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MAHA LPS 3000 Operating Instructions Manual Download Page 21

 

BA052301-en 

21

 

 

 

2.5

 

Description of the Interface Box 

 

The Interface Box records engine RPM, environmental data, OBD data, temperature, pressure 
and analog signals. This is done via modules. A maximum of 4 modules can be installed in the 
interface box. 
Additional modules can be installed in a second interface box which is connected parallel and, if 
desired, adapted to customer requirements. 

 

 

As standard equipment, the interface box 1 has an RPM and an environmental module. 

 

Dimensions (H x W x L) .......................................................................... approx. 120 x 170 x 160 mm 
Weight ............................................................................................................................. approx. 1.0 kg 

 

 

 

 

 

 

 

 
 
 

DRZ

PTH

OBD

P2T2

 

 

 

 

 

A 

B 

D 

C 

H 

E 

F 

I 

M 

L 

K 

J 

G 

Summary of Contents for LPS 3000

Page 1: ...LPS 3000 Dynamometer for Passenger Cars Commercial Vehicles and Motorcycles Original Operating Instructions BA052301 en ...

Page 2: ...he event of the grant of a patent utility model or design The contents of this edition have been checked with great care However errors cannot be fully excluded Subject to technical change without notice Manufacturer MAHA Maschinenbau Haldenwang GmbH Co KG Hoyen 20 87490 Haldenwang Germany Phone 49 8374 585 0 Fax 49 8374 585 590 Mail maha maha de Web www maha de Service MAHA SERVICE CENTER Maybach...

Page 3: ...Switch 19 2 4 Remote Control 19 2 5 Description of the Interface Box 21 2 5 1 RPM Module Standard 23 2 5 2 Environmental Module Standard 25 2 5 3 OBD Module Optional 26 2 5 4 Pressure Temperature Module Optional 26 2 5 5 Analog Input Module Optional 27 2 6 Analog Output Card Optional 27 2 7 Lambda Broadband Sensor 28 2 8 Measurement Programs 33 2 9 Calculation Basis 34 2 9 1 Road Load 34 2 9 2 Tor...

Page 4: ...the Dyno 53 7 2 Drive onto Dyno 53 7 3 Set Wheelbase only 4WD Dynos 53 7 4 Fix Vehicle 54 7 4 1 Fix Car Truck 55 7 4 2 Fix Motorcycle 56 7 5 Attach Weight Simulator Optional 57 7 6 Connect the RPM Sensor 57 7 7 Connect Oil Temperature Probe 57 7 8 Attach Exhaust Suction System 58 7 9 Position Cooling Air Fan 58 7 10 Bring the Vehicle up to Operating Temperature 58 7 11 Vehicle Ready for Testing 58...

Page 5: ...ance Curves 91 10 1 3 Time Diagram 95 10 1 4 Vehicle Data 96 10 1 5 Load simulation profile 97 10 1 6 Driving Cycle Data 99 10 2 Vehicle Data 100 10 3 RPM Setting 101 10 3 1 Driving Trial 102 10 4 Special Settings 103 10 5 Select Dyno Type 104 10 6 Units 104 10 7 Language 105 10 8 Device Interfaces 105 10 8 1 OBD Settings Optional 106 11 Diagnosis Service 107 11 1 Dyno Status 107 11 2 Driver s Aid...

Page 6: ...12 4 Troubleshooting 113 12 5 Maintenance by the Operator 113 12 5 1 Roller Set 113 12 5 2 Eddy Current Brake 113 12 5 3 Cardan Shaft 113 12 5 4 Encased Bearings 113 12 6 Spare Parts 115 13 Dismantling 115 14 Disposal 115 15 Contents of the Declaration of Conformity 115 ...

Page 7: ...ified 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 out side or in...

Page 8: ...ning stickers Danger of carbon monoxide poisoning by poisonous vehicle exhaust The test stand may on ly be operated if the room in which the test stand is installed has sufficient exhaust suction and ventilation including the appropriate warning system Avoid steering movement during the vehicle test These cause certain forces to act on the vehicle fixing in particular on the attachment units on th...

Page 9: ...omponents with storage charge Af ter switching off all voltages life threatening voltage can still be present for at least 5 minutes Check for discharge 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...

Page 10: ...anger Zone During dynamometer operation no persons are allowed to stay in the danger zone See illustration for minimum distance A Motorcycle B Car 1 Axle C Car 4WD D Truck w o Idle Roller E Truck with Idle Roller A B C E D ...

Page 11: ...motorcycle tests Tire manufacturers forbid the further use of tires on the road that have been driven on a roll er set for performance testing Undetectable damage to the tire may have occurred This ap plies to both apex and double rollers 1 11 Safety Information about the Anchoring Device LPS 3000 Truck The additional anchoring device is a supplement to the hydraulic load device on the LPS 3000 Tr...

