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Dynojet Research 200ip User's Manual

1. PD031 Figure 1 16 Install the Control Panel 1 18 Control Panel Interface Installation and User Guide CONTROL PANEL INTERFACE INSTALLATION he Routing Cables s y ROUTING THE BLOWER CABLES The high pressure blowers are an optional accessory If you did not order this accessory skip these instructions 1 Route each blower cable P N 76950315 from the CPI through the designated power pit conduit through the pit and out of the pit as shown Note Be sure to keep the power and communications cables in different pit conduits 2 From the pit route both cables into the junction box Attach the two blower connectors to the junction box using 4 40 screws 4 Connect the cables from each blower to the connectors on the junction box Note There is an extension cable P N 76950317 for the blower furthest from the junction box WwW extension cable connectors 1 ibe i O O L rs T e5 oad dyno electronics a O Qo route power cables in designated conduit PDO32 Figure 1 17 Route Blower Cables 1 19 Version 1 Control Pane Interface Installation and User Guide CHAPTER 1 Routing Cables ve ROUTING THE MOTORIZED CARRIAGE AND WHEEL CLAMP CABLES The wheel clamp is an optional accessory If you did not or
2. For operation of the starter motorized carriage or optional wheel clamp it is necessary to install a car battery in the dyno The car battery provides the necessary energy to run these components The CPI has a built in battery charging circuit to keep the battery charged Each time the starter motorized carriage or wheel clamp is used this built in charging circuit will recharge the battery The charging rate is sufficient to keep up with loading a bike operating the wheel clamp and adjusting the motorized carriage every five minutes Recharging from use of the built in dyno starter will take longer Do not add any external battery chargers to the car battery If you do not wish to use the wheel clamp and the motorized carriage or operate the built in starter then it is not necessary to install the battery Note If you do not install the battery make sure the positive battery cable is insulated from the chassis as the charging circuit is always providing charging current whenever the dyno main power breaker is turned on The battery charging circuit is active anytime the main power on the dyno is turned on If the main breaker is turned off then the battery will not be charged Frequent use of the starter will quickly deplete the battery and it may need several hours of the internal charging to bring the battery back to a full charge 1 7 Version 1 Control Panel Interface Installation and User Guide s CHAPTER 1 b Battery ws I
3. Figure 1 2 Right Side Drum Cover 1 4 Control Panel Interface Installation and User Guide ero CONTROL PANEL INTERFACE INSTALLATION one Introduction 4 Remove the four 3 8 16 x 1 2 inch button head flange screws securing the left side drum cover and set aside 5 Remove the cover and set aside PD006 Figure 1 3 Left Side Drum Cover 6 Remove the four 3 8 16 x 1 2 inch button head flange screws securing the retarder cover and set aside 7 Remove the cover and set aside PD004 Figure 1 4 Retarder Cover 1 5 Control Panel Interface Installation and User Guide Version 1 CHAPTER 1 Introduction We REMOVING THE CONTROL PANEL INTERFACE COVER The Control Panel Interface CPI comes wired and ready to install Should you need to re route the cables so they come out a different side of the box use the following instructions to access the CPI box 1 Turn off the power to the dyno Refer to Connecting and Disconnecting Power to the Dyno on page 1 3 for more information 2 Remove the eight button head screws securing the cover and set aside Remove the cover and set aside 4 Open the front panel to access the breakers and Breakout board WwW e cover z front panel access P d Nt y x fl L i S SS PD027 Figure 1 5 Accessing the CPI 1 6 Control Panel Interface Installation and User Guide CONTROL PANEL INTERFACE INSTALLATION Battery WS 4 BATTERY
4. S RESEARCH DYNORUN 002 Max Power 36 39 Max Torqu r DYNORUN 010 Max Power 1 62 Nax Torque DYNORUN 016 Max Power 2 j a CONTROL PANEL NTERFACE INSTALLATION AND USER GUIDE For Model 200ip and 250ip Motorcycle Pit Dynamometers P N 98225109 01 2005 Dynojet Research Inc All Rights Reserved Control Panel Interface Installation and User Guide For Model 200ip and 250ip Motorcycle Pit Dynamometers This manual is copyrighted by Dynojet Research Inc hereafter referred to as Dynojet and all rights are reserved This manual 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
5. This chapter is divided into the following categories e Basic Operation page 2 2 e Power Distribution Assembly page 2 8 e Maintenance and Troubleshooting page 2 9 Control Panel Interface Installation and User Guide Pf CHAPTER 2 7 Basic Operation BASIC OPERATION The control panel may be mounted to either side of the tray for easy access by the dyno user while seated on the bike The graphics on the control panel are grouped together according to function and color coded for ease of identification A description of the functions and displays follows status indicator STATUS light Flashing Error refer to manual Steady indicator light wheel F A R R I A G E AWARNING Eye and Ear protection required Read and follow all instructions and safety precautions STARTER CAUTION FRONT WHEEL MUST BE SECURED AT ALL TIMES TIE DOWN STRAPS MUST BE ere USED TO STABILIZE THE MOTORCYCLE jada filter regularly 97415160 Figure 2 1 Control Panel Features 2 2 Control Panel Interface Installation and User Guide USING THE CONTROL PANEL INTERFACE Basic Operation R gt control panel feature description Air Fuel Ratio Air Pump This optional accessory allows control of the internal air pump of the air fuel ratio sampling system Refer to page 2 3 for more information Emergency Stop Dyno Shutdown Deactivates the dyno outputs whenever the button is pr
6. dyno electronics air fuel sensor cable air pump power cable 7 bant PD036 air pump Figure 1 24 Route the Air Pump and Stack Power Cables 1 26 Control Panel Interface Installation and User Guide CONTROL PANEL INTERFACE INSTALLATION Ss Junction Box Cover Cable Cover and End Cap JUNCTION BOX COVER CABLE COVER AND END CAP 1 Secure the blower connector cover to the junction box using two 4 40 screws This cover attaches opposite the blower connectors blower connector junction box blower connector cover Eo PD046 Figure 1 25 Install the Blower Connector Cover 2 Secure the junction box cover to the junction box using two 8 32 screws junction box cover PD044 Figure 1 26 Install the Junction Box Cover 1 27 Version 1 Control Panel Interface Installation and User Guide Pf CHAPTER 1 7 amp Junction Box Cover Cable Cover and End Cap 3 Loosely attach the end cap to the pit cover using two 1 4 20 button head screws Leave these screws loose 4 Secure the cable cover to the end cap and junction box using two 8 32 screws 5 Tighten the end cap screws end cap cable cover PD042 Figure 1 27 Secure End Cap and Cable Cover 1 28 Control Panel Interface Installation and User Guide CONTROL PANEL INTERFACE INSTALLATION ss gt Testing the Motorized Carriage an
7. Check with local building codes for the correct size 1 Connect one of the 240V legs to the X terminal gold colored screw 2 Connect the other 240V leg to the Y terminal gold colored screw 3 Connect the neutral conductor to the W or WH terminal silver screw 4 Connect the ground conductor to the green grounding screw D 2 Control Panel Interface Installation and User Guide Version 1 POWER REQUIREMENTS he Power Requirements and Installation N orth America Japan and Locations Using 60 Hz Power TESTING FOR CORRECT VOLTAGES You must test the receptacle for proper voltages before the dyno is connected to the outlet AN If the voltage readings do not match the following table DO NOT connect the dyno You must have a licensed electrician correct the power connection Connecting the dyno to the incorrect voltage can result in damage to the dyno and will void the dyno warranty Contact Dynojet with any questions Using a voltmeter that is capable of measuring AC voltage measure between the points listed below and verify that the correct voltages are present probe 1 probe 2 desired voltage measurement 2 4 225V to 250V 1 4 108V to 130V 1 2 108V to 130V 1 3 lt 5V 3 box lt 5V Figure D 1 Dedicated Power Receptacle Control Panel Interface Installation and User Guide 47 w Z F APPENDIXD yy Power Requirements and Installation North America Japan and Locations Using 60 Hz Power REPLA
