MAHA ZW 500 User manual

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ZW 500
Power Take-off Dynamometer
Original Operating Instructions
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Contents
1Safety......................................................................................................................5
1.1 Introduction......................................................................................................................................... 5
1.2 Safety Information.............................................................................................................................. 5
1.3 Safety Information about the Eddy Current Brake............................................................................. 6
1.4 Further Information............................................................................................................................. 6
2Description..............................................................................................................7
2.1 General Information............................................................................................................................ 7
2.2 Specifications ..................................................................................................................................... 7
2.2.1 Brake Unit with Trailer........................................................................................................................ 7
2.2.2 Performance Table (without Gear)..................................................................................................... 8
2.2.3 Hand Terminal.................................................................................................................................... 8
3Installation...............................................................................................................9
3.1 Requirements for the Place of Installation ......................................................................................... 9
3.2 Technical Safety Measures in Test Rooms........................................................................................ 9
3.2.1 Exhaust Suction System .................................................................................................................... 9
3.2.2 Fresh Air Supply for the Test Room................................................................................................... 9
3.3 Preparations for a Performance Test............................................................................................... 10
4Operation..............................................................................................................11
4.1 Radio Hand-Held Terminal............................................................................................................... 11
4.1.1 Keyboard Assignment...................................................................................................................... 12
4.2 Program Structure............................................................................................................................ 14
4.3 Start- / Print Menu <F2>................................................................................................................... 14
4.3.1 Vehicle Data Entry............................................................................................................................ 15
4.4 Main Menu <F3>.............................................................................................................................. 15
4.4.1 Constant RPM.................................................................................................................................. 17
4.4.2 Constant Torque............................................................................................................................... 18
4.4.3 Discrete Measurement..................................................................................................................... 19
4.4.4 Warm-up Drive................................................................................................................................. 21
4.5 Setting Menu <F1>........................................................................................................................... 22
4.5.1 Set Contrast ..................................................................................................................................... 22
4.5.2 Set Date and Time ........................................................................................................................... 23
4.5.3Program Address ............................................................................................................................. 24
4.5.4 Program Variables............................................................................................................................ 24
4.5.5 Print Configuration............................................................................................................................ 26
4.6 Short Operating Instructions for Vehicle Test .................................................................................. 27
4.6.1 Constant RPM or constant Torque................................................................................................... 27
4.6.2 Discrete Measurement..................................................................................................................... 27
4.6.3 Warm-up Drive................................................................................................................................. 27
5Maintenance..........................................................................................................28
5.1 Annual Inspection............................................................................................................................. 28
5.2 Care Instructions .............................................................................................................................. 28

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5.3 Maintenance by the Operator........................................................................................................... 28
5.3.1 Bearing Positions ............................................................................................................................. 28
5.3.2 Screw Connections .......................................................................................................................... 28
5.3.3 Eddy Current Brake.......................................................................................................................... 28
5.3.4 Trailer ............................................................................................................................................... 28
5.4 Spare Parts ...................................................................................................................................... 29
6Dismantling ...........................................................................................................29
7Disposal................................................................................................................29
8Contents of the Declaration of Conformity ............................................................29
9Company Information............................................................................................30
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1 Safety
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1.1 Introduction
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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.
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Important safety instructions. Failure to comply with instructions could result in personal injury or
property damage.
Important information.
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Carefully observe all safety instructions. They are provided to warn of dangers and help prevent
personal injury and property damage.
It is the operator’s responsibility to comply with the applicable accident prevention regulations
and to bring them up to date continually.
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1.2 Safety Information
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Safety information is provided to warn about dangerous situations and help prevent damage to
equipment and injury to persons.
•The test equipment may only be used and operated for its intended purpose and within its
stated performance limits!
•The dynamometer may only be operated by trained, authorized personnel
•Explosion protection! The dynamometer may not be installed and operated in explosion
endangered rooms! Standard serial dynamometers have no EX protection.
•In case of emergency turn the main switch (the Emergency-Off switch) to 0.!
•No persons are allowed in the danger zone surrounding the dynamometer!
Rotating or moving parts are dangerous. (e.g. connection shaft) .
•Use ear protection! The ear protection must be suitable for the noise level.
•Pay close attention when engines are running. Running vehicle engines represent potential
carbon monoxide poisoning.
