Powerware ST-2400S User's Manual
Contents
1. 14 Description The function of the Model 24005 Horsepower Computer is to provide the operator with a continuous digital readout of the RPM TORQUE POWER Horsepower or Kilowatts and percentage of Torque Rise TORQUE RISE when properly attached to a compatible dynamometer The RPM readout shows the operator the rotation speed rotations per minute of the power shaft of the dynamometer The RPM is measured by a pickup and gear combination that is mounted on the dynamometer and coupled to the power shaft of the dynamometer The TORQUE readout shows the operator the torque Foot Pounds or Newton Meters being produced by the prime mover being tested This is the same as the torque applied to the dynamometer by the power source motor engine drive wheels etc The torque is measured by a load cell that is mounted on the dynamometer The POWER readout shows the operator the amount of power being produced by the prime mover and applied to the dynamometer This is the same as the power being absorbed by the dynamometer It is computed by the Horsepower Computer using the RPM and Torque measurements using the formulae below HORSEPOWER RPM TORQUE foot pounds 5252 KILOWATTS RPM TORQUE Newton Meters 9549 The Torque Rise Torque Load meter shows the torque as a percentage compared to a reference torque value It is used to measure the lugging ability of an engine The Horsepower Computer ha2. Notes There are several methods which can be used to apply a calibration torque value to the 2400S horsepower computer 1 Dead Weight Test Fixture This method uses a Torque Test Bar dead weight test fixture and one or more calibration weights The torque test bar is attached to the torque arm of the dynamometer being careful to align the position of the mark on the torque test bar with corresponding mark on the torque arm of the dynamometer Then connect the test weight s onto the torque test bar at the indicated position usually the 4 foot 1 210 meter position The torque produced by the torque test bar must be accurately known the total weight of the test weights must be accurately known and the horizontal distance from the center line of the dyno to the indicated position must be accurately known If any of these three factors is not accurate then the resulting calibration will not be accurate and the result is in accurate torque and power readings from the 13 2 dynamometer The calibration torque produced is equal to the sum of the torque produced by the Torque Test Bar itself plus the torque produced by the test weight s which is equal to the total weight of the test weight s times the horizontal distance from the center line of the dyno to the position of the test weights For example assume the torque of the torque test bar itself is 17 Ft Lbs the total weight is 100 Lbs and the horizontal distance is 4 00
3. and need to be replaced Have the horsepower computer checked Printer doesn t work or works erratically Check the printer cable between the horsepower computer and the printer Be sure both ends are tight in their respective connectors Make sure the printer is plugged into a proper power source Perform a self test on the printer to be sure it is working Have the horsepower computer checked Horsepower or Kilowatt readings are low or not correct Check the torque calibration If Chassis dyno the tires may be slipping on the dynamometer rolls increase chain tension to obtain more over center action between tires and rolls Excess speed often causes power losses If farm tractor the PTO clutch may be slipping refer to the tractor repair manual Engine may not be performing properly Have the horsepower computer checked RPM readings are inaccurate Operate the unit in the CHECK function If the reading is not 4000 RPM have the horsepower computer repaired If the CHECK reading is 4000 RPM check the RPM pickup 16 and the RPM sensor gear Make sure that they are not loose and that the runout of the RPM gear is not excessive Check the RPM sensor connector to be sure that it is tight Check the cable from the RPM pickup to the horsepower computer Check the power supply to the horsepower computer Have the horsepower computer checked Torque readings are inaccurate Operate the un
4. measurement interval are displayed and the POWER and TORQUE RISE values are computed and displayed This process is repeated continuously while the unit is in operation Computer Function Switch The computer function switch is used to turn the system power ON OFF and to control the functional operation of the horsepower computer The function switch has four positions OFF ZERO CHECK and RUN In the OFF position the power to the horsepower computer and the load cell etc is turned OFF The power is turned ON in the other three positions of the computer function switch The horsepower computer has two user controllable self test modes ZERO and CHECK These can be used to test much of the horsepower computer s internal circuits for proper operation In the ZERO position internal test signals are fed into the RPM and TORQUE measurement circuits In the ZERO position of the function switch these signals should result in readings of zero on all four displays If the reading of any display remains substantially different from zero more than 1 or 2 counts when in the zero mode some type of malfunction of the unit is indicated The second user controllable test mode is the CHECK mode In this mode internal test signals are fed to the RPM and TORQUE measuring circuits to simulate normal operation of the unit at about 37 5 of full scale torque The actual readings shown