8. brown and the blue wires through the disconnect switch 2 Connect the green yellow wire to the ground connection 3 Wrap the black wire with white tape to denote that it is a neutral connection and connect it to the neutral connection 4 Refer to the previous table for testing and probe the new connections as follows e blue wire as location 2 brown wire as location 4 e black wire as location 1 e green yellow wire as location 3 D 4 Control Panel Interface Installation and User Guide Version 1 POWER REQUIREMENTS g Power Requirements and Installation N orth America Japan and Locations Using 60 Hz Power is CONNECTING THE DYNO 1 ul Turn off the main circuit breaker on the dyno This is the large breaker in the center of the power distribution assembly behind the door on the left hand side of the dyno Refer to page 1 3 for breaker location Off is the down position Once you verify the voltages on the receptacle connect the dyno to the receptacle Connect the high pressure blowers to the dyno For more information on installing and connecting the blowers refer to page 1 11 and page 1 19 Turn on the main dyno breaker Refer to page 1 3 for breaker location Test the blowers for operation Turn on the dyno electronics and verify operation Control Panel Interface Installation and User Guide z F APPENDIXD yy Power Requirements and Installation Excluding North America and Japan POWE
9. routing cable 1 20 testing 1 29 troubleshooting 2 9 using 2 6 Version 1 Control Panel Interface Installation and User Guide 47 co Index iii
10. 20 testing 1 29 using 2 5 Index ii Control Panel Interface Installation and User Guide P PDA see also power distribution assembly pendant cable 1 15 1 18 pickup card cable 1 25 pit conduits designation 1 14 pit room layout 1 14 power D 2 D 6 connecting the dyno D 5 D 10 hard wiring D 4 D 9 installation D 2 D 6 installing receptacle D 2 D 7 replacing power plug D 4 D 9 requirements D 2 D 6 testing voltages D 3 D 8 power distribution assembly 2 8 blower circuit breakers 2 8 fuses 2 10 main circuit breaker 2 8 troubleshooting 2 10 power requirements D 2 D 6 red head anchor contact information A 1 installing A 2 setting tool A 3 warnings A 1 removing pit covers 1 4 1 5 left drum cover 1 5 retarder cover 1 5 right drum cover 1 4 retarder pit cover 1 5 right drum pit cover 1 4 routing cables 1 14 1 26 25 pin 1 25 9 pin 1 25 air fuel sensor 1 26 air pump power 1 26 battery 1 23 blower extension 1 19 blowers 1 19 control panel 1 15 1 18 dyno electronics 1 25 dyno electronics power 1 26 dyno power 1 23 eddy current brake 1 23 motorized carriage 1 20 pendant 1 15 1 18 pickup card 1 25 starter 1 23 wheel clamp 1 20 S safety switch C 2 setting tool A 3 starter routing cable 1 23 using 2 5 status indicator 2 3 support arm anchor placement 1 10 installing 1 11 T technical support 1 2 testing voltages D 3 D 8 W wheel clamp closing 2 7 installing B 5 B 6 maintenance 2 9 opening 2 7
11. Electronics Cables 1 25 Routing the Air Pump Power Air Fuel Sensor and Dyno Electronics Power Cables 0 n teen en a aa 1 26 Junction Box Cover Cable Cover and End Cap 1 27 Testing the Motorized Carriage and Wheel Clamp 1 29 ange Control Panel Interface Installation and User Guide TABLE OF CONTENTS a 4 Chapter 2 Using the Control Panel Interface Basic Operation aaun aeekes ase cbakeantaneiase aeee en dees 2 2 Using the Air Fuel Ratio Air PUMP 200 eee eee 2 3 Using the Emergency Stop Dyno Shutdown 000e aranna 2 4 Using the High Pressure Blowers 0 0 0 cece eee eee eee ees 2 4 Understanding InterlockS 0 0 eee 2 4 Using the Motorized Carriage 0 c ee 2 5 Using the Starter 2 0 aunan 2 5 Using the Status Indicator 0 0 0 ccc eee eee eens 2 6 Using the Wheel Clamp 0000 cee eee 2 6 Power Distribution Assembly 00 00 eee eee 2 8 Main Circuit Breaker 0 0 ccc ee 2 8 High Pressure Blower Circuit Breakers 0 cece eee eee eens 2 8 Maintenance and Troubleshooting 0 0 cece eee eee eee 2 9 Wheel Clamp J5 2 40224 05awnre mea phi de ce een ibd ed Pade sate 2 9 Troubleshooting Power Distribution Assembly Fuses 2 10 Appendix A Red Head Anchor Installation WamINGS 2tctattah os caren g aaa a aa adai a e a aAa a E EA A 1 Contact Information for IT
12. INTERFACE INSTALLATION This document provides instructions for installing and using the Control Panel Interface CPI with the model 200ip 250ip motorcycle pit dynamometer To ensure safety and accuracy in the procedures perform the procedures as they are described This manual will walk you through installation procedures basic operation and how to maintain and troubleshoot your hardware Appendix A contains instructions for installing the Red Head Anchors Appendix B contains instructions for installing the motorized carriage and wheel clamp Appendix C contains instructions for installing the safety switch should your country require one Document Part Number 98225109 Version 1 Last Updated 01 21 05 This chapter is divided into the following categories e Introduction page 1 2 Battery page 1 7 e Blower Mounts Support Arm and Junction Box page 1 10 e Routing Cables page 1 14 e Junction Box Cover Cable Cover and End Cap page 1 27 e Testing the Motorized Carriage and Wheel Clamp page 1 29 Control Panel Interface Installation and User Guide ay Ay 1 2 Control Panel Interface Installation and User Guide CHAPTER 1 Introduction INTRODUCTION The Control Panel Interface CPI consists of a main control board which is mounted in an external box for a pit dyno or retrofit This board provides switching and control of many functions within the dyno The front panel of this board is accessible through the door
13. Interface Installation and User Guide B 5 xy APPENDIXB ey Wheel Clamp 4 Bring the wheel clamp cable three pin connector from the cable track over to the wheel clamp This cable was routed on page 1 19 5 Install the wheel clamp cable strain relief to the side of the wheel clamp 6 Plug the wheel clamp cable into the connector on the wheel clamp motor 7 Replace the wheel clamp cover strain relief wheel clamp cable cable track WCO10 Figure B 6 Secure the Strain Relief and Cable B 6 Control Panel Interface Installation and User Guide APPENDIX SAFETY SWITCH INSTALLATION This appendix provides instructions for installing the safety switch with the model 200ip and 250ip motorcycle pit dynamometer dyno and the Control Panel Interface CPI To ensure safety and accuracy in the procedures perform the procedures as they are described Control Panel Interface Installation and User Guide APPENDIXC Installing the Safety Switch ws INSTALLING THE SAFETY SWITCH Safety requirements of your local country may require that a safety switch is installed Be sure to follow the safety requirements specific to your country The safety switch requires the air brake to work This switch is located on the dyno room door when the door is open the air brake is locked This prevents the dyno from being used when the door is open 1 Open the front panel access and turn off the main breaker 2 Unplug the dyno pow
14. arm 1 10 B battery 1 7 1 9 cable 1 23 charger 1 7 hazards 1 9 installing 1 8 type 1 8 blower cables 1 19 blower connector cover 1 27 blower mounts anchor placement 1 10 installation 1 11 blowers 1 13 circuit breakers 2 8 extension cable 1 19 using 2 4 INDEX C cable cover 1 28 cable track 1 20 adapter bracket 1 21 bracket 1 20 control panel 2 2 air pump 2 3 blowers 2 3 2 4 dyno shutdown 2 3 emergency stop 2 3 installing 1 18 motorized carriage 2 3 2 5 routing cable 1 15 1 18 starter 2 3 2 5 status indicator 2 3 wheel clamp 2 3 2 6 control panel interface 1 2 battery charger 1 7 removing the cover 1 6 conventions 1 2 coupler jaw B 2 coupler spider B 4 CPI see also control panel interface D document part number 1 1 dyno electronics cables 1 25 power cable 1 26 dyno power connecting 1 3 disconnecting 1 3 dyno power cable 1 23 dyno shutdown 2 3 2 4 2 4 2 4 Index i Control Panel Interface Installation and User Guide INDEX E eddy current brake cable 1 23 emergency stop 2 3 2 4 end cap 1 28 F flange bearing B 2 fuses 2 10 G grease zerk B 2 H high pressure blowers 1 13 interlocks 2 4 junction box 1 11 1 27 L left drum pit cover 1 5 M main circuit breaker 1 3 2 8 monitor tray 1 12 motor mount B 2 motorized carriage coupler jaw B 2 coupler spider B 4 flange bearing B 2 grease zerk B 2 installing B 2 B 4 motor mount B 2 routing cable 1
15. off The indicator light by each button will light up when that blower output is turned on If the toggle switch on the blower is turned off the blower will not operate even if the CPI output is on The blower outlets on the front of the dyno are designed to only work with Dynojet provided blowers Connecting other electrical loads or other blowers to the outlets on the dyno may damage the dyno and void the warranty If the blower indicator light on the control panel is on but the blower is not running perform the following steps 1 Verify the switch on the blower is on 2 Verify the blower power plug is firmly plugged into the dyno 3 Verify the blower circuit breakers in the power distribution assembly If the button on the breaker is extended an overload has occurred and the breaker has tripped Press in the breaker button to reset the breaker If the breaker continues to trip contact Dynojet UNDERSTANDING INTERLOCKS The interlock circuit provides inputs for normally closed switches which open when it is not safe to run the dyno Typically these switch inputs will be tied to safety gates and safety switches that are required in Europe If the Interlock circuit is open the Status Indicator light will blink on and off with the on time equal to the off time This will continue until this circuit is closed or an overriding E Stop condition is sensed In a dyno configured to comply with CE requirements the interlock signal will activat
