Torque Module Installation and User Guide for Model 250i

Transcription

©2000-2005 Dynojet Research, Inc. All Rights Reserved.
Torque Module Installation and User Guide for model 250i Motorcycle Dynamometers.
This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet,
and all rights are reserved. This manual, as well as 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: 98193107 (03/05)
TABLE OF CONTENTS
Chapter 1
Torque Module Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Connecting and Disconnecting Power to the Dyno . . . . . . . . . . . . . . . . . . 1-3
Load Cell Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Removing the Carriage and Dyno Top Cover . . . . . . . . . . . . . . . . . . . . . . . 1-4
Removing the Eddy Current Brake Top Cover . . . . . . . . . . . . . . . . . . . . . . 1-7
Installing the Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Torque Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Accessing the Dyno Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Installing the Torque Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Routing the Load Cell Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Replacing the Dyno Top Cover and Carriage . . . . . . . . . . . . . . . . . . . . . . 1-17
Replacing the Eddy Current Brake Top Cover . . . . . . . . . . . . . . . . . . . . . . 1-20
Chapter 2
Using the Torque Module
Torque Cell Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Appendix A The Torque Module and WinPEP 6
Torque Module Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Index
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i
Torque Module Installation and User Guide for Model 250i Dynamometers
i
CHAPTER
1
TORQUE MODULE INSTALLATION
This document provides instructions for installing and using the Torque Module with
WinPEP 7. Appendix A includes instructions for using the Torque Module with
WinPEP 6. To ensure safety and accuracy in the procedures, perform the procedures
as they are described.
This chapter will walk you through installing the load cell and installing the Torque
Module.
Document Part Number: 98193107
Version 2
Last Updated: 03-08-05
This chapter is divided into the following categories:
• Introduction, page 1-2
• Load Cell Installation, page 1-4
• Torque Module Installation, page 1-10
1-1
CHAPTER 1
Introduction
INTRODUCTION
...................................
The Torque Module, when added to Dynojet's market leading inertia dynamometer,
results in a complete vehicle performance test.
CONVENTIONS USED IN THIS MANUAL
The conventions used in this manual are designed to protect both the user and the
equipment.
Example of Convention
Description
The Caution icon indicates a potential hazard to the
dynamometer equipment. Follow all procedures
exactly as they are described and use care when
performing all procedures.
The Warning icon indicates potential harm to the
person performing a procedure and/or the
dynamometer equipment.
Bold
Highlights items you can select on in the software
interface, including buttons and menus.
The arrow indicates a menu choice. For example,
“select File Open” means “select the File menu,
then select the Open choice on the File menu.”

