Dynojet Research Automobile Accessories 248 User's Manual
Contents
1. Dynojet recommends using an air filter dryer Failure to use clean dry air will compromise the integrity and life of the air components 1 Mount the air pressure regulator on the wall in the shop with the bracket provided Connect a supply air hose to the inlet of the regulator from your shop air supply The regulator should be set to 60 psi Connect the 3 8 inch air hose to the outlet side of the regulator and connect the other end of the air hose to the barbed inlet fitting on the air control switch on top of the right air canister on the dyno Refer to Figure 7 Note Make sure the arrow on the regulator is the same as the direction of the air flow WIRING THE DYNOWARE EX MODULES 1 primary inductive pickup socket 25 pin socket 9 pin hand held pendant 9 pin RS 232 socket 3 pin power plug Place the DynoWare EX modules in a safe location in the shop that is close enough to the computer and the dyno for the cables to reach Attach the cables to the DynoWare EX modules Refer to Figure 8 for cable placement Attach the 9 pin shielded serial cable from the PC to the RS 232 socket on the CPU module Tighten the screws A 9 pin to 25 pin adapter may be required Attach the 25 pin shielded cable from the dynamometer to the Dynamometer Input Output module Tighten the screws Attach the 9 pin connector from the hand held pendant to Dynamometer Input Output module Tighten the2. 1 4 The DyrioWare EX System 1 5 Installing the New Dyno Hardware 1 6 Connecting Your Shop Air to the Dyno 1 8 Wiring the DynoWare Modules 1 8 Appendix A Proportional Air Brake Installation Parts ie Sees uai vine ud ERE AA ACIER RR RR UR Ra d uia dss A 1 cr M A 2 Removing the Standard Air Brake System A 2 Installing the Proportional Air Brake System A 3 Wiring the Breakout Board A 6 DynoWare EX Upgrade For The Model 248 Dynamometer xy TABLE OF CONTENTS A DynoWare EX Upgrade For The Model 248 Dynamometer LIST OF FIGURES Figure 1 PC east 1 3 Figure 2 Control 1 4 Figure 3 Disconnect Cable and Air Hose 1 4 Figure 4 DynoWare EX Modules 1 5 Figure 5 DynoWare EX Components 1 5 Figure 6 Install the New Dyno 1 6 Figure 7 Standard 1 7 Figure 8 Attach the DynoWare EX Cables 1 8 Figure 1 Proportional Air Brake A 1 Figure 2 Remove the Stand
3. Dynojet Research Inc 200 Arden Drive Belgrade MT 59714 2191 Mendenhall Drive North Las Vegas NV 89031 P N 98212100 VERSION 2 1993 2002 Dynojet Research Inc All Rights Reserved 020621SD Copyright 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 Trademarks 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 2002 Dynojet Research Inc TABLE OF CONTENTS List of i Chapter 1 DynoWare EX Upgrade Conventions Used In This 1 1 Technical SUpport ess aono me 1 1 Parts USE ioca eet oad eae 1 2 Remove the Original Hardware 1 3 Removing the Card 1 3 Removing the Control
4. 2 Unplug the power cord to both the computer and the control box 3 Remove the computer cover AW Electrostatic Discharge ESD or static shock can damage electronic components To avoid ESD damage always practice good ESD control precautions Touch the case of the computer before touching any of the electronics By touching the case you discharge any static shocks to the case instead of the to the electronics 4 Locate the PC card cable that comes from the control box and plugs into the PC card in the computer Unplug it from both the control box and the computer 5 Remove the screw s securing the PC card and remove the card from the computer 6 Replace the dust cover to cover up the hole in the back of the computer Note If you no longer have this dust cover one may be easily obtained from your local computer dealer 7 Replace the computer cover Figure 1 PC Card Version 2 DynoWare EX Upgrade For The Model 248 Dynamometer DYNOWARE UPGRADE Remove The Original Hardware REMOVING THE CONTROL BOX 1 Shut off and release the air pressure to the control box 2 Disconnect all cables and air hoses from the control box 3 Remove the control box from the wall Figure 2 Control Box 4 Disconnect the data acquisition cable from the dyno and remove the cable 5 Disconnect the air hose and remove the fitting from the top of the air canister on the right hand side of the dyno Note Leave the air hose w
