Control Panel Interface Upgrade for Model 200i/250i Dynos S/N
Contents
1. RESEARCH pees an D OD SD OD EN OD OD IN OD EDD ED O 0D ab OD ED D ED D OD ED OD ED D OD OD OD a o OD OD OD OD DD ED ED OD ED OD D gt WYNN WNAWN AA WYNN WNWNW NW i t i i i i i i i i i gt i 004 Je ans S O OaE eTa OaE Ta DT 9 e a a a a ee eee i i i i i t i y i i ae i 0 LS LLIT __ m MIN SL Oe EE 60 r r i i I a y i i i i I i t i i i i CUCUR O G ee 9 4 6 I r v i i i Pa i a i i i i i x i i i m ete ata nad ate AA jn pl udo Te eee eee uii i is i y i i i DYNORUN 010 Max Power 201 62 ax Torque J DYNORUN 016 Max Power 217 71 Max Torque i C CY UE CG TE NN N Past 30 40 50 60 70 80 90 m i i i 60 ee EL Ly Ss es ey S ST EEN r YL E E g eee eet 110 120 130 140 CONTROL PANEL NTERFACE JPGRADE INSTALLATION GUIDE For Model 200i 250i Motorcycle Dynamometers Serial Number 202xxxx P N 98123113 01 2004 Dynojet Research Inc All Rights Reserved Control Panel Interface Upgrade Installation Guide For Model 200i and 250i Motorcycle Dynamometers Serial Number 202xxxx This manual is copyrighted by Dynojet Research Inc hereafter referred to as Dynojet and all rights are2. cable to P9 on the Control Panel Interface board route behind the wires coming from the bottom of the DIN rail and between the top and middle circuit breaker connect to J1 and J2 on the power supply Observe the locking tab on the white connector lt needs to lock into place with the locking tab on the power supply connector The locking tab on the 3 pin connector at the top of the power supply should point down The locking tab on the 6 pin connector should point up a W WN R aE Ei N yy as a a ihe l LU NN i e ie p Route through here 22 23 24 20 20 Connect the wires from the DIN power rail to the Control Panel Interface board Connect the brown wire from the bottom DIN terminal 1 to Tab 4 on the Control Panel Interface board Connect the blue wire from the bottom DIN terminal 4 to Tab 3 on the Control Panel Interface board Connect the brown wire from the bottom DIN terminal 2 to Tab 2 on the Control Panel Interface board Connect the blue wire from the bottom DIN terminal 5 to Tab 1 on the Control Panel Interface board Add cable ties as shown in the picture Cut the cable ties flush y Wr E n aim Wm Fa 27 Connect the brown wire from the top left connection of the lower 15A circuit breaker to Tab 8 on the Control Panel Interface board 28 Connect the blue wire from the bottom left connection of the lower 15A circuit breaker to Tab 7
3. shown Route here and cable tie WW SH nde y jaram T t home zz A ua Tues fr ei AY Sy F yw mc run Funud Y Si i jb gt La et leo W sarri aoe MU 46 Install the starter support bracket if necessary and connect the other end of the battery cables to the starter as shown lt gt 47 Route the cables to the cable support bracket as shown Cable tie as shown Make sure that all of the cables clear any moving components Only connect the positive terminal on the battery at this time If this is the first time you have installed a battery in this dyno refer to the dyno install guide for instructions on installing the battery hold down bracket Cable Support Bracket 21 48 If you purchased either the Wheel Clamp or the Motorized Carriage position the Motorized Carriage motor and or the Wheel Clamp close to the dyno and plug in their motor cables for testing 22 49 If you have an air brake and your dyno room is equipped with a safety switch on the door it is necessary to connect the safety switch to the Control Panel Interface board interlock input to apply the air brake whenever the dyno room door is open Connect the wires feeding the switch contacts to Interlock 1 A and Interlock 6 B connection points on the Control Panel Interface board The board is shipped with a jumper wire in this location Remove the jumper wire and replace with the wires to the door Safe
4. 68 Nd am ET d a Er ih 1 HS s jj du 4 WN R s gt w te ke e Connect here as a pE Un0304 D 4 ee 7 g a F474HC123N iJ A te Strip back and crimp to barrel connectors E7963 AJI JI Pe Pe Cd 14 38 Route the wire harness to the Control Panel assembly Depending on the location of the monitor upright the wire harness can be routed to either side of the dyno The P N 76951501 cable plugs in the Control Panel Interface board P4 This cable should be cable tied to the Power Distribution assembly to make sure the cable does not pull on the board Cable tie here 39 If you do not have a monitor tray and stand it will be necessary to purchase one from Dynojet to mount the Control Panel assembly The cable bundle to the Control Panel needs to be run out the cable access port by the monitor upright and a split bushing installed to protect the cable bundle Change the cable access plate for the one included in the kit with two holes Route the pendant cable through one split bushing and the cable to the Control Panel through the other 15 40 Early production Monitor Arms uprights and the monitor tray may not have the tapped holes for routing the Control Panel cables and mounting the Control Panel If your monitor stand arms do not have these holes it will be necessary for you to drill and tap the holes in the monitor upright and the arms to allow for attaching the Control Panel cable
