Power Test SuperFlow AutoDyn AD-30 Installation Manual
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Power Test SuperFlow AutoDyn AD-30 Installation Manual

Awd chassis dynamometer pit installation
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SUPERFLOW AUTODYN AD-30
AWD CHASSIS DYNAMOMETER
PIT INSTALLATION

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Summary of Contents for Power Test SuperFlow AutoDyn AD-30

  • Page 1 SUPERFLOW AUTODYN AD-30 AWD CHASSIS DYNAMOMETER PIT INSTALLATION...
  • Page 2 PI0030CS02 REV: 3.30.2020...

  • Page 3: Table Of Contents

    Contents AutoDyn AD-30 AWD Chassis Dynamometer Safety Warnings ......................2 Dangers Due to Non-observance of Safety Instructions ...............2 Document Conventions ........................2 Test Cell Room Requirements ...................3 Hazards of Dynamometer Testing ....................3 Test Cell Design ..........................4 Pit Design .............................6 Pit Drainage ............................7 Ventilation ............................7 Combustion Air .............................8 Heat Extraction ..............................9...
  • Page 4 Drawings Drawings and Schematics AD-30 AWD Dimensions 41 AD30 AWD Pit Location 42 AD-30 AWD Pit Layout (page 1 of 4) 43 AD-30 AWD Pit Layout (page 2 of 4) 44 AD-30 AWD Pit Layout (page 3 of 4) 45 AD-30 AWD Pit Layout (page 4 of 4) 46 Vehicle Tie-down Points 47 AWD Cover Plate Locations 48...

  • Page 5: Autodyn Ad-30 Awd Chassis Dynamometer

    Product Information AutoDyn AD-30 AWD Chassis Dynamometer SuperFlow AutoDyn dynamometers can be installed in a pit so vehicles can drive on and off the rolls for testing. Pit installations have certain advantages over above-ground dynamometers— particularly that it is safer and easier to position the test vehicles on the rolls. All Wheel Drive (AWD) dynamometer are designed to be installed in a pit because of the required additional supports for the covers in front of and between the dynamometer rolls.

  • Page 6: Safety Warnings

    SuperFlow Product Information Safety Warnings To ensure safe operation, this equipment must only be operated according to the instructions in the SuperFlow Operator Manual. It is also essential that this equipment is installed, maintained, and operated according to local safety requirements. Any person instructed to carry out installation, maintenance or repair of the equipment must read and understand the SuperFlow Operator Manual and in particular the technical safety instructions.

  • Page 7: Test Cell Room Requirements

    SuperFlow Product Information Test Cell Room Requirements Notice It is imperative that you understand dynamometer testing can be hazardous. A properly designed and built test cell is a prerequisite to providing a safe environment for testing vehicles. While SuperFlow provides specific test equipment designed to test your vehicles, we have no control over how you build your test cell.

  • Page 8: Test Cell Design

    SuperFlow Product Information Test Cell Design Figure 1. AutoDyn Test Cell A dynamometer should be installed in a facility with proper lighting, electric power, compressed air, good ventilation, exhaust extraction, and a fire detection system. There must be enough room to easily install and remove the test vehicle.
  • Page 9 SuperFlow Product Information Proper airflow through the test cell is critical for engine cooling and room ventilation. Having a larger test cell than necessary makes it difficult to control airflow through the cell and increases the cost because of the need for larger air-handling equipment. A large room also increases heating and cooling costs.

  • Page 10: Pit Design

    SuperFlow Product Information Pit Design See Figures 3 through 6, “AD-30 AWD Pit Layout” on pages 43 through 46. The pit for a SuperFlow AD30-AWD chassis dynamometer is constructed on site of poured concrete with 6” minimum (20 cm) thick walls and steel rebar reenforcement. The concrete should have a minimum strength of 4000 psi [280 kg/cm Figure 3.

  • Page 11: Pit Drainage

    SuperFlow Product Information Suggested placement of floor anchors are shown in Figure 5, “AD-30 AWD Pit Layout (page 3 of 4),” on page 45 and Figure 7, “Vehicle Tie-down Points,” on page 47. Pit Drainage Water and other fluids can get into the pit from local ground water conditions or spillage from other sources.

