2015 Dynojet Research, Inc. All Rights Reserved. Torque Cell Installation Guide for Model 250i/250iP DynoWare RT Dynamometers. This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual, and the software described in it, is furnished under license and may only be used or copied in accordance with the terms of such license. This manual is furnished for informational use only, is subject to change without notice, and should not be construed as a commitment by Dynojet. Dynojet assumes no responsibility or liability for any error or inaccuracies that may appear in this manual. Except as permitted by such license, no part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Dynojet. The Dynojet logo is a trademark of Dynojet Research, Inc. Any trademarks, trade names, service marks, or service names owned or registered by any other company and used in this guide are the property of their respective companies. Dynojet Research, Inc., 2191 Mendenhall Drive, North Las Vegas, Nevada 89081, USA. Printed in USA. Part Number: 98200070 Version 2 (07/2015)
TABLE OF CONTENTS Chapter 1 Chapter 2 Torque Cell Installation Introduction............................................................ 1-2 Conventions Used In This Manual....................................... 1-2 Technical Support.................................................... 1-2 Main Dyno Power....................................................... 1-3 Connecting and Disconnecting the Power Above Ground Dyno............ 1-3 Connecting and Disconnecting the Power In Ground Dyno................ 1-4 Accessing the Dyno..................................................... 1-5 Accessing the Dyno Above Ground.................................... 1-5 Accessing the Dyno In Ground........................................ 1-8 Load Cell Installation.................................................... 1-9 Routing the Load Cell Cable............................................ 1-12 Routing the Load Cell Cable Above Ground Dyno....................... 1-12 Routing the Load Cell Cable In Ground Dyno........................... 1-13 Replacing the Covers.................................................. 1-14 Replacing the Covers Above Ground Dyno............................. 1-14 Replacing the Cover In Ground Dyno.................................. 1-17 Load Cell Calibration Load Cell Calibration.................................................... 2-2 Torque Cell Installation Guide for Model 250i/250iP DynoWare RT Dynamometers i
CHAPTER 1 TORQUE CELL INSTALLATION The torque cell along with Dynojet Power Core software provides the technician with the ability to control vehicle RPM or speed at any throttle opening. Through our exclusive closed-loop software design, the vehicle is automatically held at your predetermined setting. Use the torque cell and Power Core software to measure real-time torque, and perform sweep, step and custom load simulation tests. This document provides instructions for installing the torque cell on a Dynojet Model 250i/250iP DynoWare RT Motorcycle Dynamometer (dyno) and calibrating the torque cell using Power Core software. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Document Part Number: 98200070 Version 2 Last Updated: 07-01-2015 This chapter is divided into the following categories: Introduction, page 1-2 Main Dyno Power, page 1-3 Accessing the Dyno, page 1-5 Load Cell Installation, page 1-9 Routing the Load Cell Cable, page 1-12 Replacing the Covers, page 1-14 1-1
CHAPTER 1 Introduction INTRODUCTION The torque cell, when added to Dynojet's market leading inertia dynamometer, results in a complete vehicle performance test. Before installing and calibrating your torque module, please take a moment to read this guide for installation instructions, features, and other important information. CONVENTIONS USED IN THIS MANUAL The conventions used in this manual are designed to protect both the user and the equipment. example of convention Bold description The Caution icon indicates a potential hazard to the dynamometer equipment. Follow all procedures exactly as they are described and use care when performing all procedures. The Warning icon indicates potential harm to the person performing a procedure and/or the dynamometer equipment. Highlights items you can select on in the software interface, including buttons and menus. TECHNICAL SUPPORT For assistance, please contact Dynojet Technical Support at 1-800-992-3525, or write to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89081. Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of the art technical support, on-line shopping, and press releases about our latest product lines. 1-2