Page 12: ...e is non symmetric unbalanced load usage in tightening process Shall not be used in acid or lye Usage forbidden when there is mechanical damage deformation or damage to safety fea tures Do not load the hooks at the tip Inspection and maintenance only by trained technicians after one year and every 3 years a special chain check for fracture detection 1 12 Safety Features The safety features must be...

Page 13: ... and bandages are kept Seek first aid Provide first aid stop bleeding immobilise injured limbs report the accident and seal off the accident site Immediately report any accident to your supervisor Make sure a record is kept of every oc casion first aid is provided e g in an accident book Remain calm and answer any questions that may arise ...

Page 14: ...g modules can be connected RPM module Acquisition of engine RPM via Trigger tongs petrol engine Piezo clamp sensor diesel engine TDC sensor manufacturer specific upon request Diagnostic plug manufacturer specific upon request Oil temperature probe up to max 180 C and much more Environmental module Acquisition of ambient temperature intake air temperature air pressure and humidity fuel temperature ...

Page 15: ... Technical Data Specifications are subject to change without notice 2 2 1 Communication Desk Communication desk Version A 670 x 1400 x 800 mm Communication desk Version B available from March 2011 350 x 1230 x 860 mm A B ...

Page 16: ... 3 R100 2 Car Van 2 eddy current brakes 4 R100 1 4 wheel drive movable roller set Car Van 1 eddy current brakes 5 R100 2 4 wheel drive movable roller set Car Van 2 eddy current brakes 6 R200 1 Car Van Truck closed version 7 R200 2 Car Van Truck divided version 1 2 3 4 ...

Page 17: ...BA052301 en 17 5 6 7 ...

Page 18: ...e separation 560 mm 540 mm 540 mm 565 mm 565 mm Lifting Bar Pneumatic min 5 bar max 8 bar min 5 bar max 8 bar min 5 bar max 8 bar Hydraulic up to max 40 bar up to max 40 bar Electrical Data Eddy current brake 260 kW 260 kW 2 x 260 kW 2 x 200 kW 2 x 200 kW 2 x 200 kW Power supply 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz 400 V 50 Hz 400 V 50 Hz Fuse 16 A slow 16 A slow 35 A slow 35 A slow 35 A slow 63 A ...

Page 19: ...ons can be opened The key assign ments vary in the different menus Four boxes with diverse functions are located on the lower screen edge in these menus These options are selected with the function keys F5 to F8 on the remote control If the button bar has further levels these can be displayed using the cursor keys F5 to F8 10 Use this key to activate the load simulator It can then be operated with...

Page 20: ...about 12 to 14 hours During the re charging procedure the red LED on the re charging box will light up and Battery recharging appears on the display of the remote control To switch on the remote control press the ON key The remote control has an automatic switch off Timeout which can be variably set The remote control switches off when no key has been pressed during this time The letters on the re...

Page 21: ...aximum of 4 modules can be installed in the interface box Additional modules can be installed in a second interface box which is connected parallel and if desired adapted to customer requirements As standard equipment the interface box 1 has an RPM and an environmental module Dimensions H x W x L approx 120 x 170 x 160 mm Weight approx 1 0 kg DRZ PTH OBD P2T2 A B D C H E F I M L K J G ...

Page 22: ...tongs PTH E Fuel temperature F Intake air temperature G Atmospheric pressure H Humidity sensor OBD Option I OBD P2T2 Option J Pressure 1 K Pressure 2 L Temperature 1 M Temperature 2 Display the Interface Box Assignment 1 The assignment of the interface box appears using the keys SHIFT F1 2 Use CONTINUE or RETURN to exit this screen ...

Page 23: ...ox Piezo Clamp Piezo clamp is only used with diesel engines The piezo clamp consists of a piezo element which recognizes pressure differences at the lead in and then converts them into electric pulses It is important that the piezo clamp which is used is suitable for only one diameter of the fuel line and should only be placed at a straight section of the line at any cylinder attach ground clamp o...

Page 24: ...er drive belt or cardan shaft the RPM can be picked up free of any interference no vibration influence etc Notes on adjusting the engine rpm via the light barrier When making adjustments in the lower rpm range drive shaft rpm 800 we recommend using two reflectors in order to double the number of impulses generated When doing so please remember the following The reflectors must be systematically pl...

Page 25: ...emperature probe for car and truck with variable length 100 to 1500 mm with plug and 6 m supply line Attachment Position C on the interface box 2 5 2 Environmental Module Standard The environomental module is used to record the environmental data Plug in card CAN PTH Fuel temperature Optional Intake air temperature Ambient temperature Air pressure Humidity Fuel Temperature Optional The fuel temper...