5. sure that the shunt resistor switch is set to the OFF position 2 TORQUE SPAN CALIBRATION cannot proceed This problem occurs when the torque reading is not sufficiently close to that expected from the CALIBRATION TORQUE value Check the following 2 1 Check to be sure that the CALIBRATION TORQUE is the value expected by the 24005 horsepower computer The expected calibration torque value is normally programmed into the 2400S by your dealer to match the calibration value and method you will be using to check and adjust the calibration of your unit You can check this by setting the calibration mode switch back to the OFF position while leaving the CALIBRATION TORQUE applied to the unit The TORQUE display will now read the approximate torque you have applied If this value is within about 10 of the CALIBRATION TORQUE that you have applied then it is likely that the value expected by the 24005 for the CALIBRATION TORQUE is different than the value you are using Check with your dealer or dyno service person to determine the calibration torque you should be using or use the 2400S calibration setup software to re program the 2400S to expect the calibration torque you are currently using 2 2 If the TORQUE display does not read within abut 10 the torque that you have applied a possible defective or damaged load cell is indicated and may need to be repaired or replaced Have your dealer or dyno service person assist you Torque Calibration
6. 2400S Horsepower Computer and its power supply directly to the manufacturer for repair RIES LABS INC 2275 RAVEN ROAD FARINA ILLINOIS 62838 PHONE 618 238 1400 E MAIL ADMIN RIESLABS COM Be sure to include a written description of the problems you are having with the unit the name and phone number of a person to call if we need to discuss your problem with you and return shipping instructions If the unit is out of warranty please also include a repair order and information about how you want the repaired unit returned to you Ries Labs Inc does not open commercial accounts charge accounts for repair work Ries Labs Inc accepts electronic payments credit card or otherwise using PayPal You can sign up for your PalPal account by visiting http www paypal com Sending your payment via PalPal is FREE EASY QUICK and SAFE Ries Labs Inc does not offer repair services for the other components of your dynamometer only 2000S and 2400S horsepower computers their power supply and other items manufactured by Ries Labs Inc 15 The following table is useful for you to determine that cause of any problems that you might be able to fix yourself Problem Possible causes and remedies No indication on displays Power LED is not lit Power LED comes ON and OFF erratically There is likely no power to the unit Check the power supply to be sure it is plugged in Check the fuse on the front panel of the uni
7. Ft The calibration torque value produced by this setup is equal to 417 Ft Lbs 4 00 Ft 100 Lbs 17 Ft Lbs Shunt Resistor The 24005 horsepower computer has an internal shunt resistor which can be used to check the torque span calibration The 2400S can optionally be equipped with a precision shunt resistor which can be used to perform a NIST National Institute of Standards and Time traceable torque calibration The torque introduced by the shunt resistor depends on the resistance value of the shunt resistor as well as the properties of the load cell For the NIST traceable torque calibration to be accurate both the shunt resistor value and the load cell must have NIST traceable calibrations which should be checked periodically A 2400S horsepower computer without the precision shunt resistor is equipped with a 1 precision 45 3 K Ohm shunt resistor not adequate for NIST traceable calibrations which can be used for a quick and fairly accurate check on the torque calibration and the torque sensor circuits of the 2400S After performing the calibration of the unit using the dead weight test fixture calibration method remove the dead weight test fixture and set the Shunt Resistor Switch to ON The shunt resistor will produce a torque reading that is roughly 2 3 of the full scale torque of the unit i e about 3300 Ft Lbs on a 5000 Ft Lbs full scale 2400S More precise values are shown in the table below The reading should
8. Model ST 24008 Horsepower Computer System User Manual In the USA Star Test Dynamometer Inc 712 Thistlewood Court Normal IL 61761 Phone 309 826 1484 In Mexico Central amp South America Negociaciones Fuentes S A DE CV Av La Luz 4549 Col Cortijo del Rio Monterey N L Mexico 64890 Phone 81 8349 1416 Manufacturered by Ries Labs Inc 2275 Raven Road Farina IL 62838 Phone 618 238 1400 eMail admin O rieslabs com Table of Contents Description 3 Installation 3 Power Supply 4 Operation of the unit from 220 260 VAC 50 60 Hz 4 Operation nana 4 Computer Function Switch 5 System Power LED 6 Torque Set Switch 6 Printer Computer Interface 7 Computer Software for the 2400S horsepower computer 8 Calibration Software for the 2400S 8 Dyno32 Software 8 DynoGraph Software 9 Calibration namas 9 Calibration Procedures 10 Calibration Procedure Notes 11 Torque Calibration Notes 12 In case of Difficulty