TECHNICAL SUPPORT
For assistance, please contact Dynojet Technical Support at 1-800-992-3525, or write
to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89081.
Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of
the art technical support, on-line shopping, 3D visualizations, and press releases
about our latest product line.
PARTS LIST
The following table lists all of the parts included in the Torque Module Installation kit
(P/N 73920005). Check your kit against the parts listed to make sure you have
received all of the parts. If any part is missing, contact Dynojet Technical Support.
part number
35430899
61319001
66114002
or
66104001
76950503
description
Weight, 25 pounds
Calibration Arm Assembly
Torque Module Sub-Assembly
or
Torque Module High Resolution Sub-Assembly
Cable, Torque Cell
1-2
quantity
4
1
1
1
TO R Q U E M O D U L E I N S T A L L A T I O N
Introduction
CONNECTING AND DISCONNECTING POWER TO THE DYNO
Many instructions in this guide will require you to connect or disconnect the power to
the dyno as part of the installation process. Use the following steps to connect and
disconnect power to the dyno.
1
2
3
Use the main breaker to turn power on and off to the dyno.
The main breaker is located inside the power distribution assembly.
Disconnect the power plug to ensure all power has been removed from the dyno
before performing certain installation procedures.
power plug
main breaker
Figure 1-1: Main Breaker Location
Version 2
1-3
CHAPTER 1
Load Cell Installation
LOAD CELL INSTALLATION
...................................
This section describes how to remove the top covers, install the load cell, and replace
the top covers.
REMOVING THE CARRIAGE AND DYNO TOP COVER
You will need to remove the tire carriage and top cover in order to route the load cell
cable to the dyno electronics.
1
2
Using a 5/32-inch allen wrench, remove the two button-head screws securing the
carriage screw support bracket and set aside.
Remove the support bracket and set aside.
screws
support
bracket
carriage screw
belleville washers
Figure 1-2: Remove the Support Bracket
1-4
3
Using the hand crank or power carriage, unscrew the carriage screw until it is free
from the nut block. Slide the carriage off the dyno.
hand crank
Figure 1-3: Remove the Carriage
4
5
Verify the main dyno power is disconnected. Refer to page 1-3 for more
information.
Using a 1/2-inch wrench, remove the bolts and washers securing the nut block
and carriage clamps and set aside. Remove the nut block, carriage clamps, and
shims and set aside.
Figure 1-4: Remove the Nut Block, Carriage Clamps, and Shims
Version 2
1-5
CHAPTER 1
6
Remove the six 1/4-inch screws securing the top cover on the dyno and set aside.
Note: Dynojet recommends using a hardened 5/32-inch hex driver (such as SnapOn FA5E) to remove the 1/4-inch screws. A standard allen key may round off in
the shallow screw head.
7
Remove the cover and set aside.
top cover
Figure 1-5: Remove the Top Cover
1-6
REMOVING THE EDDY CURRENT BRAKE TOP COVER
1
2
3
information.
Remove the six screws securing the eddy current brake top cover and set aside.
Disconnect the battery ground cable.
brake cover
Figure 1-6: Remove the Brake Top Cover
Version 2
1-7
CHAPTER 1
INSTALLING THE LOAD CELL
1
2
information.
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
1-8
3
Install the load cell.
3a
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.
eyelet
bar
lock nut
distance must be
the same
Figure 1-8: Verify Load Cell Spacing
3b
Orient the load cell so the cable faces the dynamometer.
3c
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
Version 2
1-9
CHAPTER 1
TORQUE MODULE INSTALLATION
...................................
This section describes how to install the Torque Module, route the load cell cable,
replace the carriage, and replace the brake cover.
ACCESSING THE DYNO ELECTRONICS
You will need to access your dyno electronics in order to add the torque module. Use
the following steps to access the dyno electronics.
1
Turn off the main power to the dyno.
To prevent possible injury, place the breaker inside the power distribution
enclosure to the off position and unplug the dyno. Refer to page 1-3 for more
information.
2
3
Remove the four screws securing the dyno electronics enclosure and set aside.
Slide the enclosure toward you and out of the dyno. Be sure not to pinch or pull
any cables.
dyno electronics
enclosure
Figure 1-10: Remove the Dyno Electronics Enclosure
1-10
4
Remove the twelve screws securing the cover and lift the cover off.
Figure 1-11: Remove Electronics Enclosure Cover
5
6
Add the torque module to the top of the dyno electronics. Refer to “Installing the
Torque Module” on page 1-12.
Leave the dyno electronics enclosure out. You will need to route the load cell
cable to the Torque Module later.
dyno electronics
Figure 1-12: Inside the Electronics Enclosure