Page 26: ...d for recording the OBD data Plug in card CAN OBD Module This OBD data is different depending on the vehicle manufacturer Attachment Position OBD on the interface box see section Description of the Interface Box 2 5 4 Pressure Temperature Module Optional The pressure temperature module is used to record 2 temperatures and 2 pressures Plug in card CAN P2T2 Pressure 1 2 Pressure 1 2 is user specific...

Page 27: ... V or from 20 mA to 20 mA can be recorded 2 6 Analog Output Card Optional The analog output card Plug in card LON OUTA is used for further processing of measured values as analog signals for an external device e g analog display digital display There are 4 analog outputs available from 10 V to 10 V The plug in card LON OUTA is connected in the communication desk ...

Page 28: ... battery terminal B Junction and transfer box C Power supply 12 V from vehicle signal D KMS UEGO CAN controller set E Earth for Lambda heating F Lambda sensor KMS UEGO plug connection G MAHA CAN AIN 4 H Interface box terminating resistor and vehicle earth I Signal line red earth vehicle J Broadband sensor Bosch LSU 4 ...

Page 29: ... 29 Contents of the CD AIN4 voltage curves Additional option Lambda dial Lambda value can be displayed instead of engine rpm File with Load simulation profile must be imported to Load simulation profiles database ...

Page 30: ...1 en Files voltage curves preinstalled for Analog IN card Lambda and AFR and display ini Display is enabled by removing all semicolons NOTE Naming the dial is not possible via AIN4 in the display ini with Lambda ...

Page 31: ... or the MAHA adaptor cable connector provided Connect the KMS UEGO CAN controller signal line and power supply B to the MAHA junction and transfer box 4 Plug the cable harness with the 12 pin connector A into the KMS UEGO CAN controller B 5 Attach the red and black signal lines to the MAHA junction and transfer box and connect to the interface box using the optional CAN AIN4 PCB 6 Plug the 12 V po...

Page 32: ...ed in order to prevent interference with the Lambda signal Procedure 1 Replace the existing connector on the reverse of the interface box A with the cable and connector supplied B 2 Connect the earth cable terminal C to the vehicle chassis earth For a description of how to use the Lambda tester please refer to the manufacturer s user manual supplied 6 7 ...

Page 33: ...sure Engine Power Use this menu item to determine the vehicle s engine power continuous and discrete measurement Extrapolation of the Engine Power Optional Extrapolation of the engine power based on DIN 70020 EWG 80 1269 ISO 1585 JIS D 1001 SAE J 1349 Flexibility Test The engine flexibility can be checked using this menu item Once the flexibility test has been called up the vehicle weight and road...

Page 34: ...the vehicle front and air resistance coefficient cw v v v A c 0 5 P 2 0 Front W Air with e g Air density rho 1 1 kg m3 air resistance coefficient cW 0 38 Front surface VEH width x Height AFront 1 7 m 1 47m 2 5 m2 Driving speed v 90 km h 25 m s Head wind speed v0 0 m s results Pair 0 5 1 1 0 38 2 5 252 25 8 164 kW at 90 km h Flex power P Flex kW Flex power or resistance is defined as the power loss...

Page 35: ... fraction of the total Road Load it is entered as a fixed standard value on our dynamometers for steel belted radial tires approx 2 5 kW for winter tires approx 3 75 kW Setting of the vehicle mass the aerodynamic drag power and the rolling resistance power is absolutely necessary for Road Load simulation and stop watch tests in order to simulate the vehicle under the correct Road Loads Mass m Vehi...

Page 36: ...1585 6 0 1 2 298 K T mbar p 990 Ka SAE J1349 6 0 1 2 298 K T mbar p 990 Ka JIS D1001 6 0 1 2 298 K T mbar p 990 Ka with Ka correction factor p Atmospheric pressure at the dyno in mbar 1 mbar 0 001 bar T Air temperature at the dyno in Kelvin 0 C 273 K e g ambient air pressure p 936 mbar ambient temperature T 17 C 290K based on DIN 70200 the result is Ka 1 07671 ...

Page 37: ...gines Naturally Aspirated or Supercharged DIN 70020 5 0 293 K T mbar p 1013 Ka EEC 80 1269 fm 7 0 298 K T mbar p 990 Ka ISO 1585 fm 7 0 298 K T mbar p 990 Ka SAE J1349 fm 7 0 298 K T mbar p 990 Ka JIS D1001 fm 7 0 298 K T mbar p 990 Ka with fm Engine factor Standard 0 3 ...

Page 38: ...0 7 298 K T mbar p 990 Ka SAE J1349 fm 5 1 0 7 298 K T mbar p 990 Ka JIS D1001 fm 5 1 0 7 298 K T mbar p 990 Ka with fm Engine factor Standard 0 3 The extrapolation formula for Turbodiesel engines in the ISO 1585 only applies to air cooled charge air coolers The following equation applies to water cooled charge air coolers ISO 1585 water cooled fm 7 0 0 7 298 K T mbar p 990 Ka ...