9. and recording saving your dyno measurements Data printing and recording can be controlled from the 2400S horsepower computer and or using the personal computer s keyboard or mouse Recorded data can be printed on the PC s printer and or can be easily imported into Microsoft Excel or other analysis programs for further operations such as graphing etc Dyno32 is compatible with most Windows based computer systems including Win95 Win98 WinMe Win2000 and WinXP Data Recording and Graphing Software for the 24005 DynoGraph software combines most of the features of Dyno32 with a built in storage printing and graphing capability to streamline the computerization of your dynamometer system The DynoGraph software integrates the important Dyno data collection display storage and printing functions into one easy to use program that helps you to maintain complete records of the measurements you take using your dynamometer system It also creates professional reports of your measurements including graphs of the important parameters such as Torque vs RPM Power vs RPM etc Up to 100 measurement points can be included in one DynoGraph document There is provision to include your company info name address etc along with the important information about the device being measured customer info machine info date and time of the measurements etc DynoGraph software is compatible with most Windows compute
10. are used when a printer is attached to the horsepower computer Software for the 2400S horsepower computer There are several software programs for the 24005 horsepower computer These include Calibration Setup Software for the 2400S HpcOptionsW32 is software for the 2400S horsepower computer which is used to prepare the 2400S for calibration This is done so that the 24005 will know the details of the method you will use to check the torque calibration of the unit This factory setup is normally performed on the 2400S by your dealer prior to delivery of the 2400S to you so won t have to If you change your calibration method or calibration tools this program can be used to inform the 24005 of the changes so that subsequent torque calibrations will be accurate If you use a NIST traceable calibration method this program must be used periodically each time the load cell and the 20005 horsepower computer are sent in to have their NIST calibrations checked to inform the 2400S of any changes to the load cell calibration or the internal 24005 traceable shunt resistor calibration HpcOptionsW32 is compatible with most Windows based computer systems including Win95 Win98 WinMe Win2000 and WinXP Data Recording Software for the 2400S Dyno32 The Dyno32 software makes it easy to reproduce the 2400S horsepower displays on the screen of the personal computer for remote viewing etc There are also features for printing
11. ation Be sure to return the shunt resistor switch to the OFF position if you used it during the torque span calibration Replace the calibration access cover panel The unit has now been accurately calibrated Calibration Procedure Notes 1 ZERO CALIBRATION cannot proceed This problem occurs when the ZERO OFFSET is excessive too large for the zero offset correction facility of the 2400S to correct Check the following 1 1 Make sure that the load cell is properly connected to the 2400S horsepower computer Inspect the cable for damage especially at the load cell end and the connector end Make sure the connector is securely fastened to the 2400S torque sensor connector 1 2 Make sure that the load has been completely removed from the load cell Rock the drive shaft of the dynamometer CW and CCW slightly applying a small 12 positive and negative torque to the unit and verify that the torque reading returns closely to the same value A failure here indicates a likely problem with the dynamometer Have the dynamometer checked by your dealer or dyno service person 1 3 Make sure that the load has been completely removed from the load cell Disconnect the load cell from the torque arm of the dynamometer by removing the coupling fastener If this does not correct the excessive zero offset a likely defective or damaged load cell is indicated You should have the load cell checked by your dealer or dyno service person 1 4 Make
12. be within 2 or 3 of the appropriate value from the table below The tolerance derives from the 1 tolerance of the 45 3 K Ohm shunt resistor plus the tolerance of the load cell likely 1 or 2 If the reading is not this close you should double check the calibration and your procedure as a likely problem is indicated If the reading is within the above limits record its value It can be used later for a quick check on your unit s calibration as it should be stable over time and temperature to within 0 25 or better Full scale Torque Ft Lbs 45 3 K Ohm Shunt Resistor Torque 100 64 14 200 128 3 500 320 7 1 000 641 4 2 000 1283 5 000 3207 10 000 6414 14 In Case of Difficulty The following 1s a troubleshooting guide that will help you to resolve any problems that may arise The Model 2400S Horsepower Computer contains no user serviceable parts If it needs to be repaired you may return the unit to your dealer who can also assist you with other repair problems such as problem diagnosis replacement of the load cell RPM pickup other dynamometer repairs etc or directly to In the USA STAR TEST DYNAMOMETER INC 712 THISTLEWOOD COURT NORMAL ILLINOIS 61761 PHONE 309 826 1484 In Mexico Central amp South America Negociaciones Fuentes S A DE CV Av La Luz 4549 Col Cortijo del Rio Monterey N L Mexico 64890 Phone 81 8349 1416 You may also return the
