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©2005 Dynojet Research, Inc. All Rights Reserved. Control Panel Interface Installation and User Guide For Model 200ip and 250ip Motorcycle Pit Dynamometers. This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual is furnished under license and may only be used or copied in accordance with the terms of such license. This manual is furnished for informational use only, is subject to change without notice, and should no
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TABLE OF CONTENTS Chapter 1 Control Panel Interface Installation Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2 Connecting and Disconnecting Power to the Dyno . . . . . . . . . . . . . . . . . .1-3 Removing the Pit Cove
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TABLE OF CONTENTS Chapter 2 Using the Control Panel Interface Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Using the Air Fuel Ratio Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Using the Emergency Stop/Dyno Shutdown . . . . . . . . . . . . . . . . . . . . . . .2-4 Using the High Pressure Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4 Understanding Interlocks . . . . . .
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TABLE OF CONTENTS Appendix D Power Requirements Power Requirements and Installation—North America, Japan, and Locations Using 60 Hz Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2 Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2 Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3 Replacing the Power Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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C HAPTER 1 CONTROL PANEL INTERFACE INSTALLATION This document provides instructions for installing and using the Control Panel Interface (CPI) with the model 200ip/250ip motorcycle pit dynamometer. To ensure safety and accuracy in the procedures, perform the procedures as they are described. This manual will walk you through installation procedures, basic operation, and how to maintain and troubleshoot your hardware. Appendix A contains instructions for installing the Red Head Anchors.
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CHAPTER 1 Introduction INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Control Panel Interface (CPI) consists of a main control board which is mounted in an external box for a pit dyno or retrofit. This board provides switching and control of many functions within the dyno. The front panel of this board is accessible through the door on the external box. The user interface is through the Control Panel which is normally mounted on the side of the monitor
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CONTROL PANEL INTERFACE INSTALLATION Introduction CONNECTING AND DISCONNECTING POWER TO THE DYNO Many instructions in this guide will require you to connect or disconnect the power to the dyno as part of the installation process. Use the following steps to connect and disconnect power to the dyno. Always turn the power off when connecting and disconnecting cables. 1 Use the main breaker to turn power on and off to the dyno. The main breaker is located inside the power distribution assemb
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CHAPTER 1 Introduction REMOVING THE PIT COVERS Dynojet recommends using a T30 Torx driver (Snap-On PFTx30E) or a hardened 5/32-inch hex driver (Snap-On Fa5E), for dynos with serial numbers lower than 2030152, to remove the 1/4-inch screws. A standard allen key may round off in the shallow screw head. 1 Remove the four 3/8-16 x 1/2-inch button-head flange screws securing the right side drum cover to the drum module and set aside. 2 Remove the four 1/4-20 x 1/2-inch button-head flange screws s
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CONTROL PANEL INTERFACE INSTALLATION Introduction 4 Remove the four 3/8-16 x 1/2-inch button-head flange screws securing the left side drum cover and set aside. 5 Remove the cover and set aside. Figure 1-3: Left Side Drum Cover 6 Remove the four 3/8-16 x 1/2-inch button-head flange screws securing the retarder cover and set aside. 7 Remove the cover and set aside. Figure 1-4: Retarder Cover 1-5 Version 1 Control Panel Interface Installation and User Guide
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CHAPTER 1 Introduction REMOVING THE CONTROL PANEL INTERFACE COVER The Control Panel Interface (CPI) comes wired and ready to install. Should you need to re-route the cables so they come out a different side of the box, use the following instructions to access the CPI box. 1 Turn off the power to the dyno. Refer to “Connecting and Disconnecting Power to the Dyno” on page 1-3 for more information. 2 Remove the eight button-head screws securing the cover and set aside. 3 Remove the cover and set
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CONTROL PANEL INTERFACE INSTALLATION Battery BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For operation of the starter, motorized carriage, or optional wheel clamp it is necessary to install a car battery in the dyno. The car battery provides the necessary energy to run these components. The CPI has a built in battery charging circuit to keep the battery charged. Each time the starter, motorized carriage, or wheel clamp is used, this built in charging c
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CHAPTER 1 Battery INSTALLING THE BATTERY The model 200ip/250ip dyno is designed to carry a group 24 deep cycle discharge series battery for operating the built in starter. This battery is not included with your dyno. You will need to provide this battery. For more information on battery requirements and battery chargers refer to “Battery Requirements” in Chapter 1 of the Model 200ip/250ip Motorcycle Pit Dynamometer Installation Guide. 1 Locate the red battery cable on the inside of the dyno
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CONTROL PANEL INTERFACE INSTALLATION Battery BATTERY GAS WARNING INSTRUCTIONS For complete warnings, refer to the Warnings section of the Model 200ip/250ip Motorcycle Pit Dynamometer Installation Guide. Battery Fire and Explosion Hazards There is a danger of explosion if the battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Discard used batteries according to the manufacturer’s instructions. Automotive Batteries In operation,
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CHAPTER 1 Blower Mounts, Support Arm, and Junction Box BLOWER MOUNTS, SUPPORT ARM, AND JUNCTION BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before routing the cables, you must decide which side of the dyno to mount the monitor support arm. The choice is based on personal preference and easy access to your computer. For the following instructions, we will show the support arm and control panel mounted on the right side of the dyno. MARK AND DRILL THE BLOWER MOUNTS
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CONTROL PANEL INTERFACE INSTALLATION Blower Mounts, Support Arm, and Junction Box INSTALLING THE BLOWER MOUNTING PLATE, SUPPORT ARM, AND JUNCTION BOX The high pressure blowers are an optional accessory. If you did not order high pressure blowers, you will not need to install the blower mounting plates. 1 Secure each blower mounting plate to the pit floor using four 3/8 x 1-inch bolts and 5/16-inch washers. Note: The blower mounting plate is secured under the support arm. 2 Secure the sup
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CHAPTER 1 Blower Mounts, Support Arm, and Junction Box INSTALLING THE ARMS AND MONITOR TRAY 1 Insert a plastic cap in both ends of each arm. 2 Place a poly washer around the pin of the first arm and insert the pin into the support arm. 3 Place a poly washer around the pin of the second arm and insert the pin into the first arm. 4 Place a poly washer around the pin of the tray and insert the pin into the second arm. Note: The monitor tray is an optional accessory. If you did not order a monito
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CONTROL PANEL INTERFACE INSTALLATION Blower Mounts, Support Arm, and Junction Box INSTALLING THE HIGH PRESSURE BLOWERS The high pressure blowers are an optional accessory. If you did not order the high pressure blowers, skip these instructions. Repeat the following steps for each blower assembly. 1 Place two 1/4-inch thick poly washers around the pin on the blower mount. Note: Only use one 1/4-inch thick poly washer with the blower mount installed with the support arm. 2 Place the lower
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CHAPTER 1 Routing Cables ROUTING CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For the following instructions, we will show the support arm and control panel mounted on the right side of the dyno with the Control Panel Interface (CPI) and dyno electronics on the left side of the dyno. The CPI and dyno electronics must be placed near the conduits in the pit. Be sure to keep the power and communications cables in different pit conduits. For the following instructi