16. on the monitor keyboard tray since vibration can cause damage to the computer monitor tray a a J ie ogee arm i 1 I F I ji i PA Tr poly washer Cor ee washer A first arm poly washer support arm MA013 Figure 1 9 Install the Monitor Tray 1 12 Control Panel Interface Installation and User Guide CONTROL PANEL INTERFACE INSTALLATION Ss x Blower Mounts Support Arm and Junction Box S INSTALLING THE HIGH PRESSURE BLOWERS The high pressure blowers are an optional accessory If you did not order the high pressure blowers skip these instructions Repeat the following steps for each blower assembly 1 Place two 1 4 inch thick poly washers around the pin on the blower mount Note Only use one 1 4 inch thick poly washer with the blower mount installed with the support arm 2 Place the lower blower arm over the blower mount pin 3 Place a 3 8 inch thick metal washer on top of the lower blower arm 4 Secure the lower blower arm using the clamp lever 5 Place a1 8 inch thick poly washer around the pin on the upper blower arm 6 Insert the pin on the upper arm into the lower arm 7 Place a1 8 inch thick poly washer around the pin on the blower assembly 8 Insert the pin on the blower assembly into the upper arm blower clamp lever metal washer ae assembly poly washer ee ee upper arm eee a poly washer blower assembly lower arm only one 1 4 inch poly washer poly was
17. on the external box The user interface is through the Control Panel which is normally mounted on the side of the monitor tray The Control Panel allows the user to control the following items e Optional AFR Air Pump Optional High Pressure Blowers Optional Motorized Carriage e Starter Optional Wheel Clamp The CPI main control board has an on board microprocessor which reads the user input from the Control Panel monitors interlock and E Stop inputs and controls the various dyno outputs The CPI is powered internally from the main power that is provided to the dyno The power supplied is 240VAC 50 or 60 Hz 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 ATU 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 PN WARNING person performing a procedure and or the dynamometer equipment 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
18. protection for the power that is provided for the 12VDC accessories from the dyno owner installed car battery This also protects the charging circuit to the battery If this fuse is open the motorized carriage and the wheel clamp will not function Replace with a 15A mini auto fuse Fuse F1 protects the wheel clamp drive circuit If this fuse is open the wheel clamp motor will not activate Replace with a 15A mini auto fuse Fuse F2 protects the motorized carriage drive circuit If this fuse is open the motorized carriage motor will not activate Replace with a 15A mini auto fuse eal ho j PD047 F3 F4 control panel 6 interface board status light F1 F2 0 4 am Figure 2 3 Power Distribution Assembly Fuses 2 10 Control Panel Interface Installation and User Guide APPENDIX RED HEAD ANCHOR INSTALLATION This appendix contains instructions for installing the Red Head Multi Set I Anchors The anchors will be used to secure the dyno to concrete To ensure safety and accuracy in the procedures perform the procedures as they are described Be sure to read and understand the warnings included in this appendix WARNINGS A gt WARNING Always wear safety glasses and other necessary protective devices or apparel when installing or working with anchors ITW Ramset Red Head Multi Set II Anchors are designed to operate prope
19. the air brake will release and the status light will be on steady Version 1 Control Panel Interface Installation and User Guide APPENDIX POWER REQUIREMENTS This appendix contains the power requirements and instructions for all dyno installations To ensure safety and accuracy in the procedures perform the procedures as they are described _OCCOCOC CC D1 Control Panel Interface Installation and User Guide Z F APPENDIXD fy Power Requirements and Installation North America Japan and Locations Using 60 Hz Power POWER REQUIREMENTS AND INSTALLATION NORTH AMERICA JAPAN AND LOCATIONS USING 60 HZ POWER The following power requirements and instructions are for North America Japan and locations using 60 Hz power Refer to Power Requirements and Installation Excluding North America and Japan on page D 6 for all other locations The model 200ip 250ip dynamometer requires a dedicated 240VAC single phase power outlet rated for 30A for proper operation Failure to follow these instructions could result in personal injury or damage to the dyno Connecting the dyno to the incorrect voltage will void the dyno warranty Contact Dynojet with any questions The model 200ip 250ip dynamometer requires a dedicated wall receptacle which must be wired for operation and is included with the dyno or may be shipped in advanced in a separate package The dyno is equipped with a ten foot power cord with a twist lock plug pre wired
20. to allow for normal dyno operation e Status Blinking If the status indicator light is blinking with equal on and off time the interlock signal into the CPI board is open This signal monitors the condition of optional safety switches that will be attached to safety guards or the dyno room door when guards are not used this will allow dyno operation only when the guards are in place or the door is closed The E Stop circuit takes precedence over the interlock input USING THE WHEEL CLAMP This optional accessory requires the CPI and battery to operate The wheel clamp allows for quicker bike loading and unloading The internal mechanism in the wheel clamp closes on the bike s front wheel and tire to a calibrated amount of pressure securing the bike The indicator light between the wheel clamp buttons provides status of the current state of the wheel clamp A P WARNING Pinch hazard Keep hands body parts and other loose items clear Failure to follow these instructions can result in serious injury or equipment damage PSN WARNING Risk of injury Be sure the wheel clamp is free and clear of any obstruction Do not operate the dyno if the wheel clamp indicator light is not on steady 2 6 Control Panel Interface Installation and User Guide USING THE CONTROL PANEL INTERFACE Ss Basic Operation CLOSING THE WHEEL CLAMP Do not run into the edges of the whee clamp pads with the bike tire Make sure the whee
21. CING THE POWER PLUG Use the following instructions to replace the four wire plug and socket The plug and socket configuration must be rated for at least 240VAC 30A and have a minimum of four conductors The power cord that attaches to the dyno has four conductors internally and their colors are brown blue black and green yellow 1 Connect 240VAC single phase power between the brown and the blue wire connection points 2 Connect the green yellow wire to the ground connection point 3 Wrap the black wire with the white tape to denote that it is a neutral connection and connect it to the neutral connection point 4 Refer to the previous table for testing and probe the new connections as follows e blue wire as location 2 brown wire as location 4 e black wire as location 1 e green yellow wire as location 3 HARD WIRING TO THE BUILDING Use the following instructions to wire the dyno directly to the building The dyno must connect to a two pole disconnect switch to allow the removal of all power to the dyno for servicing This box may contain fusing circuit breakers or the circuit protection may be upstream in the building power system The circuit must be protected to 30A with slow blow fuses or time delayed circuit breakers The power cord that attaches to the dyno has four conductors internally and their colors are brown blue black and green yellow 1 Remove the dyno power plug and connect 240VAC single phase between the
