A200-Series installation manual

A200-Series installation manual

Introduction

This installation manual is an essential part of the dynoKRAFT A200-2WD / A200-4WD-ML dynamometer, intended to be used by technician performing the installation and commissioning of this product.

© 2022 VISION ENGINEERING e.K. , All rights reserved.

This manual is copyrighted by VISION ENGINEERING e.K., hereinafter referred to as dynoKRAFT. All rights reserved.
Original installation manual for the dynoKRAFT dynamometer.
This manual is for informational purposes only, is subject to change without notice and should not be construed as a commitment by dynoKRAFT.
dynoKRAFT assumes no responsibility or liability for errors or inaccuracies that may appear in this manual.

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 consent of dynoKRAFT. 
All trademarks, trade names, service marks, or service names owned or registered by another company and used in this manual are the property of their respective companies.

Manufacturer / Service / Warranty:
VISION ENGINEERING e.K.
Hugo-Eckener-Str. 33
D-50829 Köln
Germany


Warranty and Disclaimer


This products is meant to be installed and commissioned by trained and experienced technicians only.

Owner/user assumes responsibility for his or her own actions when installing, commissioning and/or using these products. dynoKRAFT hereby expressly disclaims liability and shall not be responsible for incidental, consequential and contingent damages or any kind or nature, including, without limitation: damages to persons or property, whether a claim for such damages is based upon warranty, contract, tort or otherwise; damages due to or arising out of the loss of time; or loss of profits.

dynoKRAFT shall not be responsible for any damages caused by the presence of error or omission in any of its manuals, instructions or related materials.
Should you have any problems or questions during the installation process, or any part of this manual is not perfectly clear, please reach to us for professional assistance before taking further steps.
Any damage to dynamometer caused by incorrect installation is not covered by warranty.

Warnings

Conventions used in this manual

The conventions used in this manual are designed to protect both user and equipment and to assure a safe work environment.
Warning!
The warning indicates a serious hazard or risk of machine damage.

Caution.
Caution means that failure to perform or incorrectly perform the described procedure can damage the test bench.

Information.
Information gives the user additional useful advice.

Precautions and other safety measures

To assure problem free installation of your dynamometer you should note these precautions and use common sense at all times.
Please read this manual before attempting to install your dynamometer.

Moving and lifting heavy objects.

All dynoKRAFT dynamometers are designed as assembly of one or more sub-assemblies, which are meant to be bolted / installed together.
Most of these sub-assemblies are heavy and require special care while lifting and transporting.
Always use adequate lifting gear with sufficient lifting capacity during the installation process.

Warning! Heavy objects. 
Use special precautions and adequate lifting gear while moving or lifting heavy objects.
Risk of serious injury of death!

Noise and debris

During the installation you will be drilling holes in concrete floor, operate an impact wrench or similar tools and perform other operations, which may pose risk to your hearing and/or damage your eyes.

Warning! Excessive noise. Eye damage.
Always use eyes and ears protection while installing with dynamometer. Fail to do so may result in serious health issues, hearing loss or visual impairment.

Electric power. Compressed air

The dynoKRAFT dynamometers are operated using electric power and compressed air.
Do not remove any covering panes, perform any service or repairs or open any electric cabinets while dynamometer is under power.

Any repairs or service which requires accessing the dynamometers electrical cabinet may only be performed by qualified electrician.

Warning! Potentially lethal voltages.
Never perform any service or remove any protective panels or open electric cabinets without previously disconnecting the main AC power cord.
Always wait min. 5 minutes after turning off the dynamometer main switch to allow for complete discharge of electromagnetic coils of the Eddy Current Brakes.
Fail to do so may result in lethal electric shock.

Before performing any service operation or repairs to pneumatic components always release the pressure from the pneumatic system. Please follow service procedures described in respective User Manual on details how to release the air pressure from the dynamometer systems.

Warning! Eye damage.
Always use eye protection while working with dynamometers pneumatic systems.
Fail to do so may result in serious eye damage and visual impairment.

Preparation

Tools and equipment

To perform this installation following tools shall be required.:
1. Spirit level, min. 3m long.
2. TX40 bit with approx. 20-25cm extension.
3. Set of allen keys 3-10mm.
4. Flat / Combination wrench, metric: 10, 13, 17, 19, 24 and 30mm.
5. Ratchet with 17 and 19mm socket.
6. Torque wrench set to 34Nm with 6mm hex key socket and 85-90Nm with 19mm socket.
7. Thread lock, medium strength.
8. Hammer drill with 10mm concrete bit.
9. Metric measuring tape.
10. Compressed air pistol and/or industrial vacuum cleaner.
11. Lifting slings with adequate load capacity (min. 1000kg per sling).
12. Fork lift or other lifting device to position the components in the final installation place.