13. harged If the battery voltage is low the POWER LED of the unit will flash on and off about once every second indicating that the power supply voltage is inadequate to power the unit properly NOTE WHEN OPERATING THE UNIT FROM A BATTERY OR POWER SUPPLY THE POLARITY WIRING MUST BE CORRECT OR THE UNIT WILL NOT OPERATE WIRING A BATTERY OR POWER SUPPLY TO THE UNIT WITH IMPROPER POLARITY MAY RESULT IN DAMAGE TO THE UNIT Operation of the unit from a 110 to 250 VAC 50 to 60 Hz power source A special universal input power supply is available as an option which will allow the unit to be operated from a wide range of AC power sources both domestic and international This power supply has a detachable power cable which may be easily replaced with a power cable which matches the local power system This power supply is also very useful when operating the unit from power sources which may be lower than standard and or slightly erratic This power supply will result in proper operation when the AC power source is a low as about 90 Volts AC Operation The horsepower computer normally operates with a two second measurement cycle It can optionally be factory programmed for a one second measurement cycle During the measurement cycle the RPM of the dynamometer shaft is measured along with the torque sensed by the dynamometer load cell At the end of each measurement cycle the RPM and TORQUE values averaged over the
14. isplay indicates the TORQUE and should read near zero If the torque indication is excessive plus or minus the POWER display will read EEEE which indicates that the zero offset of the load cell is excessive and that the ZERO calibration cannot proceed see calibration notes below Otherwise press and release the ENTER push button switch to perform the zero calibration At this point the TORQUE display should indicate zero and the zero calibration procedure has been completed Set the TORQUE SPAN calibration Apply the CALIBRATION TORQUE see calibration torque notes below to the unit and set the calibration mode switch to the SPAN position At this point the RPM display should indicate 2222 the POWER display should indicate 0000 and the TORQUE display should indicate a value approximately equal to the CALIBRATION TORQUE If the deviation between the torque reading and the calibration torque is excessive the POWER display will read EEEE indicating that the TORQUE SPAN calibration cannot proceed see calibration notes below Otherwise press and release the ENTER push button switch to perform the TORQUE SPAN calibration Now the TORQUE display should indicate the value of the CALIBRATION TORQUE and the torque span calibration has been completed 3 Resume normal operation Set the calibration mode switch back to the OFF center position This turns off calibration mode and restores the unit to normal oper
15. it using the ZERO and CHECK functions If the readings do not agree with the tables above unit needs to be repaired Check the load cell mounting to be sure that it is not loose Check the dynamometer to be sure that it is not in a bind Check the torque calibration of the horsepower computer Check the power supply to the horsepower computer Have the horsepower computer checked Residual Torque readings are high when the dynamometer is stopped Pressure or force on the dynamometer absorption unit cradle may be causing the residual readings Remove the load cell from the torque arm of the dyno to see if this removes the excessive residual torque reading Manually rock the torque arm of the dyno It should move freely and easily a minimum of 0 5 inches 12 7 mm up and down The load cell must be in a free floating position when not under load Re adjust the torque cable and connectors if necessary Check the calibration zero of the horsepower computer The load cell may be damaged and need to be replaced Have the horsepower computer checked 17
16. n Procedure The Model 2400S horsepower computer uses quick and easy push button calibration methods and can be calibrated using a variety of methods Be sure to use the one that is correct for your dynamometer system and the calibration tools that are available to you Prior to attempting calibration first verify that the 2400S is operating correctly using the ZERO and CHECK positions of the computer function switch If the 2400S does not pass these checks there is a problem with the unit and it should be repaired before any attempt is made to calibrate the unit Calibration of the Model 2400S is a simple two step process 1 Set the ZERO calibration The dynamometer should not be running and should be disconnected from the engine tractor motor etc The RPM reading should be exactly zero and the TORQUE reading should be fairly close to zero especially if the unit has previously been calibrated to the load cell If necessary disconnect the load cell from 11 2 the torque arm of the dynamometer to insure that there is no force being applied to the load cell which would result in an inaccurate zero calibration Remove the calibration access cover panel and set the calibration mode switch to the ZERO position Also be sure that the shunt resistor switch is set to the OFF position At this time note that the RPM display of the unit should indicate 1111 and the POWER display should indicate 0000 The TORQUE d