22. ING THE PICKUP CARD AND DYNO ELECTRONICS CABLES 1 Route the pickup card cable P N 66953002 from the CPI through the designated pit conduit and over to the pickup card Attach the cable to the pickup card Note Be sure to keep the power and communications cables in different pit conduits 2 Route the 25 pin cable P N 42924251 from the dyno electronics to the Breakout board Refer to Figure 1 1 for Breakout board location 3 Route the 9 pin serial cable P N 42967090 from the dyno electronics to your computer pickup card dyno electronics 9 pin cable to computer pickup card cable route communications cables in designated conduit 25 pin cable to breakout board e E i i o e y orrir PDO35 Version 1 Figure 1 23 Route the Pickup Card and Dyno Electronics Cables 1 25 Control Panel Interface Installation and User Guide zy CHAPTER 1 7 Routing Cables ROUTING THE AIR PUMP POWER AIR FUEL SENSOR AND DYNO ELECTRONICS POWER CABLES 1 Route the air pump power cable P N 76950318 from the CPI to the air pump 2 Route the air fuel sensor cable P N 76950701 from the dyno electronics to the air pump 3 Route the dyno electronics power cable to your power sosurce dyno electronics power cable aN
23. NSTALLING THE BATTERY The model 200ip 250ip dyno is designed to carry a group 24 deep cycle discharge series battery for operating the built in starter This battery is not included with your dyno You will need to provide this battery For more information on battery requirements and battery chargers refer to Battery Requirements in Chapter 1 of the Model 200ip 250ip Motorcycle Pit Dynamometer Installation Guide 1 2 1 8 Control Panel Interface Installation and User Guide Locate the red battery cable on the inside of the dyno Place the battery in the battery carrier on the inside of the dyno so the red cable can reach the positive post on the battery and the black battery cable can reach the negative post Secure the battery to the tray with the battery hold down Refer to page 1 23 for instructions on routing and connecting the battery cable bce r battery PD043 Figure 1 6 Install the Battery CONTROL PANEL INTERFACE INSTALLATION S Battery W BATTERY GAS WARNING INSTRUCTIONS For complete warnings refer to the Warnings section of the Model 200ip 250ip Motorcycle Pit Dynamometer Installation Guide AGUS Battery Fire and Explosion Hazards There is a danger of explosion if the battery is incorrectly replaced Replace only with the same or equivalent type recommended by the manufacturer Discard used batteri
24. North Las Vegas Nevada 89031 USA Printed in USA Part Number 98225109 Version 1 01 05 TABLE OF CONTENTS Chapter 1 Control Panel Interface Installation INEPQQUCHION score dd bbb oSS SE aadLMadAELE eee eEh eee sein deen ease 1 2 Conventions Used In This Manual 000 000 cee eee eee 1 2 Technical SUPPOM riia r Se aed Yee oe ee 1 2 Connecting and Disconnecting Power to the Dyno 1 3 Removing the Pit Covers 2 00 c eee 1 4 Removing the Control Panel Interface Cover 0 00 c eee eens 1 6 hs ts isd a a e a a pA a E N eh ho Sho ih ses ei eine a ah 1 7 Installing the Battery 0 0 cette 1 8 Battery Gas Warning Instructions 00 000 cee ee 1 9 Blower Mounts Support Arm and Junction Box 00 005 1 10 Mark and Drill the Blower Mounts and Support Arm Mounting Holes 1 10 Installing the Blower Mounting Plate Support Arm and Junction Box 1 11 Installing the Arms and Monitor Tray 00 0c eee eee 1 12 Installing the High Pressure Blowers 0000 cece eee eee 1 13 Routing Cables g a 5 coe oo Sic w wc hw aad hk sd tod eae ene am eb aad 1 14 Routing the Control Panel and Pendant Cables 0055 1 15 Routing the Blower Cables 0000 cece eee eee 1 19 Routing the Motorized Carriage and Wheel Clamp Cables 1 20 Routing the Eddy Current Brake Battery and Dyno Power Cables 1 23 Routing the Pickup Card and Dyno
25. OWER MOUNTING PLATE SUPPORT ARM AND JUNCTION BOX The high pressure blowers are an optional accessory If you did not order high pressure blowers you will not need to install the blower mounting plates 1 Secure each blower mounting plate to the pit floor using four 3 8 x 1 inch bolts and 5 16 inch washers Note The blower mounting plate is secured under the support arm 2 Secure the support arm and junction box to the pit floor using four 3 8 x 1 inch bolts and 5 16 inch washers Note The support arm can be mounted on either side of the dyno blower mount support arm junction box blower mount under support arm Figure 1 8 Install Blower Mounting Plates Support Arm and Junction Box 1 11 Version 1 Control Panel Interface Installation and User Guide xe CHAPTER 1 J Blower Mounts Support Arm and Junction Box INSTALLING THE ARMS AND MONITOR TRAY 1 Inserta plastic cap in both ends of each arm 2 Place a poly washer around the pin of the first arm and insert the pin into the support arm 3 Place apoly washer around the pin of the second arm and insert the pin into the first arm 4 Place a poly washer around the pin of the tray and insert the pin into the second arm Note The monitor tray is an optional accessory If you did not order a monitor tray skip this step 5 Check for clearance between the monitor arm and motorcycle walls ceiling etc Note Dynojet does not recommend placing the computer CPU
26. R REQUIREMENTS AND INSTALLATION EXCLUDING NORTH AMERICA AND JAPAN The model 200ip 250ip dynamometer excluding North America and Japan requires a dedicated wall receptacle which must be wired for operation and is included with the dyno or may be shipped in advanced in a separate package The dyno is equipped with a ten foot power cord with a three pin IEC plug pre wired on the end The power cord is located at the front of the dyno but is shipped inside of the dyno Refer to Figure 1 1 for the location of the power cord and page 1 23 for instructions on routing the power cord The model 200ip 250ip dynamometer requires a dedicated 240VAC single phase power outlet rated for 30A for proper operation Failure to follow these instructions could result in personal injury or damage to the dyno Connecting the dyno to the incorrect voltage will void the dyno warranty Contact Dynojet with any questions The dedicated wall receptacle is a three pin IEC grounded 30A type and must be wired in accordance with local building codes and requirements Installation may require a licensed electrician to conform to applicable safety standards AWM If you are installing your dyno in a location other than North America or Japan and the dyno is not equipped with a three pin IEC grounded plug contact Dynojet before attempting to connect the dyno Local and national electrical codes will require that the box containing the receptacle is grounded e Th
27. W Ramset Red Head 00005 A 1 Installation 0 00 00 cece ee eee nee nenas A 2 Appendix B Motorized Carriage and Wheel Clamp Installation Motorized Carriage 222442 dcdoviwuninivdddeaededsedeeaaeaddeds B 2 Installing the Motorized Carriage 1 2 0 cee B 2 Wheel Clamp seres te cktidtud auaa iae daa d a a a i aai dadia B 5 Appendix C Safety Switch Installation Installing the Safety Switch saassruaaa anaa C 2 Control Panel Interface Installation and User Guide TABLE OF CONTENTS Appendix D Power Requirements Power Requirements and Installation North America Japan and Locations Using 60 Hz Power 0 0 cece eee D 2 Installing the Wall Receptacle 1 2 0 0 D 2 Testing for Correct Voltages 1 0 cee D 3 Replacing the Power Plug ccc cee eee eee eens D 4 Hard Wiring to the Building 0 0000 cee ee D 4 Connecting the Dyno sssaaa aaaeeeaa D 5 Power Requirements and Installation Excluding North America andapan meetu a e a a A SAANANE ENA E D 6 Installing the Wall Receptacle anaana auaa D 7 Testing for Correct Voltages 1 0 cee D 8 Replacing the Power Plug cc ccc eee eee eee ees D 9 Hard Wiring to the Building 0000 0 cee ee D 9 Connecting the Dyno 0 cee ee D 10 1AE Er MOREEL TI SEA TIP ESEESE EIET PEETA Index i Version 1 Control Panel Interface Installation and User Guide 47 co CHAPTER CONTROL PANEL
28. ances with the press of a button Refer to Using the Motorized Carriage on page 2 5 for more information on using the motorized carriage INSTALLING THE MOTORIZED CARRIAGE 1 Insert the coupler jaw on the carriage screw making sure the inside of the coupler jaw is flush with the end of the carriage screw 2 Secure the coupler jaw with the set screw 3 Secure the motor mount to the carriage using two 1 4 20 x 1 inch bolts and two 1 4 inch lock washers The motor mount is installed in front of the flange bearing Note The flange bearing must be facing so the grease zerk is accessible facing down Note Dynojet recommends using a 1 4 inch ratchet drive with an extension and a 7 16 inch shallow socket to secure the flange bearing bolts Note f the motor mount is already installed skip this step and continue flange bearing coupler jaw SL i mount 6 6 PCO30 Figure B 1 Install the Motor Mount B 2 Control Panel Interface Installation and User Guide MOTORIZED CARRIAGE AND WHEEL CLAMP INSTALLATION Ss x Motorized Carriage 4 Bring the motorized carriage cable two pin connector from the cable track over to the motor mount This cable was routed on page 1 19 5 Secure the strain relief to the side of the motorized carriage motor mount motorized carriage cable strain relief PC031 Figure B 2 Secure Strain Relief and Cable B 3 Version 1 Control Panel Interface Installatio