•Before doing any repair / maintenance / set up work turn off the main switch and secure it
against tampering.
•Secure the dynamometer against unauthorized usage by locking the main switch.
•All work done on electrical parts of the equipment is to be carried out by trained, qualified
electricians.
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1.3 Safety Information about the Eddy Current Brake
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The eddy current brake can heat up significantly during long lasting usage (> 500 °C). The
brake rotors may become red hot.
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 600…800 rpm for 3…5 minutes.
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.
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1.4 Further Information
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During installation:
•Noise protection! Use noise protection in the work areas near the dynamometer !
During operation:
•Please read the operation & maintenance manual thoroughly. If damage or service costs are
incurred due to non-compliance with these instructions, MAHA is not liable for the damage
and/or service costs will not be covered.
•Carefully observe all accident prevention regulations!
•Adjustment and maintenance work may not be done when the dynamometer is switched on!
•The test vehicle must be road worthy!
•The dynamometer and work area must be kept clean at all times.
•The dynamometer may only be operated within its stated performance limits!
•The dynamometer should be cordoned off or covered if it is located directly in the workshop
or in an area to be which the public has access.
•Work on pulse sensors and proximity switches may only be done by trained, skilled
electricians.
•Never operate the dynamometer without the protective grating.
•Turn off dynamometer and vehicle when mounting and dismantling the connection shaft.
•Use power take-off shafts which correspond with the performance ranges.
•If the dynamometer is located outdoors both ventilators must be covered.
•Pay attention that the hand terminal is always well.charged. Maximum operating time is 4-5
hours without re-charging.
•The hand terminal can also be operated with the mains power supply.
•When transporting power take-off shafts in the dynamometer house pay close attention to
the maximum load capacity and if necessary, weigh.
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2 Description
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2.1 General Information
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Following measurements are possible:
•Measurement of the motor performance on the power take-off shaft
•Measurement of the performance with constant RPM via automatic RPM regulation
•Measurement of performance with constant torque via automatic RPM regulation
•Discrete performance measurement possible
•Performance warm-up drive program
•Emission measurement (optional)
•Consumption measurement (optional)
•Pressure-temperature-measurement (PC version optional)
The dynamometer consists of:
•A hand terminal with LCD display, keyboard and printer, radio transmission
•Load unit with two eddy current brakes
•PC or Laptop (optional)
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2.2 Specifications
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2.2.1 Brake Unit with Trailer
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Dimensions ( W x H x L) (2080 x 1515 x 3580) mm
Torque max. 6600 Nm
Test RPM (Direct drive) max. 2500 min-1
Measurement system Electronic strain gauge technology
Power connection 400V, 50/60 Hz, 16 A
Weight (with trailer) ca. 1300 kg
Support load 75 kg
Rated current 15 A
Fuse 16 A time-delay
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2.2.2 Performance Table (without Gear)
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Length of time With performance npower take off shaft 1000 min-1
1 Minute 500 kW
3 Minutes 450 kW
6 Minutes 320 kW
9 Minutes 280 kW
12 Minutes 220 kW
* Dependent upon environmental influences
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2.2.3 Hand Terminal
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Dimensions of hand terminal (W x H x D) 125 x 56 x 250 mm
Weight approx. 1 kg
Connection battery 15 V
Power consumption 150…500 mA
Working temperature 0…+50 °C
Storage temperature -20…+60 °C
Display 2 x 16 digits
RS232 interface 9600 Baud,1Start-/ 1Stopbit, 8 Databit
Paper width 58 mm
Type of paper Wood-free
Roller diameter 50 mm max.
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3 Installation
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3.1 Requirements for the Place of Installation
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The dynamometer can be operated outdoors as well as in enclosed rooms.
If the dynamometer is operated in an enclosed room, this must be in accordance with the
statutory regulations for work places. An adequate fresh-air supply and an exhaust shaft should
also be available.
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3.2 Technical Safety Measures in Test Rooms
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The following technical safety precautions must be observed by the customer at all times.
Disregarding these precautions can be life-threatening even for those who enter the room for
only a very short period.
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3.2.1 Exhaust Suction System
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As a safety precaution it is recommended that a CO warning device be installed in the test
room.