5. Cables Air Lines A 5 Version 2 DynoWare EX Upgrade For The Model 248 Dynamometer P APPENDIXA 6 v Installation WIRING THE BREAKOUT BOARD When attaching cables refer to Figure A 6 for cable location and Figure A 7 for Breakout board wiring information 1 DynoWare EX Upgrade For The Model 248 Dynamometer Attach the data acquisition cable coming from the optical pickup card on the dyno to the Breakout board The data acquisition cable has four wires which connect to the wiring block labeled DRUM 1 Red wire connects to R1 White wire connects to W1 Black wire connects to B1 Silver wire connects to S1 Attach the wires from the air pressure switch located on the prop air regulator assembly to the wiring block labeled PRESS on the Breakout board Each wire may attach in either position Attach the cable coming from the EPR to the Breakout board The EPR cable has five wires which connect to the wiring block labeled LOAD CONTROL Black wire connects to V Red wire connects to White wire connects to Green wire connects to O Silver or ground shield wire connects to SH Attach the brake wires from the brake solenoid located on the prop air regulator assembly to the wiring block labeled BRAKE on the Breakout board Each wire may attach in either position Attach the temperature sensor cable to the Breakout board The temperature sensor cable has five wires which connect to the wiring
6. block labeled TEMP on the Breakout board Green wire connects to G1 White wire connects to W1 Black wire connects to B1 Red wire connects to R1 Silver or ground shield wire connects to S1 PROPORTIONAL AIR BRAKE INSTALLATION T Installation N data acquisition EPR cable cable air pressure switch wire brake solenoid temperature wires sensor cable DynoWare cable Figure A 6 Routing Cables Breakout Board 6 The Breakout board jumper settings are preset however verify jumpers J1 and J2 are set for the proportional air brake as shown in Figure A 7 7 Plug the 25 pin DynoWare cable into the bottom of the Breakout board and tighten the thumb screws 8 Continue with Wiring the DynoWare EX Modules on page 8 load control drum 1 D 1 a ta 77 jumpers he S and J2 proportional air jumper settings DynoWare E cable SS CB005 Figure A 7 Prop Air Wiring A 7 Version 2 DynoWare EX Upgrade For The Model 248 Dynamometer
7. Model 248 Dynamometer P APPENDIXA d A Installation INSTALLATION This section describes the procedures to remove the standard air brake system install the proportional air brake system and wire the Breakout board REMOVING THE STANDARD AIR BRAKE SYSTEM 1 Turn off the power on the DynoWare EX hardware 2 Shut off and release the air pressure to the air pressure regulator 3 Remove the two black wires from the wiring block labeled BRAKE on the Breakout board 4 Remove the yellow and black wires from the wiring block labeled PRESS on the Breakout board 5 Disconnect the 3 8 inch air hose from the fitting on the air brake control switch The air brake control switch is located on top of the right side air canister Note Leave the air hose with the dyno as it will be used later Unscrew and remove the air brake control switch air hose Ml air brake control switch press Ke 0 brake e e md Figure A 2 Remove the Standard Air Brake A 2 DynoWare EX Upgrade For The Model 248 Dynamometer e PROPORTIONAL AIR BRAKE INSTALLATION e Installation INSTALLING THE PROPORTIONAL AIR BRAKE SYSTEM 1 Install the DIN rail la Clamp the DIN rail to the right post 14 inches down from the top of the dyno frame 1b Using a center punch mark two mounting holes in the middle of the top and bottom slots Remove the clamp and bracket 1c Drill and tap th
8. Ware to Computer Serial Port Cable 12 Ft 1 64111003 Brake Solenoid Sub Assembly Air Brake Control Switch Assembly 1 65291001 Breakout Board 1 66191001 CPU Module Sub Assembly 1 66192001 RPM Module Sub Assembly 1 66193001 Input Output Module Sub Assembly 1 66493001 Atmospheric Sensing Module Sub Assembly 1 66954001 Data Acquisition Cable 20 Ft 1 761900001 Power Supply 1 91114A009 Washer 8 Lock 4 A10Z2 304A Rubber Vibration Dampener Mounts 4 DE100 109S Secondary Inductive Pickup Cable 20 Ft 2 DE100 110L Primary Inductive Pickup Clip 20 Ft 1 The following parts are included in the Proportional Air Brake Installation 21619200 Temperature Sensor Bracket 1 31614100 DIN Rail 1 36560834 Screw 1 4 20 x 1 2 Button head 4 44997101 Temperature Sensor 1 64111001 Prop Air Regulator Sub Assembly 1 64111002 Control Valve Sub Assembly electronic pressure regulator EPR 1 DynoWare EX Upgrade For The Model 248 Dynamometer DYNOWARE UPGRADE S Remove The Original Hardware REMOVE THE ORIGINAL HARDWARE This section describes the procedures to remove the PC card from the computer disconnect and remove the control box disconnect the air to the dyno brake canisters and replace the air hose fitting in the top of the right air canister If you are only upgrading to the proportional air brake system skip to the instructions in Appendix A REMOVING THE PC CARD 1 Shutdown the computer