29. communications cables in different pit conduits 3 Route the dyno power cable from the CPI to your power source dyno power cable route power cables in designated conduit dyno electronics battery cable battery eddy current starter Cable brake cable PDO34 Figure 1 21 Route the Eddy Current Brake Battery and Power Cables 1 23 Version 1 Control Pane Interface Installation and User Guide CHAPTER 1 gt k s Routing Cables 4 Connect the battery and starter cables 4a 4b Ac 4d 4e battery cable blue cable 1 24 Control Panel Interface Installation and User Guide Attach the brown cable to the positive battery post Attach the red battery cable to the positive battery post and to the large stud on the starter solenoid Attach the blue and yellow cable to the negative battery post Attach the black battery cable to the negative battery post and to the grounding location on the starter brace Attach the blue cable to the starter solenoid blue yellow cable black cable brown cable battery M rea cable IA PD053 starter brace starter solenoid Figure 1 22 Attach the Brake and Starter Cables 25 pin cable to breakout board CONTROL PANEL INTERFACE INSTALLATION i Routing Cables L Da ROUT
30. d Wheel Clamp W TESTING THE MOTORIZED CARRIAGE AND WHEEL CLAMP 1 Replace the CPI cover if it was removed Refer to page 1 6 for more information Plug the dyno into the power outlet 3 Turn on the main breaker inside the CPI door Refer to Connecting and Disconnecting Power to the Dyno on page 1 3 for more information 4 Using the Control Panel press the carriage forward and backward buttons and verify that the motor does turn Refer to Using the Motorized Carriage on page 2 5 for more information on using the Control Panel Interface 5 Place a stack of catalogs into the wheel clamp 6 Using the Control Panel press the close button and observe that the wheel clamp does close Hold the button until the motor turns off and the status light is on steady 7 Press and hold the right hand wheel clamp button then press the left hand button to open the clamp Refer to Using the Wheel Clamp on page 2 6 for more information on using the Control Panel Note If your country requires you install the safety switch please refer to the instructions in Appendix C 1 29 Version 1 Control Panel Interface Installation and User Guide CHAPTER USING THE CONTROL PANEL INTERFACE This chapter will walk you through the basic operating procedures and how to maintain and troubleshoot the components associated with the Control Panel Interface CPI To ensure safety and accuracy in the procedures perform the procedures as they are described
31. der this accessory skip any steps referring to the wheel clamp cable Refer to Appendix B for motorized carriage and wheel clamp installation instructions 1 Route the motorized carriage cable P N 76950314 from the CPI through the designated power pit conduit through the pit and out of the pit as shown in Figure 1 20 2 Route the wheel clamp cable P N 76950313 from the CPI through the same conduit and along the same path as the motorized carriage cable Note Be sure to keep the power and communications cables in different pit conduits 3 From the pit route both cables through the junction box as shown in Figure 1 20 4 Press each cable into the cable track Note The cable must be pressed into the cable track before installing the cable track ends and brackets 5 Snap the cable track ends onto the cable track as shown below 6 Secure the junction box cable track bracket to the cable track end using two screws and nuts 7 Secure the wheel clamp cable track bracket to the cable track end using two screws and nuts cable track end wheel clamp cable junction box cable track bracket cable track end PDO50 Figure 1 18 Install Cable Track Ends and Brackets 1 20 Control Panel Interface Installation and User Guide CONTROL PANEL INTERFACE INSTALLATION one Routing Cables 8 Secure the cable track bracket to the junction box using two 8 32 screws 9 Secure the cable track bracket to the wheel clamp using a 1 4 20
32. e s CHAPTER 1 4 Blower Mounts Support Arm and Junction Box BLOWER MOUNTS SUPPORT ARM AND JUNCTION BOX Before routing the cables you must decide which side of the dyno to mount the monitor support arm The choice is based on personal preference and easy access to your computer For the following instructions we will show the support arm and control panel mounted on the right side of the dyno MARK AND DRILL THE BLOWER MOUNTS AND SUPPORT ARM MOUNTING HOLES 1 Using the carriage mounting plate and the dyno frame as reference position the support arm and optional blower mounts as shown Note The high pressure blowers are an optional accessory If you did not order high pressure blowers you will not need to install the blower mounts 2 Using the mounting plates as a template mark and drill 1 2 inch holes 3 Install the Red Head Anchors Refer to Appendix A for Red Head Anchor installation instructions oH 24 13 cm 24 13 cm 9 5 in A A 9 5 in mark and drill N Ji mark and drill four places oS N 5 yous pat i f G ini A 111 76 cm 4 al 111 76 cm 44 0 in Ly 44 0 in y Figure 1 7 Blower Mounts and Support Arm Placement 1 10 Control Panel Interface Installation and User Guide CONTROL PANEL INTERFACE INSTALLATION Ss Blower Mounts Support Arm and Junction Box S INSTALLING THE BL
33. e the drum air brake 2 4 Control Panel Interface Installation and User Guide USING THE CONTROL PANEL INTERFACE 5 S Basic Operation USING THE MOTORIZED CARRIAGE This accessory requires the CPI and battery to operate Use the control panel to activate the motorized carriage allowing you to center the bike s rear tire on the dyno drum The motorized carriage and wheel clamp cannot be activated at the same time Note When operating the motorized carriage with a bike on the dyno make sure the bike is in neutral Note Always loosen or remove the bike tie down straps before moving the carriage Replace and tighten the straps when the bike is in the proper position A PN WARNING Never perform a dyno run if the tie down straps are not in place or they are damaged If the carriage movement is slow during parts of its travel investigate and correct the source of the problems If you reach the end of travel of the carriage or the carriage binds and you continue to hold down the carriage movement button the motor will draw too much current and blow the carriage fuse F2 There is a short time delay built into the button operation to allow the carriage motor to coast to a stop before it moves in the opposite direction This delay is needed to prevent the motor from drawing too much current by rapidly reversing the motor USING THE STARTER The built in starter allows you to use the momentum of the drum to start moto
34. e brown blue black and green yellow 1 Remove the dyno power plug and connect 240VAC single phase between the brown and the blue wires through the disconnect switch 2 Connect the green yellow wire to the ground connection 3 Cut off the black wire Refer to the previous table for testing and probe the new connections as follows e blue wire as location 1 brown wire as location 3 e green yellow wire as location 2 Control Panel Interface Installation and User Guide Z F APPENDIXD P A Power Requirements and Installation Excluding North America and Japan CONNECTING THE DYNO 1 Turn off the main circuit breaker on the dyno This is the large breaker in the center of the power distribution assembly behind the door on the left hand side of the dyno Refer to page 1 3 for breaker location Off is the down position 2 Once you verify the voltages on the receptacle connect the dyno to the receptacle 3 Connect the high pressure blowers to the dyno For more information on installing and connecting the blowers refer to page 1 11 and page 1 19 Turn on the main dyno breaker Refer to page 1 3 for breaker location Test the blowers for operation 6 Turn on the dyno electronics and verify operation uo e D 10 Control Panel Interface Installation and User Guide 25 pin cable 1 25 9 pin cable 1 25 A air fuel sensor cable 1 26 air pump power cable 1 26 air pump using 2 3 anchor placement blower mounts 1 10 support
35. er cable Refer to Connecting and Disconnecting Power to the Dyno on page 1 3 for more information 3 Remove the eight button head screws securing the cover and set aside 4 Remove the cover and set aside e cover A j PD027 Figure C 1 Accessing the CPI C 2 Control Panel Interface Installation and User Guide SAFETY SWITCH INSTALLATION Sx Installing the Safety Switch 5 Loosen the screws that hold the jumper wires in place and remove the wire Route the black and yellow wire from the safety switch through the dyno Make sure the switch will not get caught in any moving components or chafed on any edges 7 Attach the yellow wire to the 1A position on the J2 connector 8 Attach the black wire to the 6B position on the J4 connector ey yellow wire to 1A black wire to 6B on J2 connector on J4 connector F Figure C 2 Wire the Safety Switch 9 Replace the control panel interface cover using the screws removed earlier 10 The safety switch needs to be mounted at the entry of the dyno room 11 Plug the dyno into the power outlet 12 Turn on the main breaker inside the power distribution assembly door Refer to Connecting and Disconnecting Power to the Dyno on page 1 3 for more information 13 Open the safety switch by allowing the plunger to extend The air brake should be applied holding the drum and the status light on the Control Panel will be flashing 14 Depress the safety switch and
