MAHA POWERDYNO MSR Series, 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
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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
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Transport and Storage ....................................................................................... 47
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Installation and Initial Operation ........................................................................... 47
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Installation ......................................................................................................... 47
7
Software ............................................................................................................ 51
8
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
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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
12
Diagnosis / Service ........................................................................................... 112
13
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
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Disposal .......................................................................................................... 119
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Diagnosis of SINAMICS Components ................................................................ 120
17
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.
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2

Description

2.1

General Information

RPM module
Environmental module
Analog module
OBD module
Pressure/Temperature module
Pos: 36 /Tec hn ische Dokum entation/ Alle Geräte/Üb erschriften/ Überschri ften 1/B/Üb erschrift 1: Beschr eibung @ 6\mod_1174482271453_75.docx @ 76889 @ 1 @ 1
Pos: 37 /Technische Dokument ation/Alle Gerät e/Übersc hriften/Üb erschriften 1. 1/A/Übersc hrift 1.1: Allgem eines @ 6\mod_1182865005781_75.docx @ 97736 @ 2 @ 1
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
(*)
.
(*)
(*)
(*)
).
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13
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
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14
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
15
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
A
B
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
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16
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
17
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
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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
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
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19
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
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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
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Supply voltage 230 V + N + PE
21
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
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22
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
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23
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
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24
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
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25
2.3

Main Switch

2.4

Controls and Indicators

A
D
B
E
C
F
Operating Modes
Position 1: OPERATI-
ON
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.
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26
Enabling / Disabling the Dynamometer
2.5

Emergency Stop

A
B
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
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27
2.6

Remote Control

Remote Control
PC Keyboard
1 2
3
4 5
6 7
8
9
10
11
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.
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Remote Control
PC Keyboard
12
13
14
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
1
2
3
4
5
6
7
8
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2.7

Description of the Interface Box

DRZ PTH OBD P2T2
A B D C H
E F I M L K J
G
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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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Pos: 102 /-----F orm at-----/ MAN UEL LE R UMB R UCH Z ei lensc hal tung @ 7\mod_1195138965731_0.docx @ 132177 @ @ 1
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approx. 120 x 170 x 160 mm approx. 1.0 kg
Pos: 104 /-----F orm at-----/M ANUELLE R UMBR UCH Seite numbru ch @ 0\mod_1134403577687_0.docx @ 1277 @ @ 1
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DRZ
A
B
C
D
PTH
E
F
G
H
OBD (Option)
I
P2T2 (Option)
J
K
L
M
Display the Interface Box Assignment
Pos: 105 /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 2) @ 13\mod_1234252898101_75.docx @ 336301 @ @ 1
Piezo clamp, TDC sensor Light barrier
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
Pos: 106 /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 -Be legung ( Text) @ 13\ mod_1234253839295_75.docx @ 336327 @ @ 1
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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Pos: 108 /-----F orm at-----/M ANUELLE R UMBR UCH Seite numbru ch @ 0\mod_1134403577687_0.docx @ 1277 @ @ 1
Temperature 2
BA053101-en
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