©2005-2011 Dynojet Research, Inc. All Rights Reserved. Pre-Installation Guide for Model 200i/250i, 200iP/250iP, 250iX, and 250iPX Motorcycle Dynamometers This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual, and the software described in it, is furnished under license and may only be used or copied in accordance with the terms of such license.
TABLE OF CONTENTS Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Dyno Pre-Installation Information Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Your Dyno Room . . . . . .
TA B L E O F C O N T E N T S Model 250iPX Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Pit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Room Layout—Model 250iPX Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unpacking The Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNINGS Disclaimers Dynojet Research, Inc. (Dynojet) makes no representation or warranties with respect to the contents hereof and specifically disclaims any implied warranties of merchantability for any particular purpose. Dynojet reserves the right to revise this publication and to make changes from time to time in the content hereof without obligation of Dynojet to notify any person of such revision or changes.
WA R N I N G S Electrostatic Discharge Precautions Electrostatic Discharge Electrostatic Discharge (ESD), or static shock, can damage electronic components within the dynamometer. The damage may occur at the time of an ESD occurrence, or the shock may degrade the component, resulting in a premature component failure later. To avoid ESD damage, always practice good ESD control precautions when servicing the dynamometer.
WA R N I N G S Other Potential Hazards The AC power outlet shall be installed near the equipment and it shall be easily accessible to allow for disconnect before service. The dynamometer should be located in a well ventilated area. There is a carbon monoxide hazard with all internal combustion engines. Engine exhaust contains poisonous carbon monoxide gas. Breathing it could cause death. Any dyno room design must incorporate sufficient exhaust extraction.
DYNO PRE-INSTALLATION INFORMATION Thank you for your interest in Dynojet’s Motorcycle Dynamometers. Dynojet’s software and dynamometers will give you the power to get the maximum performance out of vehicles you evaluate. Whether you are new to the benefits of a chassis dynamometer or an experienced performance leader, the repeatability and diagnostic tools of WinPEP 7 software and a Dynojet dynamometer (dyno) will give you the professional results you are looking for.
DYNO PRE-INSTALLATION INFORMATION Introduction INTRODUCTION ................................... Thank you for your interest Dynojet’s Motorcycle Dynamometers. Before receiving your dyno, please take a moment to read this guide for dyno specifications and requirements, WinPEP 7 requirements, and dyno room set-up. CONVENTIONS USED IN THIS MANUAL The conventions used in this manual are designed to protect both the user and the equipment.
DYNO PRE-INSTALLATION INFORMATION Your Dyno Room YOUR DYNO ROOM ................................... This section is not meant to imply that a dyno room is essential to repeatable results on a Dynojet dynamometer. However, a dyno room with an engine cooling intake fan, exhaust extraction, and noise reduction capabilities can add a new dimension to your shop. SETTING UP A DYNO ROOM A proper dyno room design will help to ensure repeatable, accurate runs.
DYNO PRE-INSTALLATION INFORMATION Specifications and Requirements SPECIFICATIONS AND REQUIREMENTS ................................... The following specifications and requirements apply to all motorcycle dynos in this manual. Take a moment to review the requirements and make sure you can provide what your dyno will need. BATTERY REQUIREMENTS A motorcycle starting system is included with your dyno. You will need to purchase an automotive battery locally to use this feature.
DYNO PRE-INSTALLATION INFORMATION Specifications and Requirements DRILL AND DRILL BIT REQUIREMENTS You will need to provide a drill and drill bit capable of drilling holes in concrete. Refer to Appendix A for more information on installing Red Head Anchors. • drill bit size: 1/2-inch • minimum hole depth: 1 5/8-inch (41.2 mm) ELECTRICAL REQUIREMENTS The dynamometer requires a dedicated electrical circuit for reliable and precise operation.
DYNO PRE-INSTALLATION INFORMATION Specifications and Requirements ENVIRONMENTAL REQUIREMENTS description Temperature operating min./max storage min./max Humidity specifications 10°C/50°C (50°F/122°F) 0°C/60°C (32°F/140°F) 0 to 95% non-condensing FIRE SUPPRESSION Always have adequate fire suppression or fire extinguishers in your dyno room. FORKLIFT REQUIREMENTS You will need to provide equipment capable of lifting a minimum of 1,077 kg (2,375 lb.
