MAHA Powerdyno MSR 400 User manual

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MSR 400
Single Roller Dynamometer for Motorcycles
Original Operating Instructions
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Contents
1Safety ....................................................................................................................7
1.1 Introduction..............................................................................................................7
1.2 Symbols...................................................................................................................7
1.3 Intended Use ...........................................................................................................7
1.4 Safety Instructions for Commissioning......................................................................7
1.5 Safety Instructions for Operation...............................................................................8
1.6 Safety Instructions for Servicing................................................................................9
1.7 Danger Zone............................................................................................................9
1.8 Safety Information about Tires ..................................................................................9
1.9 Safety Information about the Eddy Current Brake .....................................................9
1.10 Safety Information about the Vehicle Fixing System ................................................10
1.11 Safety Features ......................................................................................................10
1.12 Accessories ...........................................................................................................10
1.13 What to Do in the Event of an Accident ..................................................................11
2Description ..........................................................................................................12
2.1 General Information................................................................................................12
2.2 Specifications.........................................................................................................13
2.3 Main Switch ...........................................................................................................16
2.4 Controls and Indicators ..........................................................................................16
2.5 Emergency Stop ....................................................................................................17
2.6 Remote Control......................................................................................................18
2.7 Description of the Interface Box..............................................................................20
2.7.1 RPM Module (Standard) .........................................................................................22
2.7.2 Environmental Module (Standard)...........................................................................24
2.7.3 Pressure/Temperature Module (Optional)................................................................25
2.7.4 Analog Input Module (Optional)...............................................................................26
2.8 Analog Output Card (Optional)................................................................................26
2.9 Lambda Broadband Sensor ...................................................................................27
2.10 Measurement Programs.........................................................................................32
3Installation............................................................................................................33
3.1 Requirements for the Place of Installation ...............................................................33
3.2 Safety Measures ....................................................................................................33
3.2.1 Heat Balance .........................................................................................................33
3.2.2 Exhaust Suction System.........................................................................................35
3.2.3 Fresh Air Supply for the Test Room ........................................................................36
4Transport and Storage .........................................................................................36

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5Installation and Initial Operation.............................................................................36
6Software Installation .............................................................................................37
6.1 System Requirements ............................................................................................37
6.2 Starting the Setup ..................................................................................................37
6.3 Selecting the Setup Language................................................................................38
6.4 Selecting the Destination Folder .............................................................................39
6.5 Selecting the SQL Server .......................................................................................39
6.6 Selecting Features..................................................................................................40
6.7 Installing Drivers .....................................................................................................40
6.8 Finishing the Setup.................................................................................................41
6.9 Additional Settings under Windows 7 or higher.......................................................42
7Software Operation .............................................................................................. 44
7.1 Screen Design........................................................................................................44
7.1.1 Status Line.............................................................................................................44
7.1.2 Main Screen...........................................................................................................45
7.1.3 Button Bar .............................................................................................................46
7.2 Starting the Program..............................................................................................47
7.3 End Program / Switch off Dyno ..............................................................................47
7.4 Menu Overview ......................................................................................................48
8Preparations for Testing .......................................................................................50
8.1 Switch on the Dyno................................................................................................50
8.2 Drive onto Dyno .....................................................................................................50
8.3 Fix Vehicle..............................................................................................................50
8.4 Connect the RPM Sensor.......................................................................................53
8.5 Attach Exhaust Suction System..............................................................................53
8.6 Position Cooling Air Fan .........................................................................................53
8.7 Bring the Vehicle up to Operating Temperature ......................................................53
8.8 Vehicle Ready for Testing .......................................................................................54
9Measurements .....................................................................................................55
9.1 Load Simulation .....................................................................................................55
9.1.1 Identical Functions .................................................................................................55
9.1.2 Constant Traction...................................................................................................60
9.1.3 Constant Speed.....................................................................................................62
9.1.4 Driving Simulation...................................................................................................63
9.1.5 Constant Engine RPM............................................................................................64
9.1.6 Standstill ................................................................................................................65
9.2 Measure Engine Power ..........................................................................................66