TORQUE CELL INSTALLATION Main Dyno Power MAIN DYNO POWER This section describes how to connect and disconnect the power to both the above ground and in ground dyno. CONNECTING AND DISCONNECTING THE POWER ABOVE GROUND DYNO Use the following steps to connect and disconnect power to the above ground dyno. Always turn the power off when connecting and disconnecting cables. 1 Use the main breaker to turn power on and off to the dyno. The main breaker is located inside the CPI door. When the handle is in the down position all power into the dyno is turned off. 2 Disconnect the power plug to ensure all power has been removed from the dyno before performing certain installation procedures. Components attached to and within the dynamometer operate with potentially lethal voltages. The power cord must be disconnected from the power source before servicing electrical components or wiring. power plug MC153 main breaker Figure 1-1: Main Dyno Power Above Ground Dyno Version 2 1-3
CHAPTER 1 Main Dyno Power CONNECTING AND DISCONNECTING THE POWER IN GROUND DYNO Use the following steps to connect and disconnect power to the in ground dyno. Always turn the power off when connecting and disconnecting cables. 1 Use the main breaker to turn power on and off to the dyno. The main breaker is located inside the CPI door. When the handle is in the down position all power into the dyno is turned off. 2 Disconnect the power plug to ensure all power has been removed from the dyno before installing the DynoWare RT electronics. Components attached to and within the dynamometer operate with potentially lethal voltages. The power cord must be disconnected from the power source before servicing electrical components or wiring. PD231 power plug main breaker Figure 1-2: Main Dyno Power In Ground Dyno 1-4
TORQUE CELL INSTALLATION Accessing the Dyno ACCESSING THE DYNO Installing the load cell requires access to the dyno and eddy current brake. This section will walk you through accessing both the above ground and in ground dyno. Make sure you have disconnected the power to the dyno before removing the covers. Refer to Main Dyno Power on page 1-3. ACCESSING THE DYNO ABOVE GROUND You will need to remove the tire carriage, center panel, and eddy current brake top cover in order to route the load cell cable to the eddy current brake driver. 1 Remove the four screws securing the bearing bracket to the tire carriage and set aside. 2 Using the hand wheel, or the power carriage, unscrew the bearing bracket and the carriage screw and set aside. 3 Remove the tire carriage by sliding the carriage under the carriage clamps toward the back of the dyno and set aside. tire carriage carriage clamp nut block carriage screw TC080 bearing bracket screws hand wheel Figure 1-3: Remove the Tire Carriage Version 2 1-5
CHAPTER 1 Accessing the Dyno 4 Remove the two 5/16-inch bolts and washers securing each of the carriage clamps and shims and set aside. 5 Remove the three carriage clamps and shims and set aside. 6 Remove the two 5/16-inch bolts and washers securing the nut block and shim and set aside. 7 Remove the nut block and shim and set aside. 8 Remove the six 1/4-20 x 5/8-inch pan head screws securing the center panel to the dyno carriage and set aside. 9 Remove the center panel and set aside. carriage clamp screw bolt washer shim nut block shim TC081 center panel Figure 1-4: Remove the Center Panel 1-6
TORQUE CELL INSTALLATION Accessing the Dyno 10 Remove the six screws securing the eddy current brake top cover and set aside. 11 Remove the brake top cover and set aside. brake top cover Figure 1-5: Remove the Brake Top Cover Version 2 1-7
CHAPTER 1 Accessing the Dyno ACCESSING THE DYNO IN GROUND brake cover You will need to remove the eddy current brake pit cover in order to route the load cell cable to the eddy current brake driver. 1 Remove the four 3/8-16 x 1/8-inch button-head flange screws securing the eddy current brake pit cover and set aside. 2 Remove the eddy current brake pit cover and set aside. PD245 Figure 1-6: Remove the Brake Pit Cover 1-8
TORQUE CELL INSTALLATION Load Cell Installation LOAD CELL INSTALLATION This section describes how to remove the existing bar on the eddy current brake and install the load cell. Use the following instructions for both the above ground and in ground dynos. You will need the following part: part description load cell and cable, above ground P/N 76950573 load cell and cable, in ground P/N 76950759 1 Verify the main dyno power is disconnected. Refer to Main Dyno Power on page 1-3 for more information. 2 Remove the two bolts and nuts securing the existing bar on the eddy current brake and remove the bar. Set the bolts and nuts aside. bar Figure 1-7: Remove the Existing Bar Version 2 1-9