5. bundle The cable bundle needs to be arranged across the monitor arms to allow for easy movement of the monitor stand without pulling on the cables The following diagram shows where to drill and tap the holes in the monitor upright Drill and tap 8 32 holes in the arms about four inches in from each end DRILL AND TAP 8 32 HOLES 3 PLACES 42 24 FAN MONITOR ARM SUPPORT DRILLING INSTRUCTIONS 16 41 The Control Panel needs to be disassembled so the cable to the Control Panel Interface can be connected Remove the screw and nuts shown and lift off the back side cover i o owwzzi T Remove nuts AWN NVA Remove this cover Remove these screws 17 42 Connect the Control Panel cable to the Control Panel Button board Cable tie the incoming cable as shown Cable tie here 18 44 Mount the Control Panel to the side of the monitor tray The cable lengths are set to allow installing the Control Panel on either side of the monitor tray for easy access Route the cable bundle along the arms with service loops to allow movement Make sure that during normal arm movement the cable does not get pinched 19 45 The battery cables and starter cables need to be connected next The 4 pin connector plugs into the back side of the Control Panel Interface board near the middle of the board to P2 The cable routes out of the back of the Power Distribution assembly as
6. der the center partition in the carriage module and in front of the vertical angle Make sure that the cable strain relief end with the conduit nut is at the end of the cable that will connect to the carriage The strain relief for both the Power Carriage and the Wheel Clamp must end up outside of the dyno Strain relief 34 If you already had the serial cable to the PC routed through the front panel put it in with one of the new cables and put the snap bushing around the cable Install the cable pass through cover with the two holes as shown 12 35 Re install the Stack Box support bracket with four 74 20 x 1 2 inch hex head bolts Re install the Stack Box and secure with four 7 20 x 72 inch hex head bolts Support Bracket 36 Connect the P N 76950403 Air Pump cable to P11 on the Control Panel Interface front side and route the cable out the rear hole on the Control Panel Interface to the back of the dyno P11 Air Pump supply Air pump cable amp AFR sensor cable 37 If you have an air brake install P N 76950110 cable into P7 in the Control Panel Interface board and run the short cable to the Breakout board as shown and connect Cable tie as shown and route the other end to the air brake solenoid Strip back the wires to the brake air solenoid and crimp into the barrel connections on the P N 76950110 Air Brake cable If you do not have an air brake then skip installing this cable ia ME AAW ep E 01
7. e can be ordered under the P N 21721200 Starter Brace M C3 The starter brace supports the back of the starter and provides a good ground connection ag Starter Brace If a battery is installed disconnect the negative terminal of the battery first then remove the positive terminal If any battery charger has been installed remove it If you do not have a battery it will be necessary to purchase one The high current draw for the Wheel Clamp and the Motorized Carriage is pulled from the car battery The Control Panel Interface has a built in battery charger to recharge the battery after each use Refer to your dyno install manual for the battery specifications Remove the side door covering the Power Distribution assembly If the Breakout board has connections to the brake output pins on TB3 loosen the barrier strip connections and remove these two wires Ge Nes LECITO ve art eer Disconnect the red battery cable from the starter and the black battery cable from the ground connection If your dyno does not have a starter brace as shown contact Dynojet Disconnect the starter solenoid wire All wires should be removed from the starter Disconnect the red and black wires that go into the black box on the back wall of the drum module Remove Red and Black wires at other end these wires Disconnect Yellow Black If the starter switch has been installed through one of the cable access holes remove the cable acces