Unpackaging and unloading

Information.
Upon delivery please carefully check all packages.
Should you observe any damage on any of the delivered crates or palettes please annotate this in the delivery documents and notify dynoKRAFT immediately per email (info@dynoKRAFT.de) by sending us a copy of the annotated shipping documentation.
Without a copy of the shipping documents with appreciate delivery-damage notes, signed by carrier, we will not be able to process your claim!
In most cases the dynoKRAFT dynamometer is delivered on disposable wooden palette, wrapped with black stretch foil.
In case of over-sea transport the dynamometer is delivered in closed crate and wrapped in protective foil. In addition to that an humidity absorber may be found inside the packages.
Additionally an protective wax-film may be found on non-painted surfaces. This film should be removed/cleaned with appreciate non-corrosive and non-abrasive chemicals and cotton cloth as required.
Please take care of your environment and dispose or recycle all packaging materials according to your local regulations and laws. 

1. Open the wooden crate using crawl-bar or similar tool. Please proceed with care not to damage the equipment.
2. After opening the crates / removing all packaging material make sure that all parts are delivered as per packaging list and this manual.
3. Remove all coverings from all parts of the dynamometer to allow easy access to the internals of the chassis / frames.
4. Using fork-lift relocate the frames on the palettes near the intended installation place. Then you may unscrew the dynamometer vibration damper feet from the pallet using TX40 bit.

Initial checks

Before installing the dynamometer make sure to check following:
1. Please check the flatness of the surface/floor on which you plan to install your dynamometer using spirit level. Required flatness is min. 2mm per 1m of length in any direction.
In case your installation place does not meet this requirement it may be necessary to use sheet-metal plates to level the dynamometer accordingly.
Such spacers are to be installed underneath the vibration dampers, between the workshop floor and the dyno feet.
DO NOT loosen the vibration dampers from the dyno chassis and install any washers to rise/lower the main frame.



2. Please clean the floor from any dust and dirt. Make sure it's not slippery.
3. Make sure that you have all the tools and hardware required for the installation. This will speed up the process.

00. Pit installation: Wall profiles (OPTIONAL)

NOTE: This step is applicable only in case you're installing the dynamometer in a pit.
Before lowering the dynamometer into the pit make sure to install the grating support profile (marked green below) on the back wall of the pit, using provided M10 (M12) concrete anchors.
Should you lower the frames into the pit before installing these wall-profiles you may experience difficulties when doing it at later stage.




Support profile installation height is 518,5mm (approx. 20,4" ):



0. Subframe

Start the assembly process by positioning the Subframe in the intended final installation place.
The subframe carries the FRONT ROLLER (in driving direction) and it's adjustable to allow different wheelbase settings.
Lift the front Subframe using one webbing sling, or similar, near the drive shaft bearing support (at the center of gravity), so that it can be rotated 180 degrees once hung.


Rotate the Subframe 180deg then gently lower it in place. Note the position and orientation of the blue gearmotor-drive.
Use wooden blocks and rubber pads not to damage the paint.




NOTE: This step is applicable only in case you're installing the dynamometer in a pit.
Position the Front frame in the pit as per drawing below (rear pit wall to subframe ~220cm)


01. Front Frame

Lift the Front Frame using two slings - one on each side of the chassis.
Route the sling through these holes in frame (marked green below):



Like that:

Please note the orientation of the chassis / position of the retarder -> on the LEFT in driving direction.
Position the Front Frame above the Subframe and lower it.




While lowering guide the Front Frame into the threaded M20 studs found on the Subframe cradles.
DO NOT tighten these nuts yet.


02. Horizontal bars

Install lower horizontal bars into the Subframe and tighten losley (by hand), so that the bars can be moved freely to left or right at later stage of the installation.
No lateral movement is allowed. Support the free ends using wooden blocks.


Note the orientation of the bars:



03. Rear Frame

Lift the Rear Frame in same way as shown in chapter "01. Front Frame" and position it close to Horizontal bars / lower it in place.
Please note the orientation of the chassis / position of the retarder -> on the LEFT in driving direction.
Keep the Rear Frame swinging in the air, just few millimeters above the ground, before attaching the Horizontal bars - this will ease the installation:


Bolt the Rear Frame to the Horizontal bars using supplied M12 bolts and self-securing nuts.
Tighten it loosely so that the Rear Frame can be still moved to left or right, but in lateral direction (in driving direction) there is no exessive free-play possible.





04. Angular axle position

Before tightening the M20 nuts on the Subframe cradles please verify the angular position of both Front and Rear Frames with respect to each other.
To do so please place the spirit level on the side of the rollers and press it firmly against the roller side.
In the example below the FRONT Roller is base for this check while the REAR roller shows some distance to the spirit level (represented by green line in drawing below).