9. ard Air A 2 Figure 3 Install the DIN Rail and A 3 Figure A 4 Install the Temperature Sensor and Prop Air Regulator Assembly A 4 Figure 5 Routing Cables Air A 5 Figure 6 Routing Cables Breakout Board A 7 Figure A 7 Prop Air Wiring EE A 7 DynoWare EX Upgrade For The Model 248 Dynamometer xy LIST OF FIGURES A DynoWare EX Upgrade For The Model 248 Dynamometer DYNOWARE EX UPGRADE This document provides instructions for installing the DynoWare EX components on the model 248 automotive dynamometer dyno To ensure safety and accuracy in the procedures perform the procedures as they are described This manual will walk you through removing the original hardware and installing the DynoWare EX components This manual also contains instructions for removing the standard air brake system and installing the optional proportional air brake system Document Part Number 98212100 Version 2 Last Updated 06 21 02 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 AWM dynamometer equipment Follow all procedures exactly as they are described and use care when performing all proced
10. ator assembly air canister install prop air regulator assembly Figure A 4 Install the Temperature Sensor and Prop Air Regulator Assembly A 4 DynoWare EX Upgrade For The Model 248 Dynamometer PROPORTIONAL AIR BRAKE INSTALLATION ke Installation 5 Attach the air line labeled OUT from the EPR to the three way valve on the prop air regulator assembly Push the hose in and hand tighten the fitting 6 Attach the air line labeled IN from the EPR to the brass four way fitting on the prop air regulator assembly Note Pull on both hoses to ensure they are secure If there is movement tighten the fitting 7 Connect your shop air to the dyno ATU Dynojet recommends using an air filter dryer Failure to use clean dry air will compromise the integrity and life of the air components 7a Mount the air pressure regulator on the wall in the shop with the bracket provided 7b Connect a supply air hose to the inlet of the regulator from your shop air supply and a 3 8 air hose to the outlet side The regulator should be set to 60 psi 7c Connect the 3 8 air hose coming from the air pressure regulator to the barbed inlet fitting on the prop air regulator assembly Note Make sure the arrow on the regulator is the same as the direction of the air flow out EPR air line out three way valve EPR air line in brass four way fitting regulated air PAO05 M Figure A 5 Routing
11. e mounting holes for 1 4 inch UNC bolts 1d Secure the DIN rail to the dyno using two 1 4 inch button head allen bolts 2 Install the control valve assembly electronic pressure regulator EPR The EPR snaps into place Hook one side of the EPR on the DIN rail then rotate it toward the DIN rail until it snaps into place top of dyno frame post EPR DIN rail install the DIN rail install the EPR Figure A 3 Install the DIN Rail and EPR A 3 Version 2 DynoWare EX Upgrade For The Model 248 Dynamometer m APPENDIXA d A Installation 3 Install the temperature sensor 3a Clamp the temperature sensor bracket to the left post 24 inches down from the top of the dyno frame 3b Using center punch mark the bracket mounting holes in the middle of both slots Remove the clamp and bracket 3c Drill and tap the mounting holes for 1 4 inch UNC bolts 3d Loosely attach the bracket to the dyno using two 1 4 inch button head allen bolts Do not tighten the bolts 3e Install the temperature sensor so it is approximately three inches from the surface of the drum 3f Adjust the bracket so the temperature sensor is aimed at the interface of the knurl and brake surface Tighten the bolts to secure the bracket 4 Screw the prop air regulator assembly into the right side brake canister Tighten it so the air gauge is facing out top of dyno frame drum post sensor bracket install sensor install bracket prop air regul
12. egulator gauge E and mounting bracket c P d E X DynoWare to computer cable primary inductive D Sa pickup cable Figure 5 DynoWare EX Components E Version 2 DynoWare EX Upgrade For The Model 248 Dynamometer EX UPGRADE ZA d A The DynoWare EX System INSTALLING THE NEW DYNO HARDWARE 1 Mark the mounting holes for the Breakout board mounting bracket la Using the mounting bracket as a template place the bracket so the holes are centered on the cross brace and 2 25 inches in from the post 1b Using a center punch mark two mounting holes the dyno frame 1c Drill and tap the mounting holes for 1 4 inch UNC bolts 2 Secure the Breakout board to the mounting bracket using four 8 screws 3 Install the mounting bracket to the dyno frame using two 1 4 inch allen head bolts Note If you are installing a proportional air brake system skip the following instructions and continue with Installing the Proportional Air Brake System on page A 3 4 Screw the air brake control switch into the top of the air canister on the right hand side of the dyno use bracket to mark mounting holes post cross brace secure breakout board to bracket mark mounting install bracket holes air brake control switch assembly air canister install air brake control switch Figure 6 Install the New Dyno Hardware DynoWare EX Upgrade For The Model 248 Dynamom