DYNO PRE-INSTALLATION INFORMATION Model 200i/250i Dynamometer MODEL 200I/250I DYNAMOMETER ................................... The following specifications and requirements will help you set up your dyno area and verify you have the requirements necessary to operate your dyno safely.
DYNO PRE-INSTALLATION INFORMATION Model 200i/250i Dynamometer Figure 1: Model 200i Dyno Dimensions 8 Pre-Installation Guide for Model 200i/250i, 200iP/250iP, 250iX, and 250iPX Motorcycle Dynamometers
DYNO PRE-INSTALLATION INFORMATION Model 200i/250i Dynamometer Figure 2: Model 250i Dyno Dimensions Version 3 Pre-Installation Guide for Model 200i/250i, 200iP/250iP, 250iX, and 250iPX Motorcycle Dynamometers 9
DYNO PRE-INSTALLATION INFORMATION Model 200i/250i Dynamometer ROOM LAYOUT—MODEL 200I/250I DYNO Use the following information to locate various dyno equipment, power outlets, compressed air, and properly set up your dyno room. provide compressed air for the: •optional air brake •optional AFR‐4 pump provide an outlet for dyno power 109.22 cm (43.00 in.)* MC135 minimum dimensions for standard carriage 76.20 cm (30.00 in.) extended carriage 127.00 cm (50.00 in.) 436.88 cm (172.00 in.)* 245.11 cm (96.
DYNO PRE-INSTALLATION INFORMATION Model 200i/250i Dynamometer intake fan - 5200 CFM with speed control exhaust extraction fan - 5200CFM exhausts to outdoors exhaust extraction expansion box exhaust extraction muffler Figure 4: Room Layout—Model 200i/250i Side View Version 3 Pre-Installation Guide for Model 200i/250i, 200iP/250iP, 250iX, and 250iPX Motorcycle Dynamometers 11
DYNO PRE-INSTALLATION INFORMATION Model 200i/250i Dynamometer GROUND HOOK PLACEMENT—MODEL 200I/250I DYNO You may wish to install additional ground hooks (included with your dyno) for securing the motorcycle. Using Figure 5 as a guide, place the ground hooks in a location that works best for your dyno application. 1 2 3 Using the ground hook as a template, mark and drill each hole needed to secure the ground hooks to the floor. Install the Red Head anchors.
DYNO PRE-INSTALLATION INFORMATION Model 200iP/250iP Dynamometer MODEL 200IP/250IP DYNAMOMETER ................................... The following specifications and requirements will help you set up your dyno area and verify you have met the requirements necessary to operate your dyno safely. PIT SPECIFICATIONS Before proceeding, take a moment to look over the pit dimensions and requirements for your in ground dyno.
DYNO PRE-INSTALLATION INFORMATION Model 200iP/250iP Dynamometer Figure 6: Model 200iP/250iP Dyno Dimensions Figure 7: Control Panel Interface Assembly Dimensions 14 Pre-Installation Guide for Model 200i/250i, 200iP/250iP, 250iX, and 250iPX Motorcycle Dynamometers
DYNO PRE-INSTALLATION INFORMATION Model 200iP/250iP Dynamometer ROOM LAYOUT—MODEL 200IP/250IP DYNO Use the following information to locate the necessary dyno equipment, power outlets, compressed air, and properly set up your dyno room. For more detailed information about the pit requirements, refer to the pit specifications (P/N 98229102) you received from your salesman. Note: The pit must be provided with exhaust ventilation at a rate of not less than 1CFM per ft.
DYNO PRE-INSTALLATION INFORMATION Model 200iP/250iP Dynamometer intake fan - 5200 CFM with speed control exhaust extraction fan - 5200CFM exhausts to outdoors exhaust extraction expansion box 30.48 cm (12.00 in.) to 60.96 cm (24.00 in.) exhaust extraction muffler PD187 Figure 9: Room Layout—Model 200iP/250iP Side View 16 Pre-Installation Guide for Model 200i/250i, 200iP/250iP, 250iX, and 250iPX Motorcycle Dynamometers 10.16 cm (4.00 in.) to 102.87 cm (40.50 in.
DYNO PRE-INSTALLATION INFORMATION Model 250iX Dynamometer MODEL 250IX DYNAMOMETER ................................... The following specifications and requirements will help you set up your dyno area and verify you have the requirements necessary to operate your dyno safely.