The exhaust discharge for the auto exhaust can be done with suction hoses or with suction
flaps.
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3.2.2 Fresh Air Supply for the Test Room
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According to currently effective regulations in the Federal Republic of Germany, the air must be
renewed 10 to 15 times per hour in closed testing rooms with a surface area up to 100 m².
The air must be renewed 5 to 8 times per hour in rooms over 100 m².
An air throughput of approx. 5000 m³/h is required for a surface area of 100 m².
An inadequate fresh-air supply increases the burden on the test personnel and distorts the test
results.
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3.3 Preparations for a Performance Test
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1 Position the trailer with the dynamometer on a suitable, level surface.
2 Pull on the hand brakes.
3 Pull out the supports of the trailer to prevent any swinging movements:
- Lower the trailer forward over the support wheel
- Lower the support foot in the rear and fix it
- Raise the trailer over the support wheel (ca. 10 cm)
- Lower the support foot in the front and fix
- Slightly loosen the support wheel( 1 rotation)
4 Open front flap.
5 Mount the power take-off shaft so that it is aligned with the vehicle.
Switch off the dynamometer and the vehicle when mounting and removing the connection shaft.
Use a suitable power take-off shaft depending on the performance range!
Pay attention to the rotation direction of the shaft.
The rotation direction of the dynamometer shaft must show in direction of the drawbar!
The dynamometer will not brake if the rotation direction is wrong!
6 Chain on the protective sheathing for the power take-off shaft.
7 Connect dynamometer to power supply.
8 Switch on the main switch.
9 Activate the hand terminal using any key.
10 Optional: Connect consumption measurement device, see Chapter Main menu.
⇒The dynamometer is now ready for testing. The performance measurement is done after the
vehicle is warmed-up.
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4 Operation
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4.1 Radio Hand-Held Terminal
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The dynamometer can be operated via the hand-held terminal. Data or instructions can be
entered via the keypad.
The terminal is used for:
•Printout
•Data on the LCD display
A Printer mechanism
B 2-line LCD display
C Not used
D Re-charging plug
E Keypad
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A
B
C D C
E

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4.1.1 Keyboard Assignment
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G
H
I
J
N
A B FE
L
M
K
O
C D
P

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The hand-held terminal can be switched on with any key.
If the hand-held terminal is not used for longer than 20 minutes, it switches off automatically
(battery saving mode). The switch-off time is adjustable.
Key Description
A Open setting menu
B Start menu, open printer menu
C Open main menu with test mode
D Switchover between shaft rpm and motor rpm (V1.11 or higher)
E Reduction of the target value (rpm / torque)
F Increasing the target value (rpm / torque)
G Enter key, confirm selection menus and/or entries
H Delete
I Switch forward display window of menu and measurement values
J Switch back display window of menu and measurement values
K Digit block for numerical input or menu selection (if available)
L Space key, paper feed for printer
M Comma for numerical input
N Termination of current measurement, complete printout, change between the menus
O Keypad for text input
P Switchover between PS and kW; available if measurement not yet started (V1.11 or
higher)
N+A+G Switch off ⇒If the hand-held terminal is connected to the power unit, it cannot be
switched off.
Some keys have a double allocation for text entries. Press twice quickly to type the character
shown as a small symbol on the key.
2x A = Ä ; 2x O = Ö ; 2x U = Ü ; 2x . = / ; 2x S = ß
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4.2 Program Structure
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Use function keys <F1>, <F2> and <F3> to open the appropriate menu. Use the arrow key to
change to the sub-menus and select using the <*> or <ENTER> key. The description of the
sub-menus can be found in the following chapters.
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4.3 Start- / Print Menu <F2>
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The power take-off shaft can measure, short-term, up to 500 kW with 1000 min-1. Performance
input is reduced to ca. 220 kW with measurements over 12 minutes (continuous performance).
Switch on the device by pressing any key.
After switch on, the following messages appear on the display one after the other:
LPS ZW-500
V 1.0 Accu-capacity <×××××××××××××> New Measurement Start with <*>
The operating hours appear on the operating hours counter based on battery capacity.