8. es not start with 202 you will need a different kit for the upgrade Contact Dynojet with any questions This upgrade reguires that your dyno has the optional monitor tray and upright arm to allow the mounting of the Control Panel If your dyno does not already have this option you will need to order it Contact Dynojet for the information The part number and description for this option is P N 61329110 Monitor Tray and Upright Assembly This upgrade reguires the altering of wiring that carries 240 volts during normal dyno operation Failure to follow these instructions could result in exposure to hazardous voltages or damage to your dyno If you do not feel that you can follow these instructions properly and safely contact Dynojet Read all of these instructions before proceeding 1 Unplug all power cords going into the dyno This includes the main power cord and any additional cords Remove the carriage and the top cover on the carriage module Remove the covers over the retarder if present and the drum A Remove Retarder and Drum Cover Remove carriage and carriage module cover Note Dynojet recommends using a hardened 5 32 inch hex driver such as Snap On FA5E to remove the 1 4 inch screws A standard allen key may round off in the shallow screw head 2 Once the covers are off inspect your dyno to verify that the starter brace is installed If your dyno does not have a starter brace contact Dynojet The starter brac
9. on the Control Panel Interface board 29 Connect the brown wire from the top left connection of the upper 15A circuit breaker to Tab 6 on the Control Panel Interface board 30 Connect the blue wire from the lower left connection of the upper 15A circuit breaker to Tab 5 on the Control Panel Interface board Cable tie as shown Cut the cable ties flush 15A Breaker 10 31 Route the wiring to the optional Wheel Clamp and Power Carriage through the dyno You may find it easier to slide the Stack Box out of the side of the dyno and remove its support bracket for routing these cables Even if you have not purchased these optional accessories it is better to install the __ cables now for an easy upgrade in the future 32 Remove the front cable access plate Route the P N 76950307 Pod to Clamp cable from P5 on the Control Panel Interface board to the front cable hole on the dyno The cable passes under the center partition in the carriage module and in front of the vertical angle piece that forms the structure of the front of the dyno Make sure that the cable strain relief end with the conduit nut is at the end of the cable that will connect to the Wheel Clamp J tr P8 Power Control Panel P5 Wheel Carriage Interface Clamp connection board connection LS G 11 33 Route the P N 76950308 Pod to Carriage cable from P8 on the Control Panel Interface board to the front cable hole on the dyno The cable passes un
10. r light between the clamp buttons is on steady Press the right hand button first and hold then press the left hand button to release the clamp Refer to the user s manual for more details on the operation If you have an air brake and a safety switch on the dyno room door then open the dyno room door and verify that the air brakes do apply 26 RENS E ARCH DOMESTIC INTERNATIONAL Dynojet Research Inc Dynojet Research E M E A 2191 Mendenhall Drive Kromstraat 82 E North Las Vegas NV 89031 5345 AD Oss Tel 800 992 3525 The Netherlands 702 399 1423 Tel 31 0 412 403770 Fax 702 399 1431 Fax 31 0 412 403636 bikedynosales dynojet com international dynojet com autosales dynojet com www dynojet com
11. rc o 3 Oc J cp area ey ale cy cl BEL _ 5 ee ah lalo y 7 J Disconnect these wires from the 15A breakers 12 Remove the power supply bracket by cutting the cable ties and removing the two 8 32 screws from the front side of the Power Distribution assembly and save for later use ore gan ir IC COF G aS DI Ses LO oja Slole c l o Ss L Power Supply Bracket 13 Install the new power supply bracket which has the power supply installed with the two 8 32 screws from the front side of the Power Distribution assembly 14 Slide the Control Panel Interface board assembly into the rear of the Power Distribution assembly as shown Make sure to have the sheetmetal centered in the guides Fasten the assembly in place with two 8 32 x 3 8 inch screws in the back and two in the front 9 32x3 8 inch screws 9 32x3 8 inch screws VY 21 Route the fan breaker and Control Panel Interface wires You will need the wiring harness kit P N 76910601 Connect the 5 5 inch blue wire labeled H to the lower left lug of the 15A circuit breaker Connect the 8 inch blue wire labeled to the lower left lug of the upper 15A circuit breaker Connect the 6 inch brown wire labeled J to the top left lug of the bottom 15A circuit breaker Connect the 9 inch brown wire labeled K to the top left lug of the upper 15A circuit breaker 15A breaker Connect P N 76950602 Control Panel Interface power supply