DYNO PRE-INSTALLATION INFORMATION Model 250iX Dynamometer 274.32 cm (108.00 in) KU033 370.84 cm (146.00 in) 261.62 cm (103.00 in) 200.66 cm (79.00 in) 203.20 cm (80.00 in) 45.72 cm (18.
DYNO PRE-INSTALLATION INFORMATION Model 250iX Dynamometer ROOM LAYOUT—MODEL 250IX DYNO Use the following information to locate various dyno equipment, power outlets, compressed air, and properly set up your dyno room. provide compressed air for the: •optional air brake •optional AFR‐4 pump provide an outlet for dyno power KU070 center intake fan with carriage minimum dimensions for standard carriage 76.20 cm (30.00 in.) extended carriage 127.00 cm (50.00 in.) 360.68 cm (142.00 in.)* 245.11 cm (96.
DYNO PRE-INSTALLATION INFORMATION Model 250iX Dynamometer intake fan - 5200 CFM with speed control exhaust extraction fan - 5200CFM exhausts to outdoors exhaust extraction expansion box exhaust extraction muffler Figure 12: Room Layout—Model 250iX Side View 20 Pre-Installation Guide for Model 200i/250i, 200iP/250iP, 250iX, and 250iPX Motorcycle Dynamometers
DYNO PRE-INSTALLATION INFORMATION Model 250iPX Dynamometer MODEL 250IPX DYNAMOMETER ................................... The following specifications and requirements will help you set up your dyno area and verify you have met the requirements necessary to operate your dyno safely. PIT SPECIFICATIONS Before proceeding, take a moment to look over the pit dimensions and requirements for your in ground dyno.
DYNO PRE-INSTALLATION INFORMATION Model 250iPX Dynamometer standard carriage 304.80 cm (120.00 in.) extended carriage 355.60 cm (140.00 in.) 137.16 cm (54.00 in.) 45.72 - 46.67 cm (18.00 - 18.38 in.) PD104 239.00 cm (91.10 in.) pit covers 310.29 cm (122.16 in.) including eddy current brake cover 271.42 cm (106.86 in.) 76.20 cm (30.00 in.
DYNO PRE-INSTALLATION INFORMATION Model 250iPX Dynamometer ROOM LAYOUT—MODEL 250IPX DYNO Use the following information to locate the necessary dyno equipment, power outlets, compressed air, and properly set up your dyno room. For more detailed information about the pit requirements, refer to the pit specifications (P/N 98229104) you received from your salesman. Note: The pit must be provided with exhaust ventilation at a rate of not less than 1CFM per ft.
DYNO PRE-INSTALLATION INFORMATION Model 250iPX Dynamometer intake fan - 5200 CFM with speed control exhaust extraction fan - 5200CFM exhausts to outdoors exhaust extraction expansion box 30.48 cm (12.00 in.) to 60.96 cm (24.00 in.) exhaust extraction muffler PD188 Figure 16: Room Layout—Model 250iPX Side View 24 Pre-Installation Guide for Model 200i/250i, 200iP/250iP, 250iX, and 250iPX Motorcycle Dynamometers 10.16 cm (4.00 in.) to 102.87 cm (40.50 in.
DYNO PRE-INSTALLATION INFORMATION Unpacking The Dyno UNPACKING THE DYNO ................................... When you receive your dyno, examine the exterior of the shipping container for any visible damage. If damage is detected at this stage, contact the shipper or Dynojet before proceeding with unpacking. You will need to provide equipment capable of lifting and moving the dyno. Refer to “Forklift Requirements” on page 6 for more information.
APPENDIX A RED HEAD ANCHOR INSTALLATION This appendix contains instructions for installing the Red Head Multi-Set™II 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 Always wear safety glasses and other necessary protective devices or apparel when installing or working with anchors.
APPENDIX A Installation INSTALLATION ................................... Use the table below to determine the catalog number, drill bit size, minimum hole depth, and setting tool catalog number. catalog number Carbon Steel RM-38/RL-38 (9.5 mm) drill bit size 1/2-inch minimum hole depth 1 5/8-inch (41.2 mm) setting tool catalog number RT-138 Use the following instructions to install the Red Head anchors.
RED HEAD ANCHOR INSTALLATION Installation 3 Using a hammer, drive the anchor flush with the surface of the concrete, or below the surface if the hole depth exceeds minimum embedment. Figure A-3: Red Head Anchor—Drive the Anchor Flush 4 Using a hammer, 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.