Page 39: ...9 SAE J1349 and JIS D1001 65 40 r q 14 1 036 0 r q fm 40 r q 3 0 fm 65 r q 2 1 fm Pressure behavior of the supercharging E L P P r Specific fuel consumption based on SAE J1349 4 Takt Motoren n D F q 120000 2 Takt Motoren n D F q 60000 with fm Engine factor r Pressure behavior of the supercharging q Specific fuel consumption based on SAE J1349 pL Absolute boost pressure pE Absolute pressure in fron...

Page 40: ...2 Acceleration with coast down trial 2 FRot Force of the rotating mass Frot 1 2 2 1 1 2 a a a F a F mRot 1 1 a F FRot With the continuous power measurement an additional error is made during high acceleration if the set mass deviates from the actual mass The measurement power is projected from the determined mass The result is now the same as if the trial had been driven with this mass If an amoun...

Page 41: ...Traction total RPM Regulation The variable control of the eddy current brake is divided between the front and rear axle This happens again as a function of the support roller RPM y n n n y h St v St v St v y n n n y h St v St h St h with yv Variable front yh Variable rear nSt v Support roller RPM front nSt h Support roller RPM rear y Variable total Road Load Simulation The traction target value wh...

Page 42: ...e exhaust Heat volume in the test room P1 P2 P3 P4 P1 Is converted to heat by the air cooled eddy current brake and normally emitted into the test room P5 This energy is suctioned out with the exhaust suction system and does not contribute to heat volume in the test room Generally speaking the engine power to be measured is known If this is specified with 1 the following factors are given P1 Engin...

Page 43: ...oints must be considered for the ventilation concept Engine power Frequency of measurements Room temperature increase allowed by operator Room size Energy storage volume of the walls MAHA Experiences Cooling air is of special importance as modern engine management systems are equipped with control systems which reduce the engine power when intake temperatures are too high The full engine power is ...

Page 44: ...ntion to temperature consistency The respective exhaust suction system must be adapted to the needs of the operator It is recommended that the exhaust suction system not be combined with a welding smoke suction system and then connected to a ventilator It is possible that a combustible or explosive mixture may be created based see ZH 1 454 vehicle maintenance guideline Example for calculation base...

Page 45: ...n Report any transport damage to the carrier immediately During loading unloading and transport always use suitable lifting equipment material handling equipment e g cranes forklifts etc and the right load handling attachments and slings Al ways ensure that the parts to be transported are suspended or loaded properly so that they cannot fall taking into account size weight and the centre of gravit...

Page 46: ...le For external devices with RS232 connectors an RS 232 interface must be available PC speciality stores offer a wide range of USB to RS232 adapters There is however no standard guarantee that every adapter will function on the RS232 interfaces For this reason MAHA offers adapters with the order number VZ 910140 which have been tested on MAHA products When replacing old computers with PC LON cards...

Page 47: ...BA052301 en 47 6 3 Selecting the Setup Language 1 Choose a setup language German and English are available 2 Confirm with Next The InstallShield Wizard appears 3 Confirm with Next ...

Page 48: ... 6 4 Selecting the Destination Folder 1 Choose the default destination folder or click Browse to select a different folder 2 Confirm with Next 6 5 Selecting the SQL Server 1 Select the SQL server 2 Confirm with Next ...

Page 49: ...BA052301 en 49 6 6 Selecting the Dyno Type 1 Choose the dyno type 2 Confirm with Next 6 7 Selecting Features 1 Mark the check boxes of the features you want to install 2 Confirm with Next ...

Page 50: ...2301 en 6 8 Installing Drivers 1 Install the required drivers 6 9 Finishing the Setup When this window appears the instal lation has been successfully completed 1 Click Finish to exit the Install Shield Wizard ...

Page 51: ...toRun is started Use this program to install your version of EUROSYSTEM Click the equipment being used 1 Provided the User Account Control is enabled this Windows confirmation prompt appears Confirm with Yes Do the software installation as described above starting with step Selecting the Setup Language ...

Page 52: ...ed at C Programs MAHA Equipment type then right click the folder In the object menu select Properties 2 In this dialog window click tab Security and then button Edit 3 Now the user rights can be assigned Mark entry Benutzer German for User 4 and tick the Allow checkbox next to the Full control permission 5 Confirm the assignment with OK The new permissions will now be applied ...

Page 53: ...control The lifting bar moves up and the dyno roller are blocked 2 Drive on to the lifting bar with the driven axle of the test vehicle the dyno driving direction Drive the vehicle slowly and straight onto the dyno and position the vehicle in the center 3 Activate the lifting bar using the function key F3 of the keyboard or the remote control and lower it using the cursor keys The lifting bar lowe...

