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Summary of Contents for SuperFlow CycleDyn-AC
- Page 1 Operator Manual Pub. No.: 190618 Rev.: 0 June 2019 Original Instructions www.PowerTestDyno.com CHASSIS DYNAMOMETER...
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Page 2: Trademark Notices
Copyright 2019 by SuperFlow, a division of Power Test, Inc. All rights reserved. No part of this publication may be reproduced, transcribed, or translated by any means without the prior written permission of SuperFlow, N60 W22700 Silver Spring Drive, Sussex, WI 53089 USA. - Page 3 Any person instructed to carry out installation, maintenance, or repair of the equipment must read and understand this manual and in particular the technical safety instructions. SuperFlow Technologies Group is not responsible for any personal or property damage resulting from negligent actions by the user of this product.
- Page 4 • Operation Describes the basic operation principles and procedures. • Maintenance, Calibration & Troubleshooting Covers general, daily, and periodical maintenance; calibration; and basic troubleshooting procedures. • Parts Lists Replacement parts list. • Drawings Includes general drawings. Manual Conventions The following conventions indicate items of interest or concern: WARNING: Failure to take or avoid a specific action could result in physical harm to the user or the hardware.
- Page 5 Agreement made _________ __, ____ between SuperFlow Technologies Group and Date ________________________________________________________ (hereinafter called receiver) located Company Name Company Location (address) Receiver acknowledges and agrees that SuperFlow has supplied, installed and conducted training to its satisfaction on the SuperFlow equipment listed below: Contract Components Component Description Component Serial No.
- Page 7 SAFETY • Safety Warnings Dangers Due to Non-observance of Safety – Instructions • Room Requirements • General Safety Procedures • Noise Levels • Carbon Monoxide Warnings...
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Page 9: Safety Warnings
1.1 Safety Warnings WARNING: To ensure safe operation, this equipment must only be operated according to the instructions in the SuperFlow Dynamometer Operator’s Manual. It is also essential that this equipment is installed, maintained, and operated according to local safety requirements. -
Page 10: Noise Levels
• Keep all personnel, flammable items, and sensitive objects away from any rotating object that can throw debris radially outward 1.4 Noise Levels SuperFlow Technologies Group always recommends ear protection when operating the ________. Warning Signs of Hazardous Noise • You must raise your voice to be heard. -
Page 11: Carbon Monoxide Warnings
• Test air regularly in areas where CO may be present, including confined spaces. • Install CO monitors with audible alarms. 1. Information in this section was adapted from the “OSHA Fact Sheet,” U.S. Department of Labor, Occupational Safety and Health Administration, 2002, http://www.osha.gov/OshDoc/data_General_Facts/carbonmonoxide-factsheet.pdf February 2007. SuperFlow Technologies Group... - Page 12 Safety • Use a full-face piece, pressure-demand, Self-Contained Breathing Apparatus (SCBA) certified by the National Institute for Occupational Safety and Health (NIOSH) or a combination full-face piece, pressure demand supplied-air respirator with auxiliary self- contained air supply in areas with high CO concentrations (those immediately dangerous to life and health atmospheres).
- Page 13 AC MOTORING DYNAMOMETER • Introduction • Specifications • Packaging and Handling • Installation • Preliminary Checks and Calibration • Operation • Maintenance...
- Page 15 Horsepower is calculated by simultaneously measuring the torque along with the rotational speed of the dynamometer. The SuperFlow CycleDyn is a motorcycle chassis dynamometer designed to test motorcycles, go- karts, ATVs (quads), and similar vehicles within a safe, controlled environment. Testing on a dynamometer reduces road testing liability, improves measurement accuracy, and enhances productivity.
- Page 16 MUT for measuring friction, drive train losses and other factors. Figure 2-2. AC Motor Module The SuperFlow motoring dynamometer uses an AC electric motor with a specialized type of adjustable-speed drive. This setup classifies the system as a “universal” dynamometer where it can operate: •...