APPENDIX B POWER REQUIREMENTS AND INSTALLATION Different countries have different standards for delivery of AC (alternating current) electricity to homes and buildings. The frequency (number of cycles per second) in Hertz (Hz) varies from country to country. North America typically uses 60 Hz power. Western Japan including the Osaka, Kyoto, Nagoya, Hiroshima regions also uses 60 Hz power. Eastern Japan including the Tokyo, Kawasaki, Sapporo, Yokohama, and Sendai regions uses 50 Hz power.
APPENDIX B Locations Using 60 Hz Power (North America and Japan) LOCATIONS USING 60 HZ POWER (NORTH AMERICA AND JAPAN) ................................... The following power requirements and instructions are for North America, much of Japan, and other locations using 60 Hz power. All other locations should refer to the instructions found in “Locations Using 50 Hz Power (Locations other than North America and Japan)” on page B-7.
POWER REQUIREMENTS AND INSTALLATION Locations Using 60 Hz Power (North America and Japan) 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 a ground. The neutral connection is required to split the 240 volt into two 120 volt connections internal to the dyno.
APPENDIX B Locations Using 60 Hz Power (North America and Japan) TESTING FOR CORRECT VOLTAGES You must test the receptacle for proper voltages before the dyno is connected to the outlet. 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.
POWER REQUIREMENTS AND INSTALLATION Locations Using 60 Hz Power (North America and Japan) REPLACING 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.
APPENDIX B Locations Using 60 Hz Power (North America and Japan) CONNECTING THE DYNO 1 2 3 4 5 6 7 Turn off the main circuit breaker on the dyno. The main breaker is located in the CPI door. 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 connecting the blowers, refer to your dyno installation guide. Turn on the main dyno breaker. Test the blowers for operation.
POWER REQUIREMENTS AND INSTALLATION Locations Using 50 Hz Power (Locations other than North America and Japan) LOCATIONS USING 50 HZ POWER (LOCATIONS OTHER THAN NORTH AMERICA AND JAPAN) ................................... The next section of this appendix contains the power requirements and instructions for dyno installations excluding North America and 60 Hz areas of Japan. Note: Refer to page B-2 for power requirements and instructions for North America and Japan.
APPENDIX B Locations Using 50 Hz Power (Locations other than 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 mm2 (ten gauge) or larger. Check with local building codes for the correct size. 1 2 3 Connect one of the 240V legs to the N terminal (white). Connect the other 240V leg to the L terminal (no color). Connect the ground conductor to the green terminal.
POWER REQUIREMENTS AND INSTALLATION Locations Using 50 Hz Power (Locations other than 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.
APPENDIX B Locations Using 50 Hz Power (Locations other than 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.
POWER REQUIREMENTS AND INSTALLATION Locations Using 50 Hz Power (Locations other than North America and Japan) CONNECTING THE DYNO 1 2 3 4 5 6 7 Version 3 Turn off the main circuit breaker on the dyno. The main breaker is located in the CPI door. 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 connecting the blowers, refer to your dyno installation guide.
INDEX 200i dyno 1-7 chassis specifications 1-7 dimensions 1-8 ground hook placement 1-12 room layout 1-10 200iP dyno 1-13 chassis specifications 1-13 dimensions 1-14 pit specifications 1-13 room layout 1-15 250i dyno 1-7 chassis specifications 1-7 dimensions 1-9 ground hook placement 1-12 room layout 1-10 250iP dyno 1-13 chassis specifications 1-13 dimensions 1-14 pit specifications 1-13 room layout 1-15 250iPX dyno 1-21 chassis specifications 1-21 dimensions 1-22 pit specifications 1-21 room layout 1-23 2
INDEX replacing power plug 60 Hz B-5 requirements 50 Hz B-7 requirements 60 Hz B-2 testing voltages 50 Hz B-9 testing voltages 60 Hz B-4 verifying operation, 50 Hz B-11 verifying operation, 60 Hz B-6 dyno room cooling fan 1-3 exhaust extraction 1-3 fire suppression 1-3 Industrial Noise Control 1-3 E electrical requirements 1-5 electrostatic discharge iv environmental requirements 1-6 ESD precautions iv F fire suppression 1-6 forklift requirements 1-6 G ground hook placement 200i dyno 1-12 250i dyno