36. es according to the manufacturer s instructions Automotive Batteries In operation batteries generate and release flammable hydrogen gas They must always be assumed to contain this gas which if ignited by burning cigarette naked flame or spark may cause battery explosion with dispersion of casing fragments and corrosive liquid electrolyte Carefully follow manufacturer s instructions for installation and service Keep away all sources of gas ignition and do not allow metallic articles to simultaneously contact the negative and positive terminals of a battery Do not allow the positive and negative terminals to short circuit The dynamometer chassis is tied to the negative side of the battery Do not short between the positive battery terminal or the starter connections to the chassis In addition make sure metal tools such as screw drivers wrenches and torque wrenches do not come in contact with the negative and positive terminals of the battery Short circuiting the terminals of the battery can cause burn injuries damage to the dynamometer or trigger explosions Charging Batteries being charged will generate and release flammable hydrogen gas Charging space should be ventilated Keep battery vent caps in position Prohibit smoking and avoid creation of flames and sparks nearby Wear protective clothing eye and face protection when charging or handling batteries 1 9 Version 1 Control Panel Interface Installation and User Guid
37. essed or the external E Stop circuit is opened Refer to page 2 4 for more information High Pressure Blowers Blowers This optional accessory allows you to toggle the blowers on and off to control the temperature of the bike Refer to page 2 4 for more information Motorized Carriage This accessory requires the CPI and battery to operate The motorized carriage allows you to move the bike forward and backward by remote control to center the bike s rear tire on the dyno drum Refer to page 2 5 for more information Starter Allows for spinning up the dyno drum to bump start bikes that may not have a starter Refer to page 2 5 for more information Status Indicator Provides information on the status of the CPI control and the various inputs to the CPI Wheel Clamp This optional accessory requires the CPI and battery to operate The wheel clamp allows for quicker loading and unloading of the bike Refer to page 2 6 for more information USING THE AIR FUEL RATIO AIR PUMP The CPI allows control of the optional internal air pump that is part of the air fuel ratio AFR sampling system This air pump is built into the dyno to draw exhaust gases over the AFR sensor The button on the control panel allows the dyno user to turn this pump on and off The indicator light on the control panel will illuminate when power is provided to the pump If the pump does not run check the following e Verify the switch on the pump assembly is on e Verify f
38. f the wheel clamp pads with the bike tire If the wheel clamp movement is binding for any reason stop using the wheel clamp and correct the problem It is possible for the wheel clamp to bind and give a false indication that the wheel is clamped If the wheel has been clamped and the wheel clamp indicator light is on steady then the dyno power is turned off or the E Stop activated the wheel clamp indicator light will go back to the blinking state as the clamp status is unknown Pressing the clamp button again will secure the clamp If the E Stop circuit is open or the Emergency Stop button is pressed the wheel clamp will not operate 2 9 Control Panel Interface Installation and User Guide z lt I CHAPTER 2 Maintenance and Troubleshooting TROUBLESHOOTING POWER DISTRIBUTION ASSEMBLY FUSES Fuses F3 and F4 fuse the 240VAC as it enters the CPI board One fuse for each leg of the 240VAC If either of these fuses are blown there will be no power to the CPI board or any of the accessories The Status Light on the board as well as the button panel will be off Replace with a 5x20 mm 3A fast blow fuse Fuse F5 provides protection for the DC power that is produced by the on board power supply and routed to the CPI board If this fuse is blown there will be no power to the CPI board or any of the accessories The Status Light on the board as well as the button panel will be off Replace with a 5x20 mm 3A fast blow fuse Fuse F6 provides
39. her blower mount HBO13 Figure 1 10 Install the High Pressure Blowers 1 13 Version 1 Control Panel Interface Installation and User Guide zy CHAPTER 1 7 Routing Cables ROUTING CABLES For the following instructions we will show the support arm and control panel mounted on the right side of the dyno with the Control Panel Interface CPI and dyno electronics on the left side of the dyno The CPI and dyno electronics must be placed near the conduits in the pit Be sure to keep the power and communications cables in different pit conduits For the following instructions we will designate the pit conduits as shown monitor support and tray 4 junction box Pate N route communications cables B 4 in designated conduit dyno electronics ES 7 control panel control panel interface CPI route power cables in designated conduit SS PD026 Figure 1 11 Pit Dyno Room Layout 1 14 Control Panel Interface Installation and User Guide CONTROL PANEL INTERFACE INSTALLATION Ss x Routing Cables s ROUTING THE CONTROL PANEL AND PENDANT CABLES 1 Route the control panel cable P N 76951502 from the CPI through the designated communications pit conduit through the pit and out of the pit as shown 2 Route the pendant cable from the dyno electronics through the same conduit and along the same path as the control panel cable Note Be sure to keep the power and com
40. ill the Hole 2 Insert the anchor anchor Ui Figure A 2 Red Head Anchor Insert the Anchor A 2 Control Panel Interface Installation and User Guide RED HEAD ANCHOR INSTALLATION he Installation W g 3 Using ahammer drive the anchor flush with the surface of the concrete or below the surface if the hole depth exceeds minimum embedment N MQ Qs Y A N N XX AN N SSO i N N KS SS XS LX SLLLLLL LLL its Figure A 3 Red Head Anchor Drive the Anchor Flush GH003 4 Using ahammer expand the anchor with the setting tool The anchor is properly expanded when the shoulder of the setting tool is flush with the top of the anchor Note Use only Ramset Red Head setting tools to insure proper installtion setting tool df 1A YA oe GH004 Figure A 4 Red Head Anchor Expand the Anchor Version 1 Control Panel Interface Installation and User Guide APPENDIX MOTORIZED CARRIAGE AND WHEEL CLAMP INSTALLATION This appendix provides instructions for installing the motorized carriage and wheel clamp assemblies to the model 200ip 250ip motorcycle pit dynamometer To ensure safety and accuracy in the procedures perform the procedures as they are described Control Panel Interface Installation and User Guide Z 7 APPENDIXB P A Motorized Carriage MOTORIZED CARRIAGE The motorized carriage allows you to easily adjust for various wheel bases dist
41. is circuit should have a dedicated 30A double pole circuit breaker e The dyno should be the only device connected to this circuit It may be necessary to install a delayed trip breaker due to the inrush current drawn by the high pressure blowers D 6 Control Panel Interface Installation and User Guide Version 1 POWER REQUIREMENTS Ss Power Requirements and Installation Excluding North America and Japan INSTALLING THE WALL RECEPTACLE The wall receptacle is a single 240 volt 30A dedicated circuit with a ground The cable carrying the power to this receptacle should be 4 0 mm ten gauge or larger Check with local building codes for the correct size 1 Connect one of the 240V legs to the N terminal white 2 Connect the other 240V leg to the L terminal no color 3 Connect the ground conductor to the green terminal ve eee L terminal ground terminal green N terminal white ay Figure D 2 Wiring the Wall Receptacle Control Panel Interface Installation and User Guide D 8 ny APPENDIXD iA Power Requirements and Installation Excluding North America and Japan TESTING FOR CORRECT VOLTAGES You must test the receptacle for proper voltages before the dyno is connected to the outlet Using a voltmeter that is capable of measuring AC voltage measure between the points listed below and verify that the correct voltages are present probe 1 probe 2 desired voltage measureme