Version 2
1-11
CHAPTER 1
INSTALLING THE TORQUE MODULE
1
2
3
information.
Turn off the main power switch on the CPU Module on the dyno electronics and
unplug the power cord.
Remove the dust cover from the existing top module.
dust cover
power cord
input
power switch
Figure 1-13: Remove Dust Cover
4
5
6
Loosen the top right screw on the back of the existing top module.
Plug the Torque Module into the existing top module. Place the dust cover,
removed in step 3, on the Torque Module.
Secure the grounding strap on the back of the Air Fuel Module to the existing top
module.
grounding strap
Figure 1-14: Secure Grounding Strap
1-12
7
Secure the Torque Module to the dyno electronics with the plastic tie straps (one
on each side).
Note: Do not attach the load cell cable at this time.
torque module
tie strap
green LED light
load cell cable and port
do not attach at this time
Figure 1-15: Attach Torque Module
Version 2
1-13
CHAPTER 1
ROUTING THE LOAD CELL CABLE
1
Route the load cell cable from the eddy current brake through the air hole in the
drum bulkhead, under the carriage assembly bulkhead, and over to the dyno
electronics.
Make sure the load cell cable is clear of any power cables or hot or rotating
objects.
2
Secure the load cell cable with a zip tie to the underside of the carriage assembly
bulkhead.
Make sure there is enough slack in the cable to allow the dyno electronics
enclosure to slide out of the dyno.
load cell cable
air hole in drum
bulkhead
torque module
route cable under
carriage assembly
bulkhead
Figure 1-16: Routing the Load Cell Cable
1-14
3
4
5
Route the load cell cable through the cable clamp on the back of the dyno
electronics enclosure.
3a Loosen the two screws and lift the clamp up to slide the load cell cable
through.
3b Secure the clamp with the two screws.
Attach the 9-pin connector on the load cell cable to the front of the Torque
Module and tighten down the screws.
Attach the power cord to the dyno electronics and turn the power switch on.
cable clamp
torque module
load cell cable
Figure 1-17: Route the Cable to the Torque Module
Version 2
1-15
CHAPTER 1
6
7
Plug the main power cord for the dyno in and place the breaker inside the power
distribution enclosure to the on position. Refer to page 1-3 for more information.
The green LED light on the Torque Module should now be on.
torque module
green LED light
tie strap
load cell cable and port
do not attach at this time
Figure 1-18: Attach Torque Module and Load Cell Cable
8
9
Replace the dyno electronics cover. Refer to Figure 1-11 on page 1-11.
Slide the dyno electronics enclosure back in the dyno. Refer to Figure 1-10 on
page 1-10.
1-16
REPLACING THE DYNO TOP COVER AND CARRIAGE
1
Secure the top cover to the dyno using the six 1/4-inch screws removed earlier.
Note: Dynojet recommends using a hardened 5/32-inch hex driver (such as
Snap-On FA5E) to remove the 1/4-inch screws. A standard allen key may round off
in the shallow screw head.
Figure 1-19: Replace the Top Cover
Version 2
1-17
CHAPTER 1
2
Using a 1/2-inch wrench, install the shims, carriage clamps, and nut block using
the bolts and washers removed earlier.
Figure 1-20: Install the Shims, Carriage Clamps, and Nut Block
3
Using the hand crank or power carriage, screw the carriage through the nut bolck.
Figure 1-21: Replace the Carriage
1-18
4
5
Install the screw support bracket.
4a Place the belleville washers over the end of the carriage screw. It is
important the belleville washers are installed in the configuration shown in
Figure 1-22.
4b Place the screw support bracket in front of the carriage screw. The two
threaded holes in the bracket should face the two matching holes in the
carriage. Loosely install the two 1/4 x 1/2-inch button-head screws.
4c Before tightening the screws, apply some pressure to the bracket to
compress the belleville washers. The handle should still turn freely, but the
turning force should now be around five to six pounds.
To adjust the force needed to turn the crank handle, adjust the compression
of the belleville washers.
4d Using a 5/32-inch allen wrench, tighten the two button-head screws.
Tighten the clamp and nut block bolts with a 1/2-inch wrench.
screws
support
bracket
carriage screw
belleville washers
Figure 1-22: Install the Support Bracket
Version 2
1-19
CHAPTER 1
REPLACING THE EDDY CURRENT BRAKE TOP COVER
Before replacing the top cover, be sure to calibrate your load cell. Refer to Chapter 2
"Using the Torque Module".
1
2
Connect the battery ground cable.
Secure the eddy current brake top cover using the six bolts removed earlier.
Note: Before replacing the top cover, be sure to calibrate your load cell. Refer to
Chapter 2 "Using the Torque Module".
brake cover
Figure 1-23: Replace the Brake Top Cover
1-20
CHAPTER
2
USING THE TORQUE MODULE
This chapter provides instructions for using the Torque Module with WinPEP 7.