17. on the displays of the unit depend on internal factory set optional settings principally the full scale torque value which corresponds to the size of the load cell being used with the unit The RPM display should read about 4000 RPM 1 or 2 counts on all units The Torque display should read about 37 5 of the load cell rating Refer to the tables below for the proper readings of the Torque and Power displays for your unit The Power reading should agree with the power you compute from the actual RPM and TORQUE readings within 1 or 2 counts using the above formulae for the horsepower or kilowatts Load Cell Rating Ft Lbs Torque Ft Lbs Power HP 100 37 50 28 56 200 75 00 57 10 500 187 5 142 8 1 000 375 0 285 6 2 000 750 0 571 0 5 000 1875 1428 10 000 3750 2856 CHECK readings using Ft Lbs amp Horsepower Load Cell Rating Ft Lbs Torque N M Power KW 100 135 5 N M 50 84 21 30 200 271 N M 101 6 42 60 500 677 5 N M 254 2 106 5 1 000 1355 N M 508 4 213 0 2 000 2710 N M 1016 426 0 5 000 6775 N M 2542 1065 10 000 13550 N M 5084 2130 CHECK readings using Newton Meters and Kilowatts The ZERO and CHECK positions of the computer function switch provide quick checks to determine whether the horsepower computer 1s operating properly Proper readings indicate that the major portion of the computer is working c
18. orque Rise reading To set the torque reference proceed as follows Run the engine at it rated speed loaded at rated power or torque output This represents the 100 torque output condition for the engine With the engine running at its rated speed and load press the Torque Set switch momentarily The reference torque value is now set to the rated engine 100 torque and the Torque Rise display should now read 100 0 100 All future measurements will now display the torque on the Torque Rise meter as the percentage of the reference torque value For example if the torque rise meter reads 75 0 this means that the current actual torque is 75 0 of the reference or rated torque Printer Computer Interface The Model 2400S horsepower computer is equipped with a RS 232 C compatible serial interface This interface can be used to operate a small serial printer to make hard copy printouts of test results Alternately this interface can be used to connect the horsepower computer to a Windows type personal computer for calibration setup and so that test results can be saved printed using the PC s printer etc The horsepower computer senses which type of device is connected to the serial interface printer or computer and operates the interface accordingly It is NOT possible to connect a serial printer and a personal computer to the horsepower computer at the same time The print rate controls Report Rate and or Man
19. orrectly Note that the Load Cell sensor circuits and the RPM pickup circuits are NOT tested in the ZERO and CHECK modes With the dynamometer at rest and the computer function switch set to RUN the speed and power displays should show zero 0 The torque display may show some small value typically less than 3 Ft Lbs 4 N M The torque rise display reading depends on whether or not the reference torque has been set and if so to what value so the reading of this display should be ignored at this time See also the section below System Power LED The system power LED Light Emitting Diode is located on the front panel of the unit just to the left of the computer function switch This green LED indicates that power is applied to the unit and the unit is turned ON If this light is slowly flashing ON and OFF this indicates that the power supplied to the unit is inadequate voltage is too low or too un steady and that the readings produced by the unit are likely in accurate as a result Torque Set Switch The reference torque set switch is located on the front panel of the unit just to the right of the computer function switch Your unit may as an option be equipped with a remote torque set switch This switch is located remotely from the horsepower computer but functions the same as the torque set switch The torque set switch is used to set the torque reference which is used to compute the T