Page 54: ...oved on the rollers Make sure that the vehicle fixing is suitable for the vehicle being tested Only skilled trained personnel shall install the vehicle fixing Always install the vehicle fixing completely and properly and check its proper functioning before test start Check the orderly condition and suitable rigidity of the vehicle s attachment unit before every vehicle fixing procedure e g towing ...

Page 55: ...r rollers This is especially important when the fan is switched on Hot exhaust from the exhaust pipe can damage the tightening straps Maintain the proper distance Car Front drive If the vehicle is front driven the vehicle must be secured in the front and the back against lateral swing Rear drive If the vehicle is rear driven it must be fixed in the rear 4 wheel drive 4 wheel drive vehicles must be...

Page 56: ...e clamping plate firmly against the wheel a Mechanical version By turning in the threaded rod D b Pneumatic version By actuating the pneumatic cylinder E using switch or software button 4 Fasten the motorcycle laterally at the level of the footrests using tightening straps 5 Check the clamping device for tight fit by making steering movements If there is still play between wheel and clamping plate...

Page 57: ...ensor in the engine compartment The procedure depends upon the type of sensor Please pay attention to the detailed description of the various RPM sensors in section Description Interface Box Set the RPM sensor using the selection list in window RPM Sensor in the menu RPM Settings 2 Connect the RPM sensor to the interface box Other data sensors which may be needed during the test should be connecte...

Page 58: ... 2 To make sure that the fan remains in place during operation use the fixing levers on the casters of the fan 3 Switch on the air cooling fan Risk of damage Cables and tightening straps can get between tires and rollers due to the air flow 7 10 Bring the Vehicle up to Operating Temperature This can be done using the load simulation e g with a constant traction see section Load Simulation 7 11 Veh...

Page 59: ... pre selected driving cycle The main menu is divided into several sub menus which can be selected as follows Wheel mouse with mouse click Keyboard Select with the Cursor keys and open with the ENTER key During the program procedure follow the instructions in the status line The following is described in the instructions Program structure Starting the program Operation and explanation of the main s...

Page 60: ...60 BA052301 en 8 2 Tree Model ...

Page 61: ...erational and functional status of the various devices are displayed The various symbols are described in the following paragraph The messages and information in the status line should generally be adhered to Symbols in the Status line SYMBOL DESCRIPTION Dyno OK green The connection to the various dyno components e g eddy current brakes interface box etc are working trouble free An error has occur...

Page 62: ...After activation the lifting bar can be raised lowered using the cursor keys red lifting bar up green lifting bar down yellow lifting bar moves up or down Activate weight simulator After activation the weight simulator can be moved up or down using the cursor keys red weight simulator up green weight simulator down Drive mode Front drive Drive mode Rear drive Drive mode 4 wheel drive ...

Page 63: ... function key The button assignments are explained later in the respective menu items as they appear The button bar assignments depend upon the screen currently active Grey shaded buttons are not available for selection Example A B SWITCH OVER Button If the highlighted LED A appears in front of the arrow keys this means the button bar has additional functions and can be switched over with the arro...

Page 64: ...es PCBs depends upon the options that have been ordered 3 Confirm the enabling of the individual dyno components with the button F8 CONTINUE 4 If desired start a software update of the individual dyno components using F7 UPDATE After a few seconds the main menu appears 8 5 End Program Switch off Dyno First quit the program and then shut down the computer properly Improper termination can cause a s...

Page 65: ...ange the value with the keys or with the remote control scroll key If the desired value is set it is confirmed with the F5 key Target value OK F5 Start F6 The graphic recording of the measurement is started or stopped Stop F6 Driving cycle F7 A driving cycle from the database can be selected Evaluate F8 The measurement evaluation is displayed LEVEL 2 Store F5 The measurement is stored Reset F6 The...

Page 66: ...een appears 3 Select the desired driving cycle with the cursor key or the mouse and load this with OPEN 4 Start the driving cycle with the button F6 START 5 The vehicle must now follow the curve plot of the selected speed profile In the enlarged cut out of the total diagram right a green point represents the current actual value of the vehicle The actual value should move along the display blue li...

Page 67: ...aved is not limited 3 Exit the measurement screen with ESC Scaling the Power and Load Simulation Graphs The Power and Load Simulation graphs can be manually scaled as follows 1 Double click the upper left or right hand corner of the diagram An entry field opens 2 Enter the desired scaling value 3 Confirm with RETURN or ENTER The Power values kW are scaled using the left hand x axis the additional ...

Page 68: ... in 2 Press and hold left hand mouse key 3 Move the cursor to the desired diagram point The measurement values are shown in the right hand column 4 Use the F5 CURSOR OFF to blend out the cursor Insert comment 1 Press the right hand mouse key A window opens 2 Enter comment 3 Confirm with RETURN 4 Press and hold right hand mouse key to move the comment Delete comment 1 Select the desired comment wit...