Appendix A includes instructions for using the Torque Module with WinPEP 6. To
ensure safety and accuracy in the procedures, perform the procedures as they are
described.
2-1
CHAPTER 2
Torque Cell Calibration
TORQUE CELL CALIBRATION
...................................
The Torque Module must be calibrated prior to use. Follow the directions on the
screen exactly. Failure to perform the directions accurately will result in improper
torque values.
1
2
Verify you are in the MakeRun screen.
Verify you are connected to the dyno electronics.
Note: For more information on connecting to the dyno electronics, refer to the
WinPEP 7 User Guide (on your WinPEP CD or at
www.dynojet.com/manuals.shtml) or the WinPEP 7 Online Help.
3
Select Tools MakeRun Options Torque Cell Calibration.
Note: Before proceeding, be sure the eddy current brake is free and clear of any
obstructions. There should not be anything resting on the eddy current brake or
the dynamometer drum during this procedure.
4
Click Next to perform the Zero Calibration.
The Calibration window will appear. The hardware is now zeroing out the torque
cell. If the unit does not calibrate, recheck the setup and retry.
Figure 2-1: Zero Calibration Window
2-2
U S I N G T H E TO R Q U E M O D U L E
Once the Zero Calibration is complete, the Calibration Mass window will appear.
5
Enter the Torque Module calibration value. Refer to Figure 2-3.
Note: You must perform this step the first time you calibrate the load cell.
Or
If you are only performing a Zero Calibration, click Finish.
Figure 2-2: Calibration Mass Window
Enter the calibration number stamped near the bolt pattern at the end of the
calibration arm. If you do not have enough room to use the bolt pattern closest to
the end of the calibration arm, use the number stamped near the bolt pattern in
the center of the arm.
Note: Dynojet recommends you secure the calibration arm using the bolt pattern
closest to the end of the arm unless space constraints in your dyno room do not
allow you to.
bolt pattern near the
center of the
calibration arm
bolt pattern closest to
the end of the
calibration arm
Figure 2-3: Calibration Arm Number
Version 2
2-3
CHAPTER 2
6
Click Next to continue.
The Span Calibration window will appear.
7
Install the calibration arm and weights. Refer to step 8 and
Figure 2-5 on page 2-5.
Figure 2-4: Span Calibration Window
2-4
8
Install the calibration arm and weights using the bolt pattern 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 on page 2-6.
8a
8b
Secure the calibration arm to the eddy current brake using the handle to
tighten the bolt.
Gently place the weights on the calibration arm.
The calibration weights are very heavy. The weights must be set on the arm
gently or you will damage the load cell.
weights
weight support
pin
secure arm to brake by
tightening the handle
Figure 2-5: Install Calibration Arm and Weights Using the Bolt Pattern Closest to the End
Version 2
2-5
CHAPTER 2
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.
weights
weight support
pin
Figure 2-6: Install Calibration Arm and Weights Using the Bolt Pattern in the Center
2-6
While installing the calibration weights, you should notice the Torque Gauge on the
DynoTrac Window moving from 0 to about 500 foot-pounds.
Note: The Torque Gauge may or may not be in this range.
• If the torque cell has been previously calibrated incorrectly or has not been
calibrated for a while, the gauge may show values out of this range until
calibration is complete.
• If you use the bolt pattern in the center of the calibration arm, the gauge will
show values around 250-260 foot-pounds.
Note: Let the torque gauge needle stabilize before clicking Next.
9
From the Span Calibration window (Figure 2-4), click Next to continue.
At this point, the value on the gauge should match the value on the calibration
arm.
10 Remove the calibration arm and weights and click Finish.
Figure 2-7: Calibration Is Complete Window
Version 2
2-7
APPENDIX
A
THE TORQUE MODULE AND WINPEP 6
This appendix provides instructions for using the Torque Module with WinPEP 6. To
ensure safety and accuracy in the procedures, perform the procedures as they are
described.
A-1
APPENDIXA
Torque Module Calibration
TORQUE MODULE CALIBRATION
...................................
After initial calibration, the Torque Module should be Zero Calibrated approximately
every thirty hours of use.
Before proceeding, be sure the eddy current brake (retarder) is free and clear of any
obstructions. There should not be anything resting on the eddy current brake or the
dynamometer drum during this procedure.
1
Launch WinPEP and click the DynoTrac icon.
DynoTrac icon
Figure A-1: Launch WinPEP
The DynoTrac window will appear.
2
Select Options Display Eng Torque from the main menu. The gauge needs