Menu item Function
New measurement A new measurement is started
Print copy A copy of the last printout is printed
Print memory Select and print measurement based on date and time
Delete measurement Select and delete measuremt. based on date and time (V1.11 or higher)
Delete memory Delete all measurements in the memory (maximum of 11 possible)
Memory to PC Data transmission per radio to PC
A) Using the <ENTER> key to start a new measurement, see Main menu <F3>.
Occurs once after switch-on, otherwise select new measurement mode via main menu!
B) Select menu item of printer menu using the arrow keys. Confirm with <ENTER>.
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4.3.1 Vehicle Data Entry
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Vehicle data entry via print menu with <F2> and <ENTER>. Following boxes are available:
•Make max. 24 characters, alpha-numeric
•Model max. 24 characters, alpha-numeric
•Operating hours (optional) max. 24 digits, numeric
•Customer name max. 24 characters, alpha-numeric
Setting of vehicle data in Variable 4: see section "Operation / Setting Menu <F1> / Program
Variables".
Use the keypad for data entry.
Confirm with <ENTER> . Make
--
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4.4 Main Menu <F3>
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The following measurement methods can be selected:
Display Mode Entry values
•Constant n Constant RPM - Target RPM
•Constant Md Constant engine torque - Target RPM
•Discrete n Discrete RPM
measurement - RPM Start
- RPM Stop
- RPM Step
- Waiting time
•Warm-up drive Constant power at
constant RPM and p.t.o
shaft torque
- Warm-up power
With V1.11 or higher, the measurements can
be performed using the engine RPM or the
engine torque. To do this, enter the trans-
mission ratio engine/p.t.o. shaft using <F4>.
0.0 Nm →
0.0 kW 0 rpm
All display and input values bearing this factor are marked with an asterisk on the display.
First the measurement method [constant n] is
displayed: Measurement with
constant n <*> →
Key <+> or <-> Change to a different measurement method
Key <ENTER> Select desired measurement method

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To open the main menu, an active connection to the dynamometer must exist.
For safety reasons, the measurement methods are only selectable with RPM n = 0.
Consumption Measurement (Optional)
The fuel consumption measurement device
AIC is connected to the switch box in order to
conduct fuel consumption measurements.
After confirmation of a target value ca. 5 s will pass until the fuel consumption is shown on the
display. Beforehand, the display -,- l/h appears.
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4.4.1 Constant RPM
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1 Select suitable transmission/RPM range of the power take-off shaft, switch on p.t.o. shaft.
2 Select measurement method and confirm with <ENTER>. Measurement with
constant n <*> →
3 Enter value for target RPM using digit keys.
4 Use <ENTER> key for confirmation. Target RPM
2500 min-1 <*>
If a torque value < 20 % of the current RPM is entered, an error message appears: "RPM too
low" (V1.11).
5 Press the accelerator. When the target RPM is reached, regulation is automatically done.
Regulate power and engine torque using the accelerator.
6 Display of the target values:
Use the arrow keys to switch between the displays: 0.0 Nm
0.0 kW00 min-1
•P.t.o. shaft performance
•P.t.o. shaft torque P 0.0 kW
Md 0.0 Nm
•P.t.o. shaft performance
•P.t.o. shaft RPM P 0.0 kW
n 0.0 min-1
•P.t.o. shaft torque
•P.t.o. shaft RPM Md 0.0 Nm
n 0 min-1
•P.t.o. shaft consumption
•P.t.o.f shaft RPM Consumpt.-,- l/h
n -- min-1
Reducing the target value by 1 min-1 (basic setting) <F5>
Increasing the target value by 1 min-1 (basic setting) <F6>
Setting the increment in Variable 1: see section "Operation / Setting Menu <F1> / Program
Variables".
7 Printing the current measurement data using the print
menu. <F2>
8 Enter vehicle data.
9 Printing the current measurement values. <ENTER>
10 Cancel printout. Signature and stamp are printed. <ESC>
After measurement, continue driving the p.t.o. shaft without load to cool down the brake.
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4.4.2 Constant Torque
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1 Select suitable transmission/RPM range of the power take-off shaft, switch on shaft.
2 Select measurement method and confirm with <ENTER>. Measurement with
constant Md <*> →
3 Enter value for target torque using digit keys.
4 Use <ENTER>-key for confirmation. Target torque
0.0 Nm
5 Press the accelerator. Target torque is regulated over the
entire RPM range.
Regulate power and engine torque using the accelerator.