  • Page 12: Combustion Air

    SuperFlow Product Information Place the master control for the ventilation fans inside the room within easy access for the dynamometer operator and an emergency cutoff switch outside the room. See Figure 13, “AutoDyn Room and Pit Airflow (U.S. Units),” on page 53 or Figure 12, “Energy Balance (Metric Units),”...

  • Page 13: Heat Extraction

    SuperFlow Product Information Heat Extraction Chassis dynamometer testing produces a significant amount of heat that is for the most part released to the test room air. Ventilation is required to evacuate this heat from the room. If the room temperature increases during the test or exhaust gas recirculates into the engine inlet, your test results will vary in an unpredictable manner.

  • Page 14: Vehicle Cooling

    SuperFlow Product Information It is advisable to locate the fans at the rear of the test cell to extract air out of the room and therefore create a slight negative pressure in the room to help prevent fumes and heat from the test cell from entering other areas of your building or collecting in the corners.

  • Page 15: Exhaust Extraction

    SuperFlow Product Information grade. Incorporating a pressure blower in this system helps you more easily control exhaust and undercarriage temperatures. Exhaust Extraction WARNING: A proper exhaust extraction system is critical for the safety of your employees and customers both inside and outside the test room. If the room ventilation is good, a separate engine exhaust collection may not be necessary.

  • Page 16: Absorber Cooling And Pit Ventilation

    SuperFlow Product Information Alternately, connect directly to the exhaust pipes and integrate an air inlet near the pipe entrance to provide dilution air from inside or outside the test cell. Dilution air can even be introduced from outside the building. The piping prior to the dilution point must be rated for high temperatures.

  • Page 17: Vehicle Restraint Requirements

    SuperFlow Product Information • Place the master control for the ventilation fans inside the room within easy access for the dynamometer operator and an emergency cutoff switch outside the room. Figure 8. AD30-AWD Pit Ventilation An option is to replace the pit covers on one side of the absorbers and closest to the pit edge with metal grates so air is drawn from the test room into the pit and out the exit ducts.

  • Page 18: Electrical Requirements

    SuperFlow Product Information Figure 9. Vehicle Restraint – AWD The straps are attached to the floor with flush-mounted floor anchors. Floor anchors can be integrated in the room floor when the concrete is poured or special anchor pods are inserted into holes bored into the concrete floor and wedged in place.

  • Page 19: Dynamometer Chassis

    SuperFlow Product Information Dynamometer Chassis The AutoDyn power absorber requires 25 amps of 208 to 240 VAC power wired from a power distribution box through a 1” (25 mm) diameter conduit in the pit or a trench cut in the side wall to the rollset power junction box on the AutoDyn.

  • Page 20: Static Electricity

    SuperFlow Product Information • In situations where high concentrations of water may be in the air supply, install an automatic water drain in the pit at the lowest level of the air supply line. Suggested air supply equipment is shown in “Equipment Recommendations” on page 17. Static Electricity An ungrounded vehicle on a chassis dynamometer will create a very high static charge as the tires turn.

  • Page 21: Equipment Recommendations

    SuperFlow Product Information • Additional test system computer monitor in the customer viewing area, if separate from the control room (for example, the lobby of your facility). It may be a good idea to provide a cable for this purpose when building your facility. TIP: A remote computer with WinDyn installed and setup as a slave can display real-time data from the dynamometer system.
  • Page 22 SuperFlow Product Information IMPORTANT: These fan motors are not listed as explosion-proof and therefore should not be located inside the test cell or where fuel or fuel vapors are present. For better protection, request explosion-proof fan motors. Dayton Tube Axial Fan and Belt Drive with Drive Package Table 1.

  • Page 23: Air Handling

    SuperFlow Product Information Air Handling Grainger Manufacturer Description Specifications Item & Model # 6D756 Wilkerson • 1/4” Filter/regulator • NPT: 1/4” 1/4” Filter/ B18-02-FL00 • Compact 18-series air • Maximum Pressure: 250 psi Regulator line • Bowl Size: 4.09 oz. •...

  • Page 24: Water Pumps And Accessories

    SuperFlow Product Information Water Pumps and Accessories Grainger Manufacturer Description Specifications Item & Model # 2P547 Zoeller • Sump pump • Type: Sump pump, cast-iron top, 3/10-hp Pump, automatic operation, single phase, • Cast-iron top Sump 9-ft. cord • Automatic operation •...
  • Page 25 SuperFlow Product Information Part Numbers Description Specifications Grainger Web sling, eye & eye 3 ft. x 2 in 2RU88 3,200 lbs Grainger Axle strap w/ wear pad 36 in 3LLT9 Grainger Heavy-duty tuff edge web 4 ft x 2”, 4ZV46 sling, Endless loop 6,400 lbs Ancra...