to display “Eng Torque” and not “Braking”.
main menu
gauge displays
engine torque
Figure A-2: DynoTrac Window
A-2
T H E TO R Q U E M O D U L E A N D W I N P E P 6
3
Select Options Calibrate.
Note: Before proceeding, be sure the eddy current brake is free and clear of any
obstructions. There should not be anything resting on the eddy current brake or
the dynamometer drum during this procedure.
4
Enter the Torque Module calibration value.
Enter the calibration number stamped near the bolt pattern at the end of the
calibration arm. If you do not have enough room to use the bolt pattern closest to
the end of the calibration arm, use the number stamped near the bolt pattern in
the center of the arm.
Note: Dynojet recommends you secure the calibration arm using the bolt pattern
closest to the end of the arm unless space constraints in your dyno room do not
allow you to.
bolt pattern near the
center of the
calibration arm
bolt pattern closest to
the end of the
calibration arm
Figure A-3: Calibration Arm Number
Note: Follow the directions on the screen exactly. Failure to perform the
directions accurately will result in improper torque values.
Version 2
A-3
APPENDIXA
5
Click Next to continue.
Figure A-4: Calibration Mass Window
The Zero Calibration is now being performed.
Figure A-5: Zero Calibration Window
The Span Calibration window will appear.
A-4
6
Install the calibration arm and weights. Refer to step 7 and Figure 7 on page 6.
Note: You must perform this step the first time you calibrate the load cell.
Or
If you are only performing a Zero Calibration, click Cancel.
Figure A-6: Span Calibration Window
Version 2
A-5
APPENDIXA
7
Install the calibration arm and weights using the bolt pattern 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 A-8 on page A-7.
7a
7b
Secure the calibration arm to the eddy current brake using the handle to
tighten the bolt.
Gently place the weights on the calibration arm.
The calibration weights are very heavy. The weights must be set on the arm
gently or you will damage the load cell.
weight support
pin
Figure A-7: Install Calibration Arm and Weights Using the Bolt Pattern Closest to the End
A-6
weights
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 A-8.
weight support
pin
weights
Figure A-8: Install Calibration Arm and Weights Using the Bolt Pattern in the Center
Version 2
A-7
APPENDIXA
While installing the calibration weights, you should notice the Torque Gauge on the
DynoTrac Window moving from 0 to about 500 foot-pounds. The gauge is for display
purposes only and may not read correctly. The gauge remains uncalibrated until the
calibration process is complete.
• If the torque cell has been previously calibrated incorrectly or has not been
calibrated for a while, the gauge may show values out of this range until
calibration is complete.
• If you use the bolt pattern in the center of the calibration arm, the gauge will
show values around 250-260 foot-pounds.
Note: Let the torque gauge needle stabilize before clicking Next.
Figure A-9: Torque Gauge
8
9
From the Span Calibration window (Figure A-6), click Next to continue.
Remove the calibration arm and weights and click Finish.
Figure A-10: Calibration Is Complete Window
A-8
INDEX
A
N
B
P
accessing dyno electronics 1-10
battery ground cable 1-7, 1-20
belleville washers 1-4, 1-19
brake cover
removing 1-7
replacing 1-20
C
cable clamp 1-15
calibration arm 2-3, A-3
number 2-3, A-3
weights 2-5, A-6
carriage assembly bulkhead 1-14
carriage clamps 1-5, 1-18
conventions 1-2
D
document part number 1-1
drum bulkhead 1-14
dyno electronics
accessing 1-10
cable clamp 1-15
dyno top cover
removing 1-6
replacing 1-17
E
eddy current brake cover
removing 1-7
replacing 1-20
L
load cell
installation 1-4–1-16
routing the cable 1-14
nut block 1-5, 1-18
parts list 1-2
power
connecting and disconnecting 1-3
main breaker location 1-3
R
routing the load cell cable 1-14
S
screw support bracket 1-4, 1-19
T
technical support 1-2
tire carriage
belleville washers 1-4, 1-19
carriage clamps 1-5, 1-18
nut block 1-5, 1-18
removing 1-4
replacing 1-18
screw support bracket 1-4, 1-19
torque cell calibration 2-2–2-7
calibration arm 2-3, A-3
calibration number 2-3, A-3
calibration weights 2-5, A-6
torque gauge 2-7, A-8
torque module
installation 1-12–1-16
W
WinPEP 6 A-1
WinPEP 7 2-1
Z
zero calibration 2-2, A-4
M
main breaker location 1-3
Index-i

Torque Module Installation and User Guide for Model 250i

Transcription

Similar documents

frs_brz_sheet

ETP Techno

field services

Regions CD Check Viewer Installation Guide

Hotrodden the Predator Part 1 of 3

Dual Port, Four Barrel, Aluminium lnlet Manifold. Crane Cam and

The Analysis Of Dioxins And Furans Using HRGC-High

LGOBO SALE SHEET

BorgWarner eAWD

Echo Flooring Gallery will Floor You with Huge Savings and 0% 12

Pre-Installation Guide For Model 200i/250i, 200iP/250iP, 250iX, and