> or <F12> to start a

print out of the measurement. 10 Use <F5 REPEAT> to repeat a measure-

ment.

1 Change the target speed with the digit keys

and confirm with <RETURN>. 2 Use the cursor keys <↓> and <↑> to change

between the values. 3 Delete erroneously entered characters using

the <BACKSPACE> key. Delete a complete

box with the <DELETE> key. 4 Store the changes with the <F8 IMPORT>

key.

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10.4.2

Mileage

10.5

Load Adaption (Optional)

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1 Position the vehicle on the test stand and fix it.

2 Call up the menu point SPEEDOMETER

CONTROL and then the menu point MILE-

AGE.

 The following screen appears: 3 Enter the mileage in the box using the digit

keys. 4 Use the button <F8 CONTINUE>.

5 Drive a random distance with the vehicle on

the test stand and compare the values on

the vehicle display and on the monitor. 6 Use the button <F5 TRIP START> to start

the mileage counter test. 7 Use the button <F6 TRIP STOP> to Stopp

the mileage counter test. 8 Use the button <F7 TRIP RESET> to reset

the mileage counter to zero. 9 Use <ESC> to end the mileage counter test.

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Use this menu point to do various adaptions; e.g. dyno coefficients can be determined here. The iterative coefficient adaption can be done based on the following standards, whereby the vehicle must be defined in the vehicle database before doing the adaption.  After the menu point LOAD ADAPTION the following function selection appears:

• ECE

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• SAE J2264

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10.5.1

Coefficient Adaption based on ECE

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1 Position the vehicle on the dyno and fix it.

2 Call up the menu LOAD ADAPTION and then

the menu item ECE.

 The following screen appears: 3 Enter the parameter in the boxes using the

digit keys or, if available, load these from the

database with the <F6 DATABASE> key. 4 Use the button<F8 CONTINUE>.

 The measurement screen appears.

Use the cursor keys <↓> and <↑> to change between the values. Delete erroneously entered characters using the <BACKSPACE> key. Delete a complete box with the <DELETE> key.

5 Accelerate the vehicle up to 110 km/h. 6 Once the displayed target speed is reached,

the roll out trial is initiated. (release gas and

disengage clutch)

The dyno is braked based on the preset sim-

ulation model. The actual time (ECE) is

measured and displayed at each interval.

7 Repeat steps 5 and 6 until all intervals are in the green range.

With the iterative coefficient adaption based on ECE Standard the evaluation is done per interval. Referring to the target time, the time error is calculated and issued. If the time error is within the tolerance range, the line is showed in green. If the time error is outside of the tolerance range, the line is shown in red. The dyno repeats the coefficient adaption automatically until all set intervals are within the green range and/or the max. set number of runs (standard is 6) are done.

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10.5.2

Coefficient Adaption based on SAE J2264

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1 Position the vehicle on the dyno and fix it.

2 Call up the menu LOAD ADAPTION and then

the menu item SAE J2264.

 The following screen appears: 3 Enter the parameter in the boxes using the

digit keys or

if available, load these from the database

with the <F6 DATABASE> key. 4 Use the button<F8 CONTINUE>.

 The measurement screen appears.

Use the cursor keys <↓> and <↑> to change between the values. Delete erroneously entered characters using the <BACKSPACE> key. Delete a complete box with the <DELETE> key.

5 Accelerate the vehicle to 110 km/h. 6 Once the displayed target speed is reached,

the roll out trial is initiated. (release gas and

disengage clutch)

The dyno is braked based on the preset sim-

ulation model.

7 Repeat steps 5 and 6 until all intervals are in the green range.

With the iterative coefficient adaption based on SAE standard, the evaluation is done only after all intervals of a run have been done. Hereby there is no color evaluation of the Road Load error. The evaluation is displayed however on the test progress bar (green = OK, red = not OK).

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10.6

Lug-Down Test (Option)

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Country-specific! Use this option only if a MAHA diesel emission tester is connected to the software and ready for

operation.

1 Position the vehicle on the dyno and fix it.

2 Call up the menu LUG_DOWN TEST .

⇒ The following screen appears: 3 Enter the vehicle data. 4 Use the button<F8 CONTINUE>.

5 Determine the RPM with the menu DRIVNG TRIAL. 6 Do a continuous performance measurement in which the target and actual power as well as the

RPM are determined and compared 7 Then the program triggers the MDO LON measurement cell.