  • Page 26: Installation Instructions

    SuperFlow Product Information Installation Instructions WARNING: The AD-30 AutoDyn parts are very heavy. They should only be moved and lifted with forklifts or cranes. A rollset weighs approximately 4500 lbs. (2050kg). The cover frames and plates weigh more than 100 lbs. (45kg). CAUTION: Do not use electric welding equipment in the vicinity of the dynamometer while the AC power to the dynamometer or to the sensor box is turned on.

  • Page 27: Rollset Preparation

    SuperFlow Product Information The most critical installation dimension is the pit depth. If the pit is too shallow, the AutoDyn frame will extend above the pit edge. The only way to correct this is to raise the floor around the pit.
  • Page 28 SuperFlow Product Information 4. Set the rear rollset on a flat floor and adjust the leveling feet on the corners until the top edge of the rollset frame is at a height equal to 0.06” or 1/16” [1.55 mm] less than the measured pit depth (Figure 13).
  • Page 29 SuperFlow Product Information 8. Install the four front rollset wheels if not already done (Figure 15). • Remove the V-grooved wheels from the mounting brackets. • Attach the brackets to the rollset using two ½-13 x 1½ Hex-Head bolts, flat washers, and lock washers on each bracket.

  • Page 30: Placing The Autodyn In The Pit

    SuperFlow Product Information 10. Install one 1/2” adjustable foot in each end of the rollset housing, first removing the lock nut, then screwing them all the way in. These side feet will be adjusted to clear the pit wall by about 0.2”...
  • Page 31 SuperFlow Product Information NOTE: The rollsets have 2-inch holes in the front and back sides that can be used for lifting. Be careful not to damage the hydraulic hoses or electrical cables when using these holes. The balance point for the rollset is slightly off center toward the longer roll. 3.
  • Page 32 SuperFlow Product Information See Figure 3, “AD-30 AWD Pit Layout (page 1 of 4),” on page 43 for details on the location and positioning of the V-rails. 7. Loosely attach the connecting rails to the V-rails and to the rear rollset. 8.
  • Page 33 SuperFlow Product Information Ensure the supports are level. If the supports do not fit level snug between the lower crossmember and the pit wall, the rear rollset can be moved forward to take up the space. If the supports are too long, the pit wall will have to be chiseled out to accommodate the support flange.
  • Page 34 SuperFlow Product Information Figure 23. Cross-member Supports 22. Check the side and rear supports on the rear rollset to make sure they are snug against the pit wall. Check all locking nuts on the side supports and leveling feet. Confirm the dimensions between the rollset and pit walls according to Figure 2, “AD30 AWD Pit Location,”...

  • Page 35: Eddy Current Absorber Module And Driveshaft

    SuperFlow Product Information 26. Connect the hydraulic arms from the rear rollset to the front rollset using the bolts that were attached to the arms. From this point on, the front rollset can only be moved by the dynamometer control system. IMPORTANT: Do not install any covers on the rollsets until the eddy current and driveshaft are installed and plumbing and wiring is done.
  • Page 36 SuperFlow Product Information Figure 26. Typical AutoDyn Driveshaft with the U-joints Properly Phased ® Dana-Spicer is a good resource for a more in-depth presentation on drivelines and the need for proper phasing, balancing, and mechanical configurations. 5. Position the short U-joint driveshaft on the rear rollset differential and the EC absorber flange studs.

  • Page 37: Plumbing And Wiring

    SuperFlow Product Information Figure 28. AD-30 AWD AutoDyn Side View 11. Secure the driveshaft bearing to the support plate using 1/2” bolts, flat washers, and lock washers. Do not secure the baseplate to the floor until all alignments are complete. Plumbing and Wiring 1.
  • Page 38 SuperFlow Product Information 3. Connect the coiled air hose from the rear rollset air out to the front rollset air in . Load Cell Figure 30. Front rollset cable and air hose 4. Connect the 1200A-2805-AWD cable between the connector labeled Dyno 2 J2 on the rear rollset interconnect panel and the 1200A-2342-AWD30 load cell cable on the front rollset.
  • Page 39 SuperFlow Product Information Figure 32. Electrical Controls 7. Referring to Figure 10, “AWD AD-30 Junction Box Assembly,” on page 50, connect the 240VAC or 208VAC 50–60Hz, 50-amp single-phase power line to the junction box on the front side of the rear rollset EC module (shown in Figure 32). 8.