Page 69: ...so stored in the database Print 1 Use the button PRINT or key F12 The following screen appears 2 Enter the vehicle data and information in the input boxes 3 Using MEASUREMENT DATA TABLE an additional tabular print out of the measurement data can be selected Enter the increment 4 Select the desired measurement data with the buttons Select all Select individual 5 Use the button F8 COMPLETE The measu...

Page 70: ...on the larger the angle of inclination The simulated slope can be driven in any gear or speed The eddy current brake effectiveness remains constant at all speeds 1 Position the vehicle on the dyno and fix it 2 Call up the menu LOAD SIMULATION and then the menu point CONSTANT TRACTION The following screen appears 3 Enter the target value of the traction F Target using the digit keys 4 Use the butto...

Page 71: ...st Fst m g sin Calculation of the climbing power Pst Pst m g sin v 3600 with v km h and the following values Vehicle weight m 1500 kg Angle of inclination 9 Speed v 100 km h Acceleration due to gravity g 9 81 m s2 the result is 2302 N and Pst 64 kW 89 PS ...

Page 72: ...brake effectiveness increases up to full throttle but not the speed 1 Position the vehicle on the dyno and fix it 2 Call up the menu LOAD SIMULATION and then the menu point CONSTANT SPEED The following screen appears 3 Enter the target value of the speed v target into the entry box via the digit keys 4 Use the button F8 CONTINUE The measurement screen appears The entered speed must be higher than ...

Page 73: ... different as opposed to the road depending on roller diame ter and concept double or single roller Especially at low speeds 50 km h the flex and roll resistances of the rollers are larger than the total resistance on the road Vehicle weight and tire pressure also play a role These losses cannot be compensated without electric motor Consequently there are large deviations in the driving simulation...

Page 74: ...wing screen appears 3 Enter the parameters using the number keys or if available load them from the database using F6 DATABASE 4 Use button F8 CONTINUE The measurement screen appears 5 Start the measurement 6 Use switch button F6 to start or stop the graphic recording of the measurement When testing with electric motors accelerations of 1 1 2 m s2 are possible with a non driven axle This correspon...

Page 75: ... dyno is regulated in such a way that the engine RPM remains constant independent from the traction and speed created by the vehicle The pre selected target value n target is regulated independent from the traction created by the vehicle up to the max dyno motor capacity 1 Position the vehicle on the dyno and fix it 2 Call up the menu LOAD SIMULATION and then the menu item CONSTANT ENGINE RPM The ...

Page 76: ... The menu points are explained below Continuous measurement Discrete measurement Display last measurement 9 2 1 Display Last Measurement If the last conducted measurement is not stored and the measurement menu exited use the item Display last measurement to view the measurement again When exiting the LPS program the temporary storage or the last measurement conducted is deleted Only active with co...

Page 77: ...gine performance are displayed graphically If air pressure and temperature have been taken into consideration measured the engine performance is displayed as standard performance 1 Position the vehicle on the dyno and fix it 2 Open menu MEASURE ENGINE POWER and then menu item CONTINUOUS MEASUREMENT The following screen appears 3 Select the vehicle data or if available load these from the database ...

Page 78: ...aged 11 To evaluate the measurement see section Identical Functions and section Performance curves Continuous Measurement with Automatic Transmission and Converter Slip Measurement 1 Position the vehicle on the dyno and fix it 2 Open menu MEASURE ENGINE POWER and then menu item CONTINUOUS MEASUREMENT 3 Select the vehicle data or if available load them from the database with F6 DATABASE 4 Use the b...

Page 79: ...lly set at 50 km h for Car dynos Converter slip measurement 10 Accelerate the vehicle in the test gear next to last gear again to the target speed The message line shows the message Accelerate vehicle to XXX km h 11 When the target speed has been reached release the throttle and let the vehicle coast down to standstill in test gear not neutral 12 After successful measurement the engine power wheel...

Page 80: ...efore testing begins The Start and End speeds or RPM as well as the test increments and hold time are entered by the inspector Hold time is defined as the length of time which the pre set approached RPM and or speed is held constant The hold time assures a stable test point so that for example enough time is left for a fuel consumption test to be done The Start Hold time eases the regulation proce...

Page 81: ... in the background 11 With the throttle fully depressed the first set measurement point is approached The eddy current brake of the roller set maintains the vehicle or RPM speed about 5 sec i e according to the set holding time and stores the measurement value of this point 12 The brake is then released and the next measurement point is approached The inspector maintains full throttle during the e...

Page 82: ...it 2 Call up the menu FLEXIBILITY MEASUREMENT Following screen appears 3 Enter the parameter in the boxes using the digit keys or if available load these from the database with the F6 DATABASE key 4 Use the button F8 CONTINUE Use the cursor keys and to change between the values Delete erroneously entered characters using the BACKSPACE key Delete a complete box with the DELETE key 5 Drive in desire...