42. l clamp is sufficiently open before loading the motorcycle 1 Once the bike s front tire is fully seated in the clamp press and hold the close button left hand yellow square button As you hold the button the wheel clamp mechanism will close on the bike s wheel and tire The wheel clamp status light will blink as the clamp is closing A P WARNING For proper and safe operation the wheel clamp must grip the whee as well as the tire If the front tire is too wide to allow the clamp pads to grip the wheel you must use the wheel strap 2 Continue to hold the button down asthe clamp applies pressure to the wheel and tire During this process the CPI is monitoring the current that is going to the wheel clamp When the wheel clamp has reached sufficient clamping force to secure the bike the current drive to the wheel clamp is cut and the wheel clamp indicator light will turn on steady indicating that the wheel is secured AWE Do not operate the dyno if the wheel clamp indicator light is not on steady 3 Pull back on the bike to verify the bike is secured 4 Adjust the carriage to align the rear bike tire on the dyno drum 5 Secure the bike with the tie down straps A PN WARNING Never perform a dyno run if the tie down straps are not in place or they are damaged OPENING THE WHEEL CLAMP 1 Press and hold the right hand yellow square button first then press the left hand yellow button The wheel clam
43. latest product lines CONTROL PANEL INTERFACE INSTALLATION he Introduction W g 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 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 power distribution assembly 2 Disconnect the power plug to ensure all power has been removed from the dyno before performing certain installation procedures power plug main breaker breakout board AR Figure 1 1 Main Breaker Location 1 3 Version 1 Control Panel Interface Installation and User Guide gt CHA PTE R1 i Introduction REMOVING THE PIT COVERS Dynojet recommends using a T30 Torx driver Snap On PFTx30E or a hardened 5 32 inch hex driver Snap On Fa5E for dynos with serial numbers lower than 2030152 to remove the 1 4 inch screws A standard allen key may round off in the shallow screw head 1 Remove the four 3 8 16 x 1 2 inch button head flange screws securing the right side drum cover to the drum module and set aside 2 Remove the four 1 4 20 x 1 2 inch button head flange screws securing the right side drum cover to the drum guard bracket and set aside 3 Remove the cover and set aside PD007
44. munications cables in different pit conduits 3 From the pit route both cables through the junction box route communications cables dyno in designated conduit electronics CPI route power cables in designated conduit PD028 Figure 1 12 Route the Control Panel and Pendant Cables 1 15 Version 1 Control Panel Interface Installation and User Guide CHAPTER 1 gt k s Routing Cables 4 Remove the control panel rear cover 4a 4b 4c 4d 4e Remove the two nuts from the top of the cover and set aside Remove the screw on the top of the cover and set aside Remove the screw on the side of the cover and set aside Remove the four screws on the back of the cover and set aside Remove the control panel rear cover and set aside ea top screw top nuts o side screw wee 1 16 Control Panel Interface Installation and User Guide CP010 w es rear ee Figure 1 13 Remove the Control Panel Rear Cover re CONTROL PANEL INTERFACE INSTALLATION Ss x Routing Cables 5 Route the control panel cable through the access hole on the side of the control panel box and through the cable tie 6 Attach the control panel cable to the Button board access hole button board control panel cable with cable harness wrap cable tie Sy CPo08 Figure 1 14 Attach
45. n and User Guide zy APPENDIXB 7 Motorized Carriage Insert the plastic coupler spider on the carriage screw half of the coupler Place the motorized carriage motor assembly near the motor mount and plug the motor connector into the motorized carriage cable 8 Turn the carriage screw to align the coupler jaws with each other and slide the coupler jaws together until the motor assembly cover is flush with the motor mount 9 Secure the motor assembly cover to the motor mount with three 1 4 20 x 1 2 inch button head screws motor assembly coupler spider motor assembly cover PC032 Figure B 3 Assemble the Motorized Carriage B 4 Control Panel Interface Installation and User Guide MOTORIZED CARRIAGE AND WHEEL CLAMP INSTALLATION Ss Wheel Clamp WHEEL CLAMP The wheel clamp allows you to easily adjust for various wheel thicknesses with the press of a button Refer to Using the Wheel Clamp on page 2 6 for more information on using the wheel clamp 1 Remove the six 1 4 20 x 1 inch screws securing the wheel clamp cover Remove the cover and set the cover and screws aside cover Figure B 4 Remove the Wheel Clamp Cover 2 Place the wheel clamp on the carriage Align the four holes on the wheel clamp with the holes on the carriage 3 Secure the wheel clamp to the carriage using four 3 8 16 x 1 2 inch bolts f EEEE WcC009 Figure B 5 Secure the Wheel Clamp to the Carriage Version 1 Control Panel
46. nt 1 3 220V to 250V 2 box lt 5V Figure D 3 Testing the Wall Receptacle Control Panel Interface Installation and User Guide Version 1 Fa POWER REQUIREMENTS Ce Power Requirements and Installation Excluding North America and Japan REPLACING THE POWER PLUG Use the following instructions to replace the plug and socket The plug and socket configuration must be rated for at least 240VAC 30A and have a minimum of three conductors The power cord that attaches to the dyno has four conductors internally and their colors are brown blue black and green yellow 1 Connect 240VAC single phase power between the brown and the blue wire connection points 2 Connect the green yellow wire to the ground connection point 3 Cut off the black wire Refer to the previous table for testing and probe the new connections as follows e blue wire as location 1 brown wire as location 3 e green yellow wire as location 2 HARD WIRING TO THE BUILDING Use the following instructions to wire the dyno directly to the building The dyno must connect to a two pole disconnect switch to allow the removal of all power to the dyno for servicing This box may contain fusing circuit breakers or the circuit protection may be upstream in the building power system The circuit must be protected to 30A with slow blow fuses or time delayed circuit breakers The power cord that attaches to the dyno has four conductors internally and their colors ar
47. on the end The power cord is located at the front of the dyno but is shipped inside of the dyno Refer to Figure 1 1 for the location of the power cord and page 1 23 for instructions on routing the power cord The dedicated wall receptacle is a twist lock four wire grounded 30A NEMA L14 30 type and must be wired in accordance with local building codes and requirements Installation may require a licensed electrician and must conform to UL and NEC safety standards Note If you are installing your dyno in North American or Japan and the dyno is not equipped with twist lock four wire grounded plug contact Dynojet before attempting to connect the dyno Local and national electrical codes require a grounded receptacle box e This circuit should have a dedicated 30A double pole circuit breaker e The dyno should be the only device connected to this circuit e It may be necessary to install a delayed trip breaker due to the inrush current drawn by the high pressure blowers INSTALLING THE WALL RECEPTACLE The wall receptacle is included with your dyno and is shipped in a box in the center of your dyno or may be shipped in advance in a separate package The wall receptacle is a single phase 240 volt 30A dedicated circuit with a neutral connection and aground The neutral connection is required to split the 240 volt into two 120 volt connections internal to the dyno The cable carrying the power to this receptacle should be ten gauge or larger
48. p will start opening The status indicator light will be blinking to indicate the wheel is not secured and a dyno run should not be attempted 2 Continue to open the clamp far enough to allow the next bike to be loaded easily 2 7 Version 1 Control Panel Interface Installation and User Guide z lt I CHAPTER 2 7 Power Distribution Assembly POWER DISTRIBUTION ASSEMBLY The Power Distribution Assembly inside the CPI has three circuit breakers to protect the internal dyno circuits the main dyno circuit breaker and two blower circuit breakers MAIN CIRCUIT BREAKER The main circuit breaker is rated for 240VAC at 30A and all of the power into the dyno passes through this breaker In the event of a major overload or failure this breaker will trip This breaker also provides the main disconnect for the dyno When the handle is in the up position the dyno is connected to the incoming power When the handle is in the down position all power into the dyno is turned off A PSN WARNING Even if this breaker is turned off there is still the potential for lethal voltages to be present in the power distribution assembly Always disconnect the main power plug before removing the covers HIGH PRESSURE BLOWER CIRCUIT BREAKERS The high pressure blower blower circuits are protected by the two 15A breakers In the event of a motor failure or other failure with the blowers these breakers could trip The white button pops out to indicate