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9.2.1 Display Last Measurement .....................................................................................66
9.2.2 Continuous Measurement ......................................................................................66
9.2.3 Discrete Measurement ...........................................................................................69
9.3 Engine Flexibility Test .............................................................................................71
9.4 Speedometer Check ..............................................................................................72
9.4.1 Vehicle Speed ........................................................................................................72
9.4.2 Mileage ..................................................................................................................73
9.5 Load Adaption (Optional)........................................................................................74
9.5.1 Coefficient Adaption based on ECE........................................................................75
9.5.2 Coefficient Adaption based on SAE J2264 .............................................................76
10 Settings ...............................................................................................................77
10.1 Database ...............................................................................................................77
10.1.1 Identical Functions .................................................................................................77
10.1.2 Performance Curves ..............................................................................................80
10.1.3 Time Diagram.........................................................................................................84
10.1.4 Vehicle Data...........................................................................................................85
10.1.5 Load simulation profile............................................................................................86
10.1.6 Driving Cycle Data..................................................................................................88
10.2 Vehicle Data...........................................................................................................89
10.3 RPM Setting...........................................................................................................90
10.3.1 Driving Trial ............................................................................................................91
10.4 Special Settings .....................................................................................................92
10.5 Select Dyno Type...................................................................................................93
10.6 Units ......................................................................................................................93
10.7 Language...............................................................................................................94
10.8 Device / Interfaces..................................................................................................94
11 Diagnosis / Service...............................................................................................95
11.1 Dyno Status ...........................................................................................................95
11.2 Driver’s Aid Setup (Optional)...................................................................................95
11.2.1 Test Driving Cycle ..................................................................................................96
11.2.2 Edit Profile..............................................................................................................97
11.2.3 New Profile.............................................................................................................97
11.2.4 Delete Profile..........................................................................................................98
11.3 Backup/Restore Database .....................................................................................98
11.3.1 Backup Database ..................................................................................................98
11.3.2 Restore Database ..................................................................................................98
11.3.3 Delete Table...........................................................................................................99

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11.3.4 Delete Database.....................................................................................................99
12 Maintenance ...................................................................................................... 100
12.1 Important Information...........................................................................................100
12.2 Annual Inspection.................................................................................................100
12.3 Care Instructions..................................................................................................100
12.4 Troubleshooting ...................................................................................................101
12.5 Maintenance by the Operator ...............................................................................101
12.5.1 Roller Set .............................................................................................................101
12.5.2 Eddy Current Brake..............................................................................................101
12.5.3 Roller Bearings.....................................................................................................101
12.6 Spare Parts..........................................................................................................102
13 Dismantling........................................................................................................ 102
14 Disposal............................................................................................................. 102
15 Contents of the Declaration of Conformity...........................................................102
16 Company Information......................................................................................... 103

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1Safety
1.1 Introduction
Thoroughly read this manual before operating the equipment and comply with the instructions.
Always display the manual in a conspicuous location.
Personal injury and property damage incurred due to non-compliance with these safety
instructions are not covered by the product liability regulations.
1.2 Symbols
Important safety instructions. Failure to comply with instructions could result in personal injury or
property damage.
Important information.
1.3 Intended Use
This dynamometer is to be used exclusively for the performance testing of motor vehicles. It is not
suitable for brake testing or noise detection. Observe the rated axle load.
The equipment may not be modified without the express written consent of the manufacturer. In
case of non-compliance the declaration of conformity becomes void.
Any use other than described is inappropriate.
1.4 Safety Instructions for Commissioning
Only authorized service technicians may install and commission the test stand.
The test stand may not be installed and operated in fire-endangered operation facilities, outside
or in damp rooms (e.g. wash halls).
Mount components of the vehicle fixing unit in advance on a suitable lift on the test stand.
Warning stickers must be attached by the operator:
–Hearing damage due to high noise level. Wear hearing protection.
–Severe eye injuries due to flying particles. Wear protective goggles! Operator is responsible.
Wear personal protective clothing as required or as regulated by law. The personal protective
clothing must meet the safety-technical regulations for the respective work application.