Measure the difference in this distance between two edges of the same roller so verify that the angle between axles is near 0 degrees.
NOTE: Due to manufacturing tolerances the distance X must not necessary be exactly 0 - some offset is allowable - usually less then 10mm.



If X1 = X2 the angle is zero
If X1 ≠ X2 the Front Frame angle "A" must be adjusted on the cradles accordingly



After the axle angle has been setup please tighten the M20 nuts bolting together the Front Frame and Subframe cradles.:
Torque: min. 150Nm



05. Link shaft installation to Rear Frame (slit version)

Suspend the Link Shaft in the air to ease the installation.
Make sure to have the central support bearing moved onto the Link Shaft as shown below.


Attach compressed air to the Air Supply inlet and release the pneumatic brake calipers by pressing the orange button on the pneumatic valve.


While holding the pneumatic valve open rotate the rollers so that the feather key on the Link Gearbox is on the bottom of the output shaft.


Using flat-head hammer-thru screwdriver widen the slit in the cardan-joint:


While having the screwdriver positioned under an angle insert the Link Shaft through the hole in Rear Frame


 and move the cardan-joint over the Link Gearbox:


If the joint is hard to install on the output shaft you may use crawl-bar to push it in.
Caution!
Do not excessively stretch the cardan joint with the hammer-thru screwdriver as you may damage it.


Push the universal joint over the output shaft so that approx. 3mm of free play to the joint itself is provided.
Look through the slit - the output shaft must not touch the joint itself:


Install two 80mm Collar Clamps over the Universal Joint to clamp it on the output shaft of the Link Gearbox.
With the dyno there are a total of 4 clamps delivered. On some dynos with pre-glued shaft Support Bearing two of these clamps are used to secure the bearing during shipping.
Please re-use them to secure the cardan joint.

Mark the bolt heads with paint marker as shown.
Torque: 34Nm
Caution!
This is critical step thus make sure to keep the specified torque of 34Nm.
Please make sure to orient the slit of the Collar Clamp directly above the slit in the cardan-joint itself.


06. Link shaft installation to Front Frame (slit version)

Connect the Compressed Air pass-through hose to supply air pressure to Front Frame and connect the air coupling inside the Front Frame.
Connect the black power connector to electric cabinet (found on the back of PC-trolley). 
Turn the Mains ON and press green "Reset" button to supply electric power to Front Frame gearmotor drive.
You may use the Wheelbase adjustment during this step to ease the installation of the cardan-joint on the Link Gearbox.
Simply press the respective button on the wired remote to move the Front Frame back and forth.

While holding the pneumatic valve open rotate the rollers so that the feather key on the front Link Gearbox is on the bottom of the output shaft.
The feather key itself is held in place using cable-tie, which will be removed during this installation as soon, as the cardan-joint is moved over the key.


Using flat-head hammer-thru screwdriver widen the slit in the cardan-joint, which is later installed into the Front Frame:


Move the cardan-joint over the gearbox shaft and pull the screwdriver out:


Then relocate the hammer-thru screwdriver to the inside of the frame, slit the cardan-joint again and remove the cable-tie:


Push the joint further so that it's flush with the housing.


Remove the screwdriver and install 80mm Collar Clamps in similar manner as previously in Rear Frame.
Mark the bolt heads with paint marker as shown.
Torque: 34Nm

Caution!
This is critical step thus make sure to keep the specified torque of 34Nm.
Please make sure to orient the slit of the Collar Clamp directly above the slit in the cardan-joint itself.


07. Support Bearing part 1

After installing the cardan joints on both ends please adjust the wheelbase to the middle setting by pressing the respective button on the wired remote.



Loosely install the fixing brackets on the Support Bearing housing



and push it against the Subframe:


Mark the bearing position over the shaft to determine the position of the bearings inner race.
Apply medium thread-lock (glue) around the whole circumference of the drive-shaft, to glue the inner race onto the Link Shaft.

Push the Support Bearing back in place (push against the Support frame as shown below) before the glue dries out!
Leave the bearing for min. 15 minutes to let the glue set.

Caution!
On dynos with pre-glued central Support Bearing this gluing operation was performed during manufacturing of the dyno.
In such case please spread the cardan-joint slit in the Rear Frame before pushing the Central Bearing against the Subframe.
Should you try to bolt down the central bearing without spreading the slit in cardan joint and pushing the bearing housing agaist the Subframe
you will damage/tear the vulcanized rubber in the bearing housing.