CHAPTER 1 Load Cell Installation 3 Verify the eyelets on the load cell are spaced the same as the bar removed earlier. Adjust the load cell spacing by loosening the lock nut and turning the eyelet. bar eyelet lock nut distance must be the same Figure 1-8: Verify Load Cell Spacing 4 Secure the load cell to the mounting bracket using the two bolts and nuts removed earlier. load cell cable load cell Figure 1-9: Install the Load Cell Above Ground Dyno 1-10
TORQUE CELL INSTALLATION Load Cell Installation install the load cell (the brake is not shown for clarity) Figure 1-10: Install the Load Cell In Ground Dyno PD229 Version 2 1-11
CHAPTER 1 Routing the Load Cell Cable ROUTING THE LOAD CELL CABLE Use the following instructions to identify and route the load cell cable. cable 76950573 load cell and cable above ground dyno 76950759 load cell and cable in ground dyno brief routing description connects the load cell to the eddy current brake driver ROUTING THE LOAD CELL CABLE ABOVE GROUND DYNO 1 Route the load cell cable from the eddy current brake through the air hole in the drum bulkhead and over to eddy current brake driver. Make sure the load cell cable is clear of any power cables or hot or rotating objects. 2 Attach the load cell cable to the eddy current brake driver. 3 Secure the load cell cable with a zip tie to the underside of the carriage assembly bulkhead. DynoWare RT air hole in drum bulkhead eddy current brake driver load cell cable load cell MC158 Figure 1-11: Routing the Load Cell Cable Above Ground Dyno 1-12
TORQUE CELL INSTALLATION Routing the Load Cell Cable ROUTING THE LOAD CELL CABLE IN GROUND DYNO 1 Open the front panel of the CPI to access the eddy current brake driver. 2 Route the load cell cable from the eddy current brake, through the designated communications pit conduit, and attach to the eddy current brake driver inside the CPI. Note: Be sure to keep the power and communications cables in different pit conduits. DynoWare RT main module load cell cable route communications cables in designated conduit eddy current brake driver load cell control panel interface (CPI) air fuel ratio module (AFR) PD246 Figure 1-12: Routing the Load Cell Cable In Ground Dyno Version 2 1-13
CHAPTER 1 Replacing the Covers REPLACING THE COVERS Before replacing the covers, verify the load cell is installed and the load cell cable is routed to the eddy current brake driver. Before replacing the eddy current brake top cover, be sure to calibrate your load cell. Refer to Load Cell Calibration on page 2-2. REPLACING THE COVERS ABOVE GROUND DYNO 1 Secure the center panel to the dyno carriage using the six 1/4-20 x 5/8-inch pan head screws removed earlier. 2 Secure the nut block and shim using the two 5/16-inch bolts and washers removed earlier. 3 Secure each carriage clamps and shim using two 5/16-inch bolts and washers removed earlier, carriage clamp screw bolt washer shim nut block shim TC081 center panel Figure 1-13: Replace the Center Panel 1-14
TORQUE CELL INSTALLATION Replacing the Covers 4 Starting from the back of the dyno, slide the carriage under the carriage clamps. 5 Slide the carriage screw, bearing bracket, and the hand wheel toward the nut block until the carriage screw is touching the nut block. 6 Using the hand wheel, or the power carriage, screw the carriage through the nut block and into the screw support bracket. 7 Secure the bearing bracket to the carriage using four screws removed earlier. tire carriage carriage clamp nut block carriage screw TC080 bearing bracket screws hand wheel Figure 1-14: Replace the Tire Carriage Version 2 1-15
CHAPTER 1 Replacing the Covers 8 Secure the eddy current brake top cover using the six bolts removed earlier. Note: Before replacing the eddy current brake top cover, be sure to calibrate your load cell. Refer to Load Cell Calibration on page 2-2. eddy current brake cover EB242 Figure 1-15: Replace the Eddy Current Brake Top Cover 1-16
TORQUE CELL INSTALLATION Replacing the Covers REPLACING THE COVER IN GROUND DYNO brake cover Before replacing the eddy current brake pit cover, be sure to calibrate your load cell. Refer to Load Cell Calibration on page 2-2. Secure the eddy current brake pit cover using the four screws removed earlier. PD245 Figure 1-16: Replace the Brake Pit Cover Version 2 1-17
CHAPTER 2 LOAD CELL CALIBRATION This chapter will walk you through calibrating the load cell on both the above ground and in ground dynos. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Torque Cell Installation Guide for Model 250i/250iP DynoWare RT Dynamometers 2-1