49. rcycles that are not equipped with an on board starting system The starter requires a battery to operate Refer to page 1 7 for more information on the battery If the E Stop button is pressed the starter will not engage If the interlock circuit is open the starter will not operate Make sure the dyno brakes are not activated Verify the bike is in neutral or disengage the clutch Press and hold the green starter button until the drum reaches maximum speed Release the green starter button Use the momentum of the drum to start the bike Note Do not re engage the starter while the drum is turning ObBWN FH 2 5 Version 1 Control Panel Interface Installation and User Guide xF CHAPTER 2 Basic Operation ws USING THE STATUS INDICATOR The status indicator provides information on the status of the CPI control and the various inputs to the CPI e Status Off indicates the CPI may not be receiving power due to the dyno being turned off or lack of power being applied to the dyno e Status Steady On indicates all inputs into the CPI are okay for normal dyno operation and the CPI is receiving power e Status Blinking If the status indicator light is flashing with two short blinks on and along pause off the Emergency Stop circuit is open This can be caused by the red button on the control panel being pressed or an external E Stop Emergency Stop condition is being fed to the CPI board The E Stop circuit must be closed
50. rly only when installed with ITW Ramset Red Head brand Setting Tools The use of a 24 to 40 ounce hammer is recommended for expanding Multi Set I anchors The use of carbide drill bits manufactured with ANSI B94 12 77 drill bit diameter requirements is recommended for installation of this anchor Not recommended for use in lightweight masonry material such as block or brick Use of core drills is not recommended to drill holes for use with this anchor Not recommended for use in new concrete which has not had sufficient time to cure Anchor spacing and edge distance requirements anchor installation locations are the responsibility of the engineer of record CONTACT INFORMATION FOR ITW RAMSET RED HEAD Contact ITW Ramset Red Head at 1 630 350 0370 or 1300 North Michael Drive Wood Dale IL 60191 A 1 Control Panel Interface Installation and User Guide y APPENDIXA b Installation ws INSTALLATION Use the table below to determine the catalog number drill bit size minimum hole depth and setting tool catalog number setting tool catalog number drill bit size minimum hole depth catalog number Carbon Steel 1 2 inch 1 5 8 inch 41 2 mm RT 138 RM 38 RL 38 9 5 mm Use the following instructions to install the Red Head anchors 1 Drill the hole in the concrete the same outside diameter as the anchor being used to any depth exceeding minimum embedment 4 GHO01 Figure A 1 Red Head Anchor Dr
51. screw Note If you do not have the wheel clamp you will need to install the adapter bracket to the tire stop using the tire stop hardware cable track bracket tire stop junction box wheel clamp cable track bracket adapter bracket PD041 Figure 1 19 Install the Cable Track 1 21 Version 1 Control Panel Interface Installation and User Guide CHAPTER 1 Jm Routing Cables 10 Connectthe motorized carriage cable to the motorized carriage Refer to page B 3 for more information 11 Connect the wheel clamp cable to the wheel clamp cable track motorized carriage wheel clamp dyno electronics CPI route power cables in designated conduit PD033 Figure 1 20 Route the Motorized Carriage and Wheel Clamp Cables 1 22 Control Panel Interface Installation and User Guide CONTROL PANEL INTERFACE INSTALLATION Routing Cable a ROUTING THE EDDY CURRENT BRAKE BATTERY AND DYNO POWER CABLES 1 Route the eddy current brake cable P N 66952005 from the eddy current brake through the designated power pit conduit and to the theta controller 2 Route the battery cable P N 76950312 from the CPI through the same conduit and over to the battery Refer to the steps and Figure 1 22 on page 1 24 for instructions on connecting the battery and starter cables Note Be sure to keep the power and
52. the Control Panel Cable to the Button Board 7 Secure the rear cover to the control panel 7a Replace the four screws on the back of the cover removed earlier 7b Replace the screw on the top of the cover removed earlier 7c Replace the screw on the side of the cover removed earlier 7d Replace the two nuts removed from the top of the cover removed earlier o C P007 6 Figure 1 15 Replace the Control Panel Rear Cover 1 17 Version 1 Control Panel Interface Installation and User Guide CHAPTER 1 AY oui PA outing Cables 8 Secure the control panel to the monitor tray using two 8 32 inch screws Note If you did not order a monitor tray you will need to install the pin plate to the bottom of your control panel using four 8 32 screws Once installed place the pin on the control panel into the support arm where the monitor tray is 9 Place the pendant in the slot on the control panel 10 Route the cable bundle along the support arms with service loops to allow movement as shown below 11 Using the provided cable clamps and 8 32 inch screws attach the cable bundle to the arms and the support arm Adjust the service loops to allow for easy movement of the monitor arms without pulling on the cables H r jes ig g place pendant here dyno j electronics control panel CPI
53. the circuit has tripped Pressing in the white button will reset the breaker The top breaker protects the right blower circuit right side of dyno as you are sitting on the bike and the bottom breaker protects the left blower circuit These breakers do not provide a manual disconnect main dyno circuit breaker and disconnect PD047 blower circuit breakers right blower on top Figure 2 2 Power Distribution Assembly Circuit Breakers 2 8 Control Panel Interface Installation and User Guide Version 1 Fa Dr USING THE CONTROL PANEL INTERFACE Maintenance and Troubleshooting MAINTENANCE AND TROUBLESHOOTING This section contains basic maintenance and troubleshooting information for the wheel clamp and power distribution assembly fuses WHEEL CLAMP Make sure the bike tire and wheel are clean to reduce the possibility of scratching the rim Keep the wheel clamp pads clean using Isopropyl Alcohol Do not allow any products to be applied or transferred to the wheel clamp that could interfere with the gripping action If you run the clamp all the way open against the hard stops the CPI will turn off the motor before any damage can occur Follow the prescribed service for the wheel clamp lubrication for frequency and type of lube Grease or lube the screw and slides monthly or every 500 bikes Do not run into the edges o
54. uses F3 and F4 on the CPI board Ifthe E Stop button is pressed or the external E Stop circuit is open then the AFR pump will not run Refer to the Air Fuel Ratio Module Installation and User Guide for proper operating and maintenance procedures P N 98295110 Failure to follow proper procedures may result in inaccurate data or damage to the equipment This manual can be found on your WinPEP CD or at www dynojet com manuals shtml 2 3 Version 1 Control Panel Interface Installation and User Guide F CHAPTER 2 Basic Operation ws USING THE EMERGENCY STOP DYNO SHUTDOWN The emergency stop dyno shutdown button is designed to deactivate the dyno outputs whenever the button is pressed or the external E Stop circuit is opened When E Stop is activated the blowers will be turned off the motorized carriage will stop and the wheel clamp will stop The starter will be deactivated as well as the AFR air pump and the retarder will be de activated If the dyno is properly equipped with the air brake option the air brake will be applied stopping the dyno drum If the air brake is not installed the drum will freewheel During an E Stop condition the Status Indicator light will be flashing with two short blinks on and long pause off USING THE HIGH PRESSURE BLOWERS The CPI allows the dyno operator to toggle the optional high pressure blowers on and off from the control panel If the E Stop is activated the blowers will be automatically turned

Dynojet Research 200ip User's Manual

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