13. eter DYNOWARE EX UPGRADE The DynoWare System 5 Plug the data acquisition cable into the optical pickup card on the dyno 6 Attach the data acquisition cable coming from the optical pickup card on the dyno to the Breakout board The data acquisition cable has four wires which connect to the wiring block labeled DRUM 1 Red wire connects to R1 White wire connects to W1 Black wire connects to B1 Silver wire connects to S1 7 Attach the two black wires from the air brake control switch to the wiring block labeled BRAKE on the Breakout board Each wire may attach in either position 8 Attach the yellow and black wires from the brake control to the wiring block labeled PRESS on the Breakout board Each wire may attach in either position 9 The Breakout board jumper settings are preset however verify jumpers J1 and J2 are set for the standard air brake as shown in Figure 7 Note Make sure that the cables are clear from all moving parts 10 Plug the 25 pin DynoWare Cable into the bottom of the Breakout board and tighten the thumb screws pickup card regulated air air brake control switch DynoWare cable z standard air e i e jumper settings CB005 NC cable Figure 7 Standard Air Wiring Version 2 DynoWare EX Upgrade For The Model 248 Dynamometer m DYNOWARE UPGRADE d A The DynoWare EX System CONNECTING YOUR SHOP AIR TO THE DYNO
14. ith the dyno as it will be used later remove air hose air canister remove data acquisition cable Figure 3 Disconnect Cable and Air Hose DynoWare EX Upgrade For The Model 248 Dynamometer DYNOWARE UPGRADE Io The DynoWare EX System THE DYNOWARE EX SYSTEM The DynoWare system is comprised of four modules the CPU Module the Dynamometer Input Output Module the RPM Module and the Atmospheric Sensing Module The upgrade requires a new Breakout board the interface between the dyno and the new DynoWare hardware These modules need to be located where they will be visible during a dyno run It is recommended that they be mounted on a shelf on the wall or on a cart along side the personal computer This section will provide you with the information necessary to install and connect the new components atmospheric sensing module RPM module dynamometer input output module CPU module Figure 4 DynoWare Modules Breakout board mounting DynoWare modules bracket and hardware wall mounting bracket Breakout board and and hardware data acquisition cable optical pickup card co E Breakout board to DynoWare cable power supply and power cord secondary inductive air brake control pickup cables switch assembly air pressure r
15. screws Attach the 3 pin plug from the power supply to the CPU module with the flat side facing down Plug the power supply into an electrical outlet Turn the power switch on at the CPU module and verify operation with WinPEP power LEDs power switch DynoWare EX Upgrade For The Model 248 Dynamometer Figure 8 Attach the DynoWare EX Cables APPENDIX PROPORTIONAL AIR BRAKE INSTALLATION This appendix contains instructions for installing the proportional air prop air brake system to the model 248 automotive dynamometer dyno To ensure safety and accuracy in the procedures perform the procedures as they are described PARTS LIST The following table lists all of the parts included in the Proportional Air Brake Installation kit 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 description quantity 21619200 Temperature Sensor Bracket 1 31614100 DIN Rail 1 36560834 Screw 1 4 20 x 1 2 Button head 4 44997101 Temperature Sensor 1 64111001 Prop Air Regulator Sub Assembly 1 64111002 Control Valve Sub Assembly electronic pressure regulator EPR 1 prop air regulator pn assembly temperature sensor bracket control valve assembly EPR DIN rail temperature sensor Figure A 1 Proportional Air Brake Components 1 DynoWare Upgrade For The
16. ures The Warning icon indicates potential harm to the Ke WARNING i erson performing a procedure and or the KA D gap 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 89031 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 DynoWare EX Upgrade For The Model 248 Dynamometer UPGRADE A Wi PARTS LIST The following table lists all of the parts included in the DynoWare EX Upgrade Installation kit 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 description quantity DynoWare EX Upgrade 98198106 134490301 Nut 8 32 4 145300001 Air Pressure Regulator 1 145800001 Air Pressure Gauge 1 21646100 DynoWare EX Mounting Base 1 21696200 1 Breakout Board Mounting Bracket and 2 1 DynoWare EX Module Wall Mounting Bracket 31616200 Air Pressure Regulator Mounting Bracket 1 318110301 Power Cord 125V 10A 7 1 2 Ft 1 36540643 Screw 8 32 x 3 8 Ph Phil 4 42924090 Breakout Board to DynoWare Cable 1 42924250 Dyno
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