12. 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 not be construed as a commitment by Dynojet Dynojet assumes no responsibility or liability for any error or inaccuracies that may appear in this manual Except as permitted by such license no part of this manual may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical recording or otherwise without the prior written permission of Dynojet The Dynojet logo is a trademark of Dynojet Research Inc Any trademarks trade names service marks or service names owned or registered by any other company and used in this guide are the property of their respective companies Dynojet Research Inc 2191 Mendenhall Drive North Las Vegas Nevada 89031 USA Printed in USA Part Number 98123113 Version 1 04 04 April 12 2004 Control Panel Interface upgrade for 200i 250i Dynos Serial Number 202xxxx These instructions are intended for use with installing the Control Panel Interface upgrade into Dynojet Research model 200i and 250i dynos with a serial number prefix of 202 Before proceeding check the serial number on the dyno front left corner to verify it is in this range The Dynojet part number for this upgrade is P N 78121003 If the serial number on your dyno do
13. s plate and feed the starter switch back into the dyno and coil up in the front inside of the dyno This will not be used with the new hardware lf your dyno has an air brake installed trace the wires from the air brake solenoid to the black box Cut the black solenoid wires at the point where the wires are extended to connect to the black box If your dyno has an external switch attached to your dyno room door disconnect it from the black box Remove the black box and the external starter switch 9 Disconnect the white 4 pin connector from the DIN barrier strip rail on the back side of the Power Distribution assembly to the lower fuse panel assembly Disconnect the Air Pump power connector on the front side of the Power Distribution assembly Ne alors SFarG IA ERS rar ww 1 o lol Ol o lololo ALOIS FN A Disconnect this connector 10 Remove the two screws that hold the fuse sub panel in place then remove the panel and set aside Disconnect air a T E i B amp 5 M S pump power cable p Remove screw Remove screw 11 Disconnect the blue and brown wires that connect from the DIN barrier strip on the back of the Power Distribution assembly from the 15A fan breakers Pull only on the quick lug connectors on the back of the breakers and take care to not pull on the wires Do not disturb any other connections a i i i Ap DIN barrier strip i P e A J m rOoro
14. ty switch This circuit must be closed for normal dyno runs ne Connect safety switch wires here in place of jumper UD Te Ar 4 Bung Er A iriri say Fire ae d jd O a0 E ni polao Poop aL dd onuog 90 Connect the negative terminal on the battery Plug the dyno in to the 240VAC single phase outlet 23 51 Turn on the main breaker on side of the dyno by moving it to the up position Make sure the E Stop button on the Control Panel is in the out position Twist if necessary to take it out of E Stop Turn on the switch on the front of the Stack box 52 If you have the optional High Speed Blowers verify they are plugged in to the sides of the dyno then press the fan control buttons on the Control Panel and verify that the fans turn on and off Press once to turn on and once to turn off 53 If you have the optional internal AFR pump installed turn on the AFR pump and verify its operation Press once to turn on and once to turn off Pr STA fe Ongs Nahon ere High Speed A i Blower Control 24 54 If you purchased the optional Wheel Clamp then press the left hand clamp button and verify that the Wheel Clamp closes Release the button Press the right hand clamp button first then press the left hand clamp button and hold both buttons to open the clamp Refer to the user s manual for more details of the operation 55 If you purchased the optional Motorized Carriage then press the carriage for
15. ward and back buttons and verify carriage movement Carriage Control Buttons 96 Turn off the dyno main breaker and unplug the dyno main power cord Install the Control Panel Interface drip cover with three 8 32 x 1 4 inch screws 25 of 58 59 60 61 62 63 64 65 Install the door stop chain with the two 8 32 nuts a cei Hm Se Put the carriage module cover back on Put the drum and retarder module covers back on Install the Carriage Plug the dyno power cable in and turn on the main breaker on the power distribution assembly Turn on the power switch on the front of the stack box Start up the WinPEP software and verify that the program still communicates to the dyno hardware Press the starter switch and hold to verify starter operation The speed indication in WinPEP should show drum speed Release the starter switch when the drum is up to top speed Press the red pendant button and verify that the dyno brakes or retarder do stop the dyno If you have the optional high speed blowers turn then on and off to verify operation If you have the optional AFR integral pump turn it on and off to verify its operation If you have the optional Motorized Carriage run it back and forth to verify its operation If you have the optional Wheel Clamp either load a bike or put a bike wheel into the clamp and press the left hand clamp button and hold until the clamp stops and the indicato
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