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1.5 Safety Instructions for Operation
The dynamometer shall be used and operated exclusively for its intended purpose and only
within its performance limits.
The dynamometer shall only be operated by trained personnel. Dynamometer and working area
must be kept clean.
The dynamometer shall only be operated by persons who are physically and mentally fit. These
persons shall be well rested and not under the influence of alcohol, drugs or medication.
When not in use the system must be switched off and the main switch protected against re-
start.
No persons shall be in the danger zone of the dynamometer. Rotating or moving parts are dan-
gerous.
Pay close attention to accident prevention regulations.
Never climb on roller sets even when locked.
Avoid unnecessary strain on vehicle and dynamometer. Drive the vehicle slowly onto the dyna-
mometer.
Regularly check the tightness of the cover plate attachment screws.
No persons shall be in the pit with dynamometers in conjunction with a working pit while a vehi-
cle with rotating wheels is on the roller set.
Wear personal protective clothing. If necessary wear protective goggles. Particles ejected from
rotating vehicle wheels can cause severe injuries. Wear tightly fitting working clothes and bind
long hair together. Clothing or hair can get caught and pulled into machinery.
Danger of hearing damage due to high noise level! Use hearing protection approved up to
120 dB(A). Noise levels over 110 dB(A) can be reached during vehicle testing. The operator is
responsible for determining the noise level in vehicle and test room. When necessary, wear
suitable hearing protection. The operator must attach warning stickers.
Danger of carbon monoxide poisoning by poisonous vehicle exhaust. The dynamometer shall
only be operated if the room and working pit in which it is installed have sufficient exhaust suc-
tion and ventilation including the appropriate warning system.
Avoid steering movements during the vehicle test. These cause certain forces to act on the ve-
hicle fixing, in particular on the attachment units on the test vehicle.
Before exiting the vehicle, put the gear into idle. If necessary decelerate the vehicle in a con-
trolled manner avoiding steering movements. Wait until vehicle and rollers have stopped moving
before exiting the vehicle. Danger of body parts and clothing being pulled into rotating rollers
and vehicle wheels.
Keep the dyno surface clean and dry. Danger of slipping when surface is wet, oily or icy! Do not
place any objects (tools, material etc.) on the dynamometer. Wear protective shoes with anti-
slip soles and steel toe caps to avoid slipping and mechanical injuries. Parts which protrude
more than 20 mm out of the floor are to be marked with black-yellow tape.
In addition to the danger zone, the operator is responsible for confining the area of the test
room in which no persons are allowed during testing with a safety catch device or a cell wall.
Mark the danger zone (roller width + 1100 mm) on both sides behind the vehicle up to cell
wall/safety catch device.
Danger of accident due to vehicle fixing fracturing! Do a visual check for damage to the vehicle
fixing before each use. Never start the test operation without suitable and correctly installed ve-
hicle fixing.