08. Central Bridge part 1

Place the Central Bridge in place




Bolt the Central Bridge to Rear Frame using M12 bolts and self-securing nuts
Torque: 85Nm



Then bolt the Central Bridge into Subframe (total of six M12 bolts)
Torque: 85Nm, medium thread lock

(HD-washers option)


(pressure plate option)



Please torque down all bolts fixing the Horizontal Bars which were only loosely tighten in step 02.
Torque 85Nm, medium thread lock




Please fix the Rear Frame to the floor using concrete anchors. Minimum anchor one per machine feet.
Torque: 20Nm



09. Support Bearing part 2

After finishing the installation of Central Bridge please fix the Link Shaft support bearing to both Central bridge and Subframe.
Make sure to insert the spacer bushing between the Subframe and Central bridge.

Torque:
M12 -> 85Nm
M10 -> 60Nm






Now please torque down the remaining bolts of the Central Bearing housing
Torque 85Nm, medium thread lock




10. Grating Frames and Forks

Once the Central Bridge and Link-Shaft Support Bearing is fixed proceed with installation of the Grating Frames using M12 bolts and self-securing nuts.
Align the Grating Frames to left and right so assure proper movement of the components when wheelbase is being adjusted.
Torque 85Nm







Install the Forks in similar manner by bolting them to Front Frame using two M12 bolts per Fork, HD-washers and self-securing nuts.
To adjust the angle of the Fork (shortest wheelbase setting) so that it wont protrude above the level of the Central Bridge please slide the M12 left or right in the angled hole accordingly.
Torque 85Nm








11. Front Bridge

Install the Front Bridge to the Front Frame.
Hang it under an angle of approx. 30 degrees.


And install in the front of the dyno


The Front Bridge is bolted using M12 bolts and self-securing nuts.
Use standard and HD-washers accordingly.
Torque 85Nm







To level the Front Bridge you may need to place distance washers between the lower mounting tab and Front Frame:



12. Electric and Pneumatic installation

Turn the Mains OFF and perform following installation steps:

1. Connect compressed air supply to Air Inlet (upper coupling), max 7-8 bar
Connect pass-through hose from Subframe to Rear Frame to Air Outlet (lower coupling)
Secure the black air hose with cable ties to the chassis so that it will not get damaged by the trapezoidal screw during wheelbase adjustment (shortest wheelbase setting)


2. Connect the air coupling inside the Front Frame and secure the air hose with cable-tie if needed.


3. Connect the black power connector to side of the Electric cabinet found on Front Frame (twist-lock)


4. Secure the power cable from small electric cabinet to gearmotor by fixing it to Front Bridge using cable tie.


5. Connect both power lines (from Front and Rear Frames) to the main electric cabinet found on the back of the PC-Trolley (twist-lock)
6. Connect the 3-way DIN connector to the respective plug found on the main electric cabinet.
7. Connect the Hall-Sensor, Load Cell and PWM Signals in the terminal box found on Front Frame.

Sensor side Data bundle side
Sensor Function (chassis)
(cradle)
Load Cell V+ RED WHITE
Sig + GREEN GREEN
Sig - WHITE YELLOW
gnd BLACK BROWN
shield shield shield
Hall Sensor V+ RED (BROWN) WHITE
Sig + BLACK GREEN
gnd BLUE BROWN
shield shield shield
PWM PWM WHITE WHITE
gnd BROWN BROWN





13. ADAQ System. Final steps

1. Mount the ADAQbase controller and ADAQexiom extension module (if supplied - see scope of delivery) on the 35mm DIN rail located on the side of the supplied PC-trolley.
Connect the three green terminals to the ADAQbase module and complete the installation as per ADAQbase and ADAQ Software manual.
Complete the ADAQexiom installation per user manual.

2. Install back all coverings and fix them firmly. Place all gratings into the Central and Front Bridge.


3. Connect the dynamometer to grid and power it up by turning the Mains switch on the side of the electric cabinet.
When powered up, provided that compressed air is connected and sufficient pressure is available, the dynamometer will be in E-STOP state.
To start using your dynamometer please release the E-Stop button and reset the dynamometer to normal working condition by pressing green button on Control Panel.
Warning! Read User Manual before use.
Before using your dynamometer please complete the installation and carefully read User Manual.

4. After approx. first 20 test runs please check and if needed adjust the gap of the pneumatic brake caliper to max. 0,5mm free-play.
To do so please power-up and reset your dynamometer to normal operation mode and remove top covers from both Front and Rear Frames.
Assure that the air pressure level is min. 7 bar, preferably exactly 8 bar.
Using 24mm flat wrench please adjust the gap of the brake caliper, then lock the bolt with counter-nut.



5. Please fill-out the provided "Commissioning Protocol" and perform the described test runs upon finishing this installation.
An copy of this protocol together with both .csv test files must be sent to dynoKRAFT per E-mail (info@dynoKRAFT.de) to validate your warranty.



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