6 Display of the target values:
Use the arrow keys to switch between the displays: 0.0 Nm →
0.0 kW 0 U/m
•P.t.o. shaft performance
•P.t.o. shaft torque P 0.0 kW
Md 0.0 Nm
•P.t.o. shaft performance
•P.t.o. shaft RPM P 0.0 kW
n 0.0 min-1
•P.t.o. shaft torque
•P.t.o. shaft RPM Md 0.0 Nm
n 0 min-1
•P.t.o. shaft consumption
•P.t.o. shaft RPM Consumpt.-,- l/h
n -- min-1
Reducing the target value by 1 min-1 (basic setting) <F5>
Increasing the target value by 1 min-1 (basic setting) <F6>
Setting the increment in Variable 2: see "Operation / Setting Menu <F1> / Program Variables".
7 Printing of the current measurement data using the print
menu. <F2> and <ENTER>
8 Enter vehicle data.
9 Printing the current measurement values. <ENTER>
10 Cancel printout. Signature and stamp are printed. <ESC>
After measurement, continue driving the p.t.o. shaft without load to cool down the brake.
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4.4.3 Discrete Measurement
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Pre-defined points in relation to the RPM are measured in the discrete performance measure-
ment. The start and end RPM as well as the increment are defined by the operator.
1 Select suitable transmission/RPM range of the p.t.o. shaft, switch on the shaft.
2 Select measurement method and confirm with <ENTER>. Measurement with
Discrete n <*> →
3 Enter value for RPM start using the digit keys.
4 Use <ENTER> key for confirmation. RPM Start
- min-1
5 Enter value for RPM stop using the digit keys.
6 Use <ENTER> key for confirmation. RPM Stop
- min-1
7 Enter value for RPM step using digit keys.
8 Use <ENTER> key for confirmation. RPM Step
- min-1
9 Enter value for waiting time using the digit keys.
10 Use <ENTER> key for confirmation. Waiting time
10 s
During the waiting time the approached RPM is held constant to keep a stable measurement
point. A waiting time of at least 10 s is recommended. Please pay attention to the vehicle
manufacturer’s instructions.
The printout starts automatically with the printing of the header data. This message appears:
"Please wait, printing data". During the measurement the current measurement values are
printed.
11 Press the accelerator to full throttle.
The first measurement point entered is approached with full throttle.
The eddy current brake hold the RPM constant based on the pre-selected waiting time and
files the measurement of this point. Then the brake is released and the next measurement
point is approached. The operator presses the accelerator during the entire test.
Example of measurement value entry:
Sequence of the measurement values RPM measurement values - example
Minimum to maximum 500 600 700 800 900 1000
Maximum to minimum 1000 900 800 700 600 500
With V1.11 or higher, the start value can be set automatically during measurements from high to
low:
1 Enter "0" as start value, then the lower end value, step and waiting time.
2 Raise the RPM to the desired start RPM. This must be greater than stop RPM + step.
►<*> appears on the display.
3 Press the <*> key to select the current RPM as start value.

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The upper left part of the display shows in what range the RPM is:
•If the flashing square is within the limits, the RPM is within
the tolerance corridor. > < 0.0 Nm
0.0 kW 0 min-1
•If the square is located to the left of the limit, the RPM is
too low. The vehicle cannot approach the next target RPM.
Cancel the test with <ESC>. This case may occur if an
exaggerated target RPM was entered, e.g. tractor has
Umax = 1050min-1, and Utar = 1200 min-1 was entered.
> < 0.0 Nm
0.0 kW 0 min-1
•If the square is located to the right of the limit, the RPM is
too high. In this case, the dynamometer can no longer
regulate the RPM, because the performance range of the
brakes is exceeded. This message appears: "Error Brake 1
100% performance".
> < 0.0 Nm
0.0 kW 0 U min-1
A printout is automatically created with a discrete measure-
ment. After the discrete measurement has been completed, the
program returns automatically to the measurement display of
the main menu. There, using <F3>, a different measurement
method can be selected or a new menu opened once the
power take-off shaft has come to a standstill.
0.0 Nm →
0.0 kW 0 min-1
In the event of overload the measurement value "−−" is shown.
After measurement, continue driving the power take-off shaft without load to cool down the
brake.
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