CHAPTER 2 Load Cell Calibration LOAD CELL CALIBRATION This section provides instructions for calibrating the load cell. Follow the directions on the screen exactly. Failure to perform the directions accurately will result in improper torque values. You will need the following parts: part description part description weight, 25 pounds (4) P/N 35430899 calibration arm assembly P/N 61319001 1 Verify the dyno is connected to power. Refer to Main Dyno Power on page 1-3. 2 Double-click the Power Core program icon. 3 Click Dyno Control from the Application Launcher. 4 Verify you are connected to the DynoWare RT main module. Note: For more information on connecting to the dyno electronics, refer to the Power Core Quick Start Guide (on your Power Core CD or at www.dynojet.com) or the Power Core Online Help. 5 From the Configuration ribbon, click Load Cell Calibration. 6 Remove the calibration arm and mass if it is installed. 7 Release the dyno brake. Make sure the drums are free to rotate. Note: There should not be anything resting on the eddy current brake or the dyno drum during this procedure. 8 Click Next to zero the connected torque cell. Figure 2-1: Zero Calibration Window Torque Cell Installation Guide for Model 250i/250iP DynoWare RT Dynamometers 2-2
LOAD CELL CALIBRATION Load Cell Calibration 9 Using the drop-down arrow, set the index to zero. Note: Powersports Dynos have one load cell, leave the index set to zero. 10 Enter the calibration weight. This value is stamped into the calibration arm. bolt pattern closest to the end of the calibration arm Figure 2-2: Calibration Mass Window Enter the calibration number stamped near the bolt pattern at the end of the calibration arm in the Mass box. If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the number stamped near the bolt pattern in the center of the arm. Note: Dynojet recommends you secure the calibration arm using the bolt pattern closest to the end of the arm unless space constraints in your dyno room do not allow you to. bolt pattern near the center of the calibration arm Figure 2-3: Calibration Arm Number Version 2 Torque Cell Installation Guide for Model 250i/250iP DynoWare RT Dynamometers 2-3
CHAPTER 2 Load Cell Calibration 11 Install the calibration arm and weights using the bolts at the end of the calibration arm. Note: If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm. Refer to Figure 2-6 for above ground dynos and Figure 2-7 for in ground dynos. 11a Secure the calibration arm to the eddy current brake by tightening the bolt using the handle. 11b Gently place the weights on the calibration arm. Note: Verify the calibration arm is not contacting the cover. The calibration weights are very heavy. The weights must be set on the arm gently or you could damage the load cell. weights weight support pin secure arm to brake by tightening handle TM074 Figure 2-4: Install the Calibration Arm and Weights Using the Bolt Pattern Closest to the End Above Ground Dyno Torque Cell Installation Guide for Model 250i/250iP DynoWare RT Dynamometers 2-4
LOAD CELL CALIBRATION Load Cell Calibration secure arm to brake by tightening handle weight support pin TM076 weights Figure 2-5: Install the Calibration Arm and Weights Using the Bolt Pattern Closest to the End In Ground Dyno Version 2 Torque Cell Installation Guide for Model 250i/250iP DynoWare RT Dynamometers 2-5
CHAPTER 2 Load Cell Calibration If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm as shown in Figure 2-6 for above ground dynos and for Figure 2-7 in ground dynos. weight support pin weights secure arm to brake by tightening handle TM075 Figure 2-6: Install the Calibration Arm and Weights Using the Bolt Pattern in the Center Above Ground Dyno Torque Cell Installation Guide for Model 250i/250iP DynoWare RT Dynamometers 2-6
LOAD CELL CALIBRATION Load Cell Calibration secure arm to brake by tightening handle weight support pin weights TM077 Figure 2-7: Install the Calibration Arm and Weights Using the Bolt Pattern in the Center In Ground Dyno Version 2 Torque Cell Installation Guide for Model 250i/250iP DynoWare RT Dynamometers 2-7
CHAPTER 2 Load Cell Calibration 12 With the calibration arm and weights secured, click Next to calibrate. 13 Remove the calibration arm and weights and click Finish. Figure 2-8: Finish Calibration Window 14 Confirm the calibration was successful. For more information refer to the Power Core Online Help. Torque Cell Installation Guide for Model 250i/250iP DynoWare RT Dynamometers 2-8