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Page 17: Specifications
– AC Drive Unit: 175 lbs / 39 x 17 x 24 inches [80 kg / 99 x 43 x 61 cm] – AC Load Bank: 250 lbs / 36 x 22 x 46 inches [115 kg / 92 x 56 x 117 cm] SuperFlow Technologies Group... -
Page 18: Packaging And Handling
2.3 Packaging and Handling The components of a CycleDyn dynamometer are shipped on wooden pallets or in crates. It is shrinkwrapped and covered by a fitted cardboard box secured by plastic or metal straps. CAUTION: The dynamometer modules may have UNEVEN weight distributions. 2.3.1 Lifting and Handling Instructions If possible, leave the dynamometer and auxiliary modules on the shipping pallets until ready for installation. -
Page 19: Installation
Inspect all crates and boxes for external damage. Be sure to check underneath the crate for possible forklift damage. Report any damage to the shipping company and SuperFlow Customer Service. Unpack the equipment and take inventory of all the provided parts. Contact SuperFlow Customer Service if there are any questions. - Page 20 1. Attach the AC Motor cube to the side of the main CycleDyn chassis ensuring the cube is level. 2. Insert the shaft keys and slide the couplers on the shafts. 3. Place the keys and couplers on the in-line torque/speed transducer 4.
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Page 21: Electrical Connections
If a manual was not included with the AC Motor assembly, check the manufacturers website for a download version or contact SuperFlow Customer Service with the make and model number of the motor drive. - Page 22 4. Motor Drive Power Cable Connections: • Make sure the motor drive is disconnected from the main power source during installation. • Remove the cover on the motor controller frame to access the entry holes for the cables. Open the holes if necessary. •...
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Page 23: Cooling Fan Motor
• Set to run for a minimum of 30 seconds after the remote signal is turned off. 3. Connect a cable to the remote control input on the cooling fan motor drive. The other end of the cable is covered in the next section. SuperFlow Technologies Group 2-11... -
Page 24: Control Cable Connections
2.4.4 Control Cable Connections There are two control cables that connect between the motor controller and the data acquisition sensor box system interconnect panel. A third control cable goes to the cooling fan motor drive. 1200A-0270 1200A-0271 Fan Motor Switching Cable Switching Cable Control Cable Figure 2-6. - Page 25 X23-1 +24Vdc X23-2 Black Ground X26-2 Relay 2 Input X26-3 Relay 2 Output Figure 2-9. Motor Drive Fan Motor Switching Connection The jumper between terminals X23-1 and X26-2 is to connect +24Vdc to the relay control. SuperFlow Technologies Group 2-13...
- Page 26 2.4.5 Sensor Box Connections Connect the 1200A-0270, 1200A-0271, and main dynamometer cables to the data acquisition sensor box as shown below. All other connections on the sensor box should be made according to the primary system operator’s manual. 1200A-0271 connects here 1200A-0270 connects here dynamometer cable connects here...
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Page 27: Motor Rotation Direction
Preliminary Checks and Calibration 2.5 Preliminary Checks and Calibration The AC motor and controller were setup by SuperFlow prior to shipping with all the required parameters programmed in the controller. If the controller or motor has been replaced or repaired, the programming may have to be performed again. -
Page 28: Remote Control Test
“mated”. This is done through a process using the local mode on the controller panel. The Motor ID is done by SuperFlow prior to shipping but it can be done on site as a test or motor operation check. - Page 29 10 minutes. Once the OK button is pressed the process will begin automatically. Pressing the EXIT button will abort the process. 2.5.5.3 Coastdown Test Detailed information for this section is pending. SuperFlow Technologies Group 2-17...
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Page 30: Operation
2.6 Operation Detailed information for this section is pending NOTE: The EC cube and AC Motoring cube may not be controlled concurrently. While the EC cube can remain attached to the AC Motor cube, the data acquisition and control system cannot control both at the same time.
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