20. r systems including Win95 Win98 WinMe Win2000 and WinXP Calibration The calibration of the Model 2400S horsepower computer should be checked at least once per year or sooner if any doubts or questions arise as to whether the readings produced by the unit are within the accuracy specifications of the unit The Model 2400S should also have its calibration checked if any of the following events occur 1 The instrument has been dropped or otherwise mistreated 10 2 The instrument has been moved re installed from one dynamometer to another 3 The load cell of the dynamometer has been replaced overloaded dropped or otherwise mistreated 4 The power supply to the unit has been repaired or replaced 5 Prior to any measurements that require especially high accuracy 6 The instrument has been repaired exchanged or replaced IMPORTANT NOTE The Model 2400S is a delicate instrument and should be treated accordingly It should not be allowed to get wet be exposed to excessive temperatures dropped or subjected to excessive shock or vibration It should only be used with an approved power supply It contains no user serviceable parts and no attempt should be made to repair or modify the unit If the unit is in need of repair it should be returned to the dealer or directly to Ries Labs Inc for repair When it becomes necessary to check the calibration of the unit follow the procedure below Calibratio
21. s a RS 232 compatible serial interface which can be connected EITHER to compatible serial printer OR to an external computer system When connected to a printer the system may be used to provide a hard copy printout of measurement results When connected to an external computer the system may be used for printing storing graphing etc the measurements performed by the dynamometer system including the dynamometer horsepower computer and external computer Installation The Model 2400S horsepower computer should be installed in a location where the unit is not exposed to wetness extremely high temperatures prolonged direct sunlight or other environmental factors that would shorten the life expectancy of the unit Power Supply The Model 24005 horsepower computer is normally operated from 110 to 125 VAC 60 Hz using the outlet mounted power supply that is supplied with the unit The power consumption of the computer is very low and the unit has a very high tolerance for power supply variations so nearly any standard 115 VAC utility power outlet should power the unit adequately See below information on a special optional wide range power supply which will power the unit properly when the line voltage is either very low or very high The computer may also be operated from a source of 12 to 18 Volts DC such as a small DC power supply or 12 Volt storage battery If a storage battery is used be sure that it is properly c
22. t Replace ONLY with the correct 2 amp fuse DO NOT use a slow blow or higher value fuse as this can result in severe damage to the unit Check to be sure the power supply is plugged in securely Try another outlet Make sure the power connector is fastened tightly to the front of the unit Power LED flashes ON and OFF regularly Power supply voltage 1s too low Check the power supply or battery The supply voltage must be at least 12 Volts with low power supply ripple for the unit to operate properly Unit blows fuses Power supply voltage may be too high The power supply voltage should be less than 20 Volts DC or damage to the unit will occur Send the 2400S for repairs if the unit blows fuses when the power supply voltage is less than 20 Volts DC Use only the correct size amp and type fast blow fuse or severe damage to the unit will likely occur RPM display reads zero all the time or is erratic Check the RPM pickup on the dynamometer Be sure that it 1s not loose Check the wiring from the RPM pickup to the horsepower computer Make sure the RPM sensor connector 1s tight Have the horsepower computer checked Torque display reads EEE or some other value all the time or is erratic Check the load cell on the dynamometer Be sure that it is not loose Check the cable between the load cell and the horsepower computer Make sure the Torque Sensor connector is tight The load cell may be bad
23. ual Print are used to select which measurements are printed or sent to the personal computer These controls are located on the front panel of the unit above the Computer Function switch Your unit may optionally be equipped with a remote manual print switch which functions the same as the manual print switch but which may be located remotely from the horsepower computer The Report Rate switch is used to control the rate at which the unit prints test results Various automatic rates are available from one report every 10 seconds up to one report every thirty minutes There is also a manual position on this switch In the manual position the unit only makes a printout when the manual print switch is pressed momentarily The manual print switch can be used at all settings of the report rate switch It is NOT necessary to set the report rate switch to manual in order to use the manual print switch or the optional remote print switch to trigger a print report When the horsepower computer is used with a companion personal computer a standard 9 pin RS 232 C extension cable is used to connect the two computers together This extension cable is normally 10 feet long but can be up to 50 feet long and even longer if special long range RS 232 C extension cables are used The print rate and manual print switches serve to notify the personal computer which measurements are to be saved or printed in much the same way they
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