⇒ Readiness is then briefly displayed on the screen.

8 Now the vehicle must be accelerated to the

previously determined max. power (100 %)

⇒ The dyno maintains 100 % power for 5

seconds and the K-value is measured and

averaged in this time period. 9 Then the dyno regulates to 90 % of the max.

power. The dyno maintains 100 % power for

5 seconds and the K-value is measured and

averaged in this time period. 10 The 3rd test point is correspondingly meas-

ured and averaged.

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11 The results can then be printed out.

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Settings

11.1

Database

11.1.1

Identical Functions

Button description

Clean Up

Delete

Export

Import

Clean Up

Performance Curves and Time Diagram

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Various points can be administered using the menu point DATABASE: power curves, time diagrams, vehicle data, load simulation profile and the driving cycle data. Tests conducted can be displayed and printed out using the appropriate menu point. The following describes how data can be entered, changed and deleted in the respective databases.

1 Use the menu point DATABASE.

 Following screen opens: 2 Select the desired database.

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1 Enter the date and confirm with <ENTER>. 2 Use <ESC> to exit the window without delet-

ing the datasets.

• Use this button to remove the data sets from the databse via the date

• Using this button datasets can be removed from the database.

• Using this button, datasets can be exported from the database.

• Using this button datasets can be imported from the database.

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Driving Cycle Data

Delete

Export

1 To delete the data of the last 7 days, select

YES. 2 Select NO if you do not want to delete the

dataset.

1 Select the desired database.

 The database Browser appears: 2 Select with the cursor keys or mouse. 3 To delete a marked dataset, press <F6 DE-

LETE>.

 Following safety inquiry appears. 4 To delete the dataset select YES.

 The dataset is deleted from the database.

Select NO if the dataset should not be delet-

ed.

1 Select the desired database.

 The Browser database appears: 2 Select using the cursor keys or the mouse. 3 To export a marked dataset, press <F7 EX-

PORT>.

 Following window opens. 4 Enter a file name and if necessary select a

path. 5 Confirm with <STORE>.

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C:\MAHA\*Dyno Model*\Export\...

Import

C:\MAHA\*Dyno Model*\Import\...

The datasets are stored on the hard disk under

1 Select the desired database.

 The database Browser appears: 2 Use the key <F8 IMPORT>.

 Following window opens. 3 Select with the Cursor-keys or the mouse if

necessary to change the path. 4 Import the dataset with <OPEN>.

As standard, the datasets are imported from

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11.1.2

Performance Curves

Button Description

Repeat

x-Axle=v

Curve selection

Power correction

Cursor

Zoom out

Units

Save

Load

Save in background

Excel Export

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1 Call up the menu DATABASE and then the

menu item PERFORMANCE CURVES

 The database browser appears: 2 Select a dataset with the cursor keys or the

mouse key. 3 Open the dataset by double clicking or

pressing the button <ENTER>.

 The measurement screen appears.

LEVEL 1

• Use this button to repeat the measurement.

• Use this button to switch over the display of the x-axis between speed

and RPM.

LEVEL 2

LEVEL 3

• Use this button switch the display between curve selection and max.

value.

• Use this button to select various standard calculations from a list.

• Use this button to blend the cursor in and out.

The cursor can be moved using the mouse key.

• Use this button to display the original picture again, step by step.

• Use this button to change the units.

• Use this button to store the buttons.

• Use this button to load a stored measurement.

• Use this button to display a loaded measurement in the background.

• Use this button to export power curves as text files.

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Vehicledata

RPMsettings

P-drag wizzard

Finish wizzard

Curve Selection

LEVEL 4

• Use this button to display the vehicle data.

• Use this button to display the RPM setting.

• Use this switch button to smooth the power curve (P-drag) by extrapola-

tion and then to store.

1 Use the button <F7 CURVE SELECTION>.

 The following screen appears: 2 Use the keys 1 to 4 or the appropriate but-

tons to blend in the individual performance

curves.

3 Using the keys 5 to 7 or the appropriate

buttons a max. of 3 additional measurements

(torque and engine power), if loaded, can be

blended in and out in the background.

4 A max. of 3 additional curves can, if loaded,

be blended in or out in the background with

the selection boxes or the appropriate but-

tons. 5 With <F7 MAX. VALUES> the max. values

are re-displayed.

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Power Correction

Load

The additional curves can only be displayed when the appropriate sensors and measurement units are connected.