Page 83: ...et speed v speed must be approached with the vehicle speedometer 4 Use the button F8 CONTINUE 5 Accelerate the vehicle to the target speed Base it on the vehicle speedometer 6 If the speed is held constant for 3 seconds the value is automatically taken over Otherwise store the measurement value with F8 CONFIRM The display jumps to the next target speed 7 Repeat the test for each target speed Use t...

Page 84: ... fix it 2 Call up the menu point SPEEDOMETER CONTROL and then the menu point MILEAGE The following screen appears 3 Enter the mileage in the box using the digit keys 4 Use the button F8 CONTINUE 5 Drive a random distance with the vehicle on the test stand and compare the values on the vehicle display and on the monitor 6 Use the button F5 TRIP START to start the mileage counter test 7 Use the butt...

Page 85: ...r keys and to change between the values Delete erroneously entered characters using the BACKSPACE key Delete a complete box with the DELETE key 5 Accelerate the vehicle up to 110 km h 6 Once the displayed target speed is reached the roll out trial is initiated release gas and disengage clutch The dyno is braked based on the preset simulation model The actual time ECE is measured and displayed at e...

Page 86: ...lete erroneously entered characters using the BACKSPACE key Delete a complete box with the DELETE key 5 Accelerate the vehicle to 110 km h 6 Once the displayed target speed is reached the roll out trial is initiated release gas and disengage clutch The dyno is braked based on the preset simulation model 7 Repeat steps 5 and 6 until all intervals are in the green range With the iterative coefficien...

Page 87: ...h the target and actual power as well as the RPM are determined and compared 7 Then the program triggers the MDO LON measurement cell Readiness is then briefly displayed on the screen 8 Now the vehicle must be accelerated to the previously determined max power 100 The dyno maintains 100 power for 5 seconds and the K value is measured and averaged in this time period 9 Then the dyno regulates to 90...

Page 88: ...ases 1 Use the menu point DATABASE Following screen opens 2 Select the desired database 10 1 1 Identical Functions Button description Clean Up F5 Use this button to remove the data sets from the databse via the date Delete F6 Using this button datasets can be removed from the database Export F7 Using this button datasets can be exported from the database Import F8 Using this button datasets can be...

Page 89: ...LETE Following safety inquiry appears 4 To delete the dataset select YES The dataset is deleted from the data base Select NO if the dataset should not be de leted Export 1 Select the desired database The Browser database appears 2 Select using the cursor keys or the mouse 3 To export a marked dataset press F7 EXPORT Following window opens 4 Enter a file name and if necessary select a path 5 Confir...

Page 90: ...e The database Browser appears 2 Use the key F8 IMPORT Following window opens 3 Select with the Cursor keys or the mouse if necessary to change the path 4 Import the dataset with OPEN As standard the datasets are imported from C MAHA Dyno Model Import ...

Page 91: ...e selection F7 Use this button switch the display between curve selection and max value Power correction F8 Use this button to select various standard calculations from a list LEVEL 2 Cursor F5 Use this button to blend the cursor in and out The cursor can be moved using the mouse key Zoom out F6 Use this button to display the original picture again step by step Units F8 Use this button to change t...

Page 92: ...ton F7 CURVE SELECTION The following screen appears 2 Use the keys 1 to 4 or the appropriate buttons to blend in the individual performance curves 3 Using the keys 5 to 7 or the appropriate buttons a max of 3 additional measurements torque and engine power if loaded can be blended in and out in the background 4 A max of 3 additional curves can if loaded be blended in or out in the background with ...

Page 93: ...ulated and displayed based on the desired power correction 3 Using the keys 5 to 7 or the appropriate buttons a max of 3 further measurements if loaded can be blended in and out in the background rund ein und ausgeblendet werden Load 1 Use the button F6 LOAD The following selection box opens 2 Select where the desired measurement is to be loaded The database Browser opens 3 Select a dataset with t...

Page 94: ...vehicle data and information in the entry boxes 3 Use the button F8 COMPLETE 4 Enter a file name and select if necessary a path 5 Confirm with STORE The data records were stored on the hard disk under C MAHA Dyno Model Export P Drag Wizard 1 Use the button F7 P DRAG WIZARD The wand is blended in 2 Move the wand with the mouse onto the desired point on the power curve ...

Page 95: ... a dataset with the cursor key or the mouse 3 Open the dataset by double clicking or press the ENTER key The measurement screen appears Cursor F5 Use this button to blend the cursor in and out The cursor can be moved using the mouse key Zoom out F6 Use this button to display the original picture again step by step see paragraph Zoom Function in Chapter Measurements Store F7 Use this button to stor...

Page 96: ...ine the load simulation model 5 Use the button F8 CONTINUE The vehicle data screen appears 6 Select the vehicle data 7 Use F8 STORE to store the data Calculate ABC coefficients 1 Use the button CALCULATE ABC COEFFICIENTS Following screen appears 2 Enter mass including driver and fuel and confirm with ENTER The total mass at roll out trial and the share of the rotating mass are calculated and displ...