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1.6 Safety Instructions for Servicing
Service work shall only be carried out by authorized service technicians.
The operating mode selection switch must be put in the correct position with repair, mainte-
nance and set-up work. Remove the key to protect against unauthorized usage.
The safety devices must be set by authorized service technicians.
Do not replace or override the safety devices.
Wear tight-fitting safety gloves when doing setup work to reduce the danger of pinching. Wear
a protective helmet when doing service work in the test stand pit to avoid impact injuries.
Life-threatening electrical voltage! Only authorized electricians are allowed to work on the elec-
trical parts of the equipment based on valid electro-technical rules and guidelines. Before doing
any work on the test stand electrics switch off all voltage and secure against re-starting. Test
for absence of voltage! Cabinet contains components with storage charge. After switching off
all voltages life-threatening voltage can still be present for at least 5 minutes! Check for dis-
charge before starting work! Lock circuit box and store key securely. Hand out key only if
needed to authorized electricians.
Errors and deviations from normal operating conditions are to be inspected only by trained
skilled workers who are authorized to do this kind of work. Circuits which are fed by an uninter-
ruptible power supply are still under voltage even after the test stand has been switched off
from the mains connection. The control has circuits which are tapped before the mains discon-
nection device of the test stand and are not voltage-free after switch off using the mains dis-
connection. All equipment which are connected before the mains disconnection device are
wired with the colors YELLOW or ORANGE. Pay attention to calibration instructions.
Use suitable lifting device with sufficient load capacity to open heavy dyno components. Re-
moval and transport only by qualified skilled personnel. Adhere to all valid safety regulations and
relevant work protection guidelines. Lift dyno components only on the designated lifting points.
1.7 Danger Zone
During dynamometer operation no persons are allowed to stay in the danger zone. Minimum
distance is 1100 mm on all sides of the roller(s).
1.8 Safety Information about Tires
Check tire pressure and do a visual check of the tires for any signs of damage.
To avoid tire damage we recommend that test tires be used during the performance test.
According to tire manufacturers, tires which have been used for performance testing shall not
be used for the road. Invisible tire defects may occur.
No vehicles shall be tested which have snow tires, racing tires or retreaded tires!
Pay attention that the rated speed for the tires is not exceeded!
Check all wheel components to make sure they are tight before testing.
1.9 Safety Information about the Eddy Current Brake
Optionally available.
The eddy current brake can heat up significantly during long lasting usage. The brake rotors may
become red hot.

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After a long lasting measurement under load, the eddy current brake should continue to be rotated
without load by the vehicle at a speed of approx. 50 –80 km/h.
The rotating rotors suck cooled air from the side and throw it radially off. The eddy current brake is
thereby effectively cooled preventing heat build-up at the rotors damaging the coil insulation.
1.10 Safety Information about the Vehicle Fixing System
Lifting Straps
Tension belt (50 mm width) Tensile strength 2000 kg, Length 4 m
Only authorized and trained personnel are allowed to use it.
Lifting straps should be checked for damage and safety before using.
Do not exceed permissible load capacity. Place the straps so that the load is distributed across
the entire width.
Use only suitable anchoring positions.
Only use undamaged lifting straps / tension belts with identifiable tension labels.
Do not knot or twist the lifting straps and do not tie together to extend them.
Wind the straps a min. of 1.5 times and a max.of 3 times around the ratchet.
Only use lifting bands with protective edges when loads have sharp edges.
Do not put stress on the tip of or up to the bending point of fixed parts.
Operating temperature: -40…+100 °C
Load capacity reduction with:
- non-symmetric (unbalanced) load
- usage in tightening process only with permissible end loop reinforcement
Shall not be used in lye.
Usage forbidden when there are mechanical damages, deformation or damages to any safety
features.
Inspection and maintenance after one year and only by skilled technicians.
1.11 Safety Features
The safety features must be checked regularly by an authorized service technician. Pay attention to
statutory requirements. The dyno shall not be operated with defective safety features.
Lockable Main Switch
Serves as a normal On and Off switch and as an emergency switch. The switch can be protected
against unauthorized usage by locking with a padlock.
Pit Safety (optional)
Light barrier or infrared movement sensor. Issues audible and visual signals in the event that per-
sons are in the working pit.
Warning and Information Labels
Warning and information labels are attached to the dyno. The labels shall not be changed or
removed. Defective warning and information labels must be replaced.
1.12 Accessories
The equipment shall be operated only with accessories which have been approved or permitted by
MAHA.