1 Use the button <F8 POWER CORREC-

TION>.

 The following selection box opens: 2 Select the desired engine power projection.

The power and torque are calculated and

displayed based on the desired power cor-

rection. 3 Using the keys 5 to 7 or the appropriate

buttons a max. of 3 further measurements, if

loaded, can be blended in and out in the

background. rund ein- und ausgeblendet

werden.

1 Use the button <F6 LOAD>.

 The following selection box opens: 2 Select where the desired measurement is to

be loaded.  The database Browser opens: 3 Select a dataset with the cursor key or the

mouse. 4 Open the dataset by double clicking or press

the <ENTER> key.

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Excel Export

C:\MAHA\*Dyno Model*\Export\...

P-Drag Wizard

Using this menu item, power curves can be exported as a text file.

1 Use the button <F8 EXCEL EXPORT>.

 The following screen appears: 2 Enter the vehicle data and information in the

entry boxes. 3 Use the button <F8 COMPLETE>.

4 Enter a file name and select, if necessary, a

path. 5 Confirm with <STORE>.

The data records were stored on the hard disk under

1 Use the button <F7 P-DRAG WIZARD>.

The wand is blended in. 2 Move the wand with the mouse onto the

desired point on the power curve.

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100

11.1.3

Time Diagram

Call up the menu DATABASE and then menu

Cursor

Zoom out

Store

Units

3 Press the left hand mouse key.  The curve is smoothed by interpolating.The

interpolation is only done on the upper half of

the curve.

4 Use the button <F7 END WIZARD >.

 The following window appears: 5 Select YES to store the changes, if not,

select NO.

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point TIME DIAGRAM

⇒ The database Browser appears: 2 Select a dataset with the cursor key or the

mouse. 3 Open the dataset by double clicking or press

the <ENTER> key.

⇒ The measurement screen appears.

• Use this button to blend the cursor in and out.

The cursor can be moved using the mouse key.

• Use this button to display the original picture again, step by step,

(see paragraph

"Zoom-Function"

in Chapter

"Measurements"

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• Use this button to store the vehicle and customer data (see Chapter 6,

Paragraph "

Identical Functions

" and function "

Store"

• Use this button to change the units.

"Units"

(see paragraph

in Chapter

"Settings"

MAHA POWERDYNO MSR, POWERDYNO MSR 500, POWERDYNO MSR 1000, POWERDYNO MSR 1050, POWERDYNO MSR 800 Original Operating Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety

Introduction

Symbols

Intended Use

Safety Instructions for Commissioning

Safety Instructions for Operation

Safety Instructions for Servicing

Danger Zone

Safety Information about Tires

Safety Information about the Eddy Current Brake

Safety Features

Accessories

What to Do in the Event of an Accident

Description

General Information

Specifications

Dimensions

Communication Desk

MSR 500/1

MSR 500/2

MSR 500/2 4WD

MSR 500/3 4WD

MSR 800

MSR 830

MSR 850

MSR 1000

MSR 1050

Main Switch

Controls and Indicators

Emergency Stop

Remote Control

Description of the Interface Box

RPM Module (Standard)

Environmental Module (Standard)

OBD Module (Optional)

Pressure/Temperature Module (Optional)

Analog Input Module (Optional)

Analog Output Card (Optional)

Measurement Programs

Calculation Basis

Road Load

Torque

Extrapolation of the Engine Power with Gasoline Engines

Extrapolation of the Engine Power with Diesel Engines (Naturally Aspirated or Supercharged)

Extrapolation of the Engine Power with Turbodiesel Engines

Calculate Engine Factor fm

4 Wheel Drive Operation

Description of the SINAMICS Components

Special Safety Instructions for the SINAMICS Components

Mains Connection for Booksize Drive Assembly

Basic Setup

Transport and Storage

Installation and Initial Operation

Installation

Requirements for the Place of Installation

Safety Measures

Heat Balance

Exhaust Suction System

Fresh Air Supply for the Test Room

Software

System Requirements

Starting the Setup

Selecting the Setup Language

Selecting the Destination Folder

Selecting the SQL Server

Selecting the Dyno Type

Selecting Features

Installing Drivers

Finishing the Setup

Additional Settings under Windows 7 or higher

Preparations for Testing

Switch on the Dyno

Drive onto Dyno and Secure Vehicle

Connect the RPM Sensor

Connect Oil Temperature Probe

Attach Exhaust Suction System