DynoWare EX+ Upgrade Installation Guide ©1993-2002 Dynojet Research, Inc. All Rights Reserved. 020621SD For The Model 248 Automotive Dynamometer Dynojet Research, Inc.
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.
TABLE OF CONTENTS List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Chapter 1 DynoWare EX+ Upgrade Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TA B L E O F C O N T E N T S ii DynoWare EX+ Upgrade For The Model 248 Dynamometer
LIST OF FIGURES Figure 1: PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Figure 2: Control Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Figure 3: Disconnect Cable and Air Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Figure 4: DynoWare EX+ Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Figure 5: DynoWare EX+ Components . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES iv 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.
DYNOWARE EX+ UPGRADE 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.
D Y N O WA R E E X + U P G R A D E 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.
DYNOWARE EX+ UPGRADE Remove The Original Hardware REMOVING THE CONTROL BOX 1 2 3 Shut off and release the air pressure to the control box. Disconnect all cables and air hoses from the control box. Remove the control box from the wall. Figure 2: Control Box 4 5 Disconnect the data acquisition cable from the dyno and remove the cable. Disconnect the air hose and remove the fitting from the top of the air canister on the right hand side of the dyno.
D Y N O WA R E E X + U P G R A D E The DynoWare EX+ System THE DYNOWARE EX+ SYSTEM ................................... The DynoWare EX+ 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 EX+ hardware). These modules need to be located where they will be visible during a dyno run.
DYNOWARE EX+ UPGRADE The DynoWare EX+ System INSTALLING THE NEW DYNO HARDWARE 1 use bracket to mark mounting holes cross brace Mark the mounting holes for the Breakout board mounting bracket. 1a 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 in the dyno frame. 1c Drill and tap the mounting holes for 1/4-inch UNC bolts.
D Y N O WA R E E X + U P G R A D E The DynoWare EX+ 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.
DYNOWARE EX+ UPGRADE The DynoWare EX+ System CONNECTING YOUR SHOP AIR TO THE DYNO Dynojet recommends using an air filter/dryer. Failure to use clean, dry air will compromise the integrity and life of the air components. 1 2 3 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.
APPENDIX A 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.
APPENDIXA 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 2 3 4 5 6 Turn off the power on the DynoWare EX+ hardware. Shut off and release the air pressure to the air pressure regulator. Remove the two black wires from the wiring block labeled BRAKE on the Breakout board.
PROPORTIONAL AIR BRAKE INSTALLATION Installation INSTALLING THE PROPORTIONAL AIR BRAKE SYSTEM 1 2 Install the DIN rail. 1a 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 the 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.
APPENDIXA Installation 3 4 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 a 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.
PROPORTIONAL AIR BRAKE INSTALLATION Installation 5 6 7 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. 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. Connect your shop air to the dyno. Dynojet recommends using an air filter/dryer.
APPENDIXA 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 2 3 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.
PROPORTIONAL AIR BRAKE INSTALLATION Installation data acquisition cable EPR cable air pressure switch wire brake solenoid wires temperature sensor cable DynoWare cable Figure A-6: Routing Cables—Breakout Board 6 7 8 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. Plug the 25 pin DynoWare cable into the bottom of the Breakout board and tighten the thumb screws.