  • Page 40: Rollset Covers

    SuperFlow Product Information 16. Use the handheld controller to test the hydraulic system for moving the front rollset. • Press the “C” button (PUMP) to turn on the hydraulic pump • Verify that hydraulic fluid is not leaking anywhere in the system •...
  • Page 41 SuperFlow Product Information All of the pit covers will have a lip along the short sides with threaded holes that are use to secure the pit covers to the rollset covers. Refer to Figure 8, “AWD Cover Plate Locations,” on page 48 for a detailed drawing showing the cover plate locations.
  • Page 42 SuperFlow Product Information Figure 34. Center Covers 4. Place two stationary covers on the short roll end with the lips toward the center of the rollset. Bolt them to the rear rollset cover. 5. Locate one of the two access covers. Place it in the gap with the edges resting on the lips of the adjoining covers (refer to Figure 34).
  • Page 43 SuperFlow Product Information Figure 35. Front Covers 12. Set two more of the bridge covers in place and check the alignment of the pit edge anchor plate. Make sure the front rollset can move all the way forward and back without binding. 13.
  • Page 44 SuperFlow Product Information Drawings and Schematics AD-30 AWD Pit Installation Page 40 3.30.2020...
  • Page 45 Parts List ITEM PART NUMBER DESCRIPTION Roll Set, 30AWD Roll Set, 30AWD Absorber Assembly 2, AWD Absorber, Add-on Assembly Roll Set, 30AWD- F Roll Set, 30AWD- F 2300Z-0366 Rail Track 2 Wheel, 8x2.5 V groove Wheel, 8x2.5 V groove 2300Z-0364 Support, Wheel Assembly 2 Cover Assembly, AWD Center Cover Assembly, AWD Center...
  • Page 46 $/,*1  ',$ +2/(6 72  &(17(5 /,1( 2) 3,7 3/$&(6  )/86+...
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  • Page 51                                                 ...
  • Page 52 Parts List ITEM PART NUMBER DESCRIPTION 2300Z-0360 Cover, Lower Extension 2300Z-0365 Cover, Center Lower Extension 2300Z-0361 Cover, Bridge Gap 2300Z-0356 Support, Front Edge AWD **Access cover. **Access cover.
  • Page 53 REVISION HISTORY DESCRIPTION DATE NAME 832 AWD CHASSIS DYNO 3/25/08 INITIAL DESIGN 1200A-0383-AWD LOAD CELL 2 FRONT ROLL SET AIR IN 1200A-2805-AWD30 1200A-2342-AWD30 LOAD CELL AC POWER EDDY CURRENT ABSORBER WHEEL BASE PUMP 1200A-2376-02 Junction Box LOAD CELL 1 AIR OUT AIR IN 1200A-2373 Temp Sensor...
  • Page 55 5(9,6,21 +,6725< '(6&5,37,21 '$7( 1$0( 237,21$/ 6(&21' $%625%(5 ,1,7,$/ '(6,*1 (&2  $''(' 7(03 6:,7&+ :,5,1*   :$51,1*  $ (''< &855(17 %2;(6 6725( (/(&75,&$/ $ (1(5*< 83 72  92/76 $ $ $ 9(5,)< 7+( &$3  /,1(6 $5( = (52 9'& %()25( &$7 -803(5 &$%/( &$7 -803(5 &$%/( :25.,1* 21 7+( 6) %2$5'...
  • Page 56 Energy balance on an E/C absorber chassis dynamometer (Metric units) There are generally two sources of energy flowing into the test room: 1. Fuel. blue User provided 2. Electricity to power the system, fans, etc. 428 Energy released to test cell air All energy is converted to heat.
  • Page 57 Energy balance on an AWD AD-30 chassis dynamometer (US units) There are generally two sources of energy flowing into the test room: 1. Fuel. blue User provided 2. Electricity to power the system, fans, etc. 574 Energy released to test cell air All energy is converted to heat.

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