Page 97: ...ofile settings appears The profile setting screen is divided up into the following areas PROFILE NAME ANALOG DISPLAY DIGITAL DISPLAY PRINT OUT SETTING Analog display Two analog displays are available 1 Select the measurement values to be displayed from the list 2 Enter the min and max values as well as the scaling factor 3 Enter the limit values for the green yellow and red ranges 4 Use F6 IMPORT ...

Page 98: ...re Ignition point Fuel pressure Suction pipe pressure Air quantity throughput flow Throttle valve position OBD Lambda from vehicle ISE Travel distance Speed Simulated inertia Simulation target value Simulation actual value Simulation error Positive simulation Negative simulation Max pos simulation Max neg simulation Force on vehicle Vehicle energy Energy from vehicle Energy from vehicle Road Load ...

Page 99: ...ct the boxes and enter the desired values 5 The changes are displayed with F6 IMPORT 6 The changes are stored with F8 STORE Export Profile See paragraph Identical Functions function Export Import Profile See paragraph Identical Functions function Import 10 1 6 Driving Cycle Data 1 Call up the menu DATABASE and then the menu point DRIVING CYCLE The database browser appears 2 Select a dataset with t...

Page 100: ...ission Manual Automatic Slip if Automatic transmission no slip measure slip converter slip input Drive Front drive Rear drive 4 wheel drive Performance class 10 25 50 100 250 500 kW Performance correc tion None DIN EEC ISO JIS SAE Additional factors optional fm engine factor Qv PVA Limit values If one of these limit values is exceeded a warning message will appear on the screen and the display cha...

Page 101: ...ction point is selected from the list the dyno automatically recognizes the RPM sensor being used RPM source no RPM recording Standard LPS RPM Module Driving trial OBD Emission tester Opacimeter Operating system 2 stroke 4 stroke Wankel RPM Sensor Trigger tongs Licht barrier sensor TDC sensor Clamp W Diagnostic plug Rotophon Rotophon Mode 2 Piezo clamp Ignition coil clamp 1 Ignition type One spark...

Page 102: ...on close to 1 1 During the test which follows the software converts the current speed in an engine RPM Please note The calculated RPM only agrees with the actual RPM of the power measurement when driving with the Test gear The driving trial makes no sense on automatic vehicles without converter lockup because the engine RPM deviates due to the converter slip 1 Position the vehicle on the dyno and ...

Page 103: ...erefore be raised Sensitivity for the automatic recognition of the roll out trial If the roll out trial is not automatically recognized the sensitivity should be raised If the wheel power measurement is then erroneously terminated too early a smaller sensitivity should be selected Delay until the drag power recording begins If a clear bend is seen at the end of the drag power up and then down the ...

Page 104: ...w 10 6 Units Use the menu item UNITS to select among Power in PS SI Us or GB units 1 In order to change the units use the menu item UNITS A selection box opens in which the available unit models are shown e g 2 Select the unit model needed Variable SI Units Power in PS US Units Brit Units Power kW PS HP BHP Engine speed R min R min rpm rpm Speed km h km h mph mph Torque Nm Nm lbf ft lbf ft Meas un...

Page 105: ...ges with F8 IMPORT 10 8 Device Interfaces Use the menu item DEVICES INTERFACES to activate deactivate the externally connected devices In addition measurement of the refrigerant temperature via OBD can be optionally selected 1 Use menu item DEVICE INTERFACES A screen opens in which the external devices are activated deactivated and temperature measurement via OBD can be selected 2 Select the check...

Page 106: ...diagnostic interface 3 Start the engine and let it run in idle 4 Confirm with COMPLETED After communication has been set up the OBD symbol appears green in the status line Following screen appears 5 Select the desired measurement values for Channel 1 to 4 from the list 6 Use F8 IMPORT to accept the settings If the communication cannot be set up the first time wait approx 10 seconds and repeat the ...

Page 107: ...plays e g the set operating mode the rotation direction the active axle various regulator and fan target values as well as malfunctions warnings 11 2 Driver s Aid Setup Optional Administer the driver s aid using this menu point After calling up this menu point the following screen appears Select the desired option ...

Page 108: ...selection screen appears 3 Select the driving cycle with the cursor keys or the mouse and load it with OPEN 4 Start the driving cycle with the button F6 START 5 Now the vehicle must drive the selected curve of the speed profile A green point represents the current value of the vehicle in the enlarged cut out of the total diagram The actual value should move along the displayed blue line A line in ...

Page 109: ...w profile it must first be created with the menu point NEW PROFILE Use the button F6 WORK PROFILE to set the colors of the profile Double click the desired box and the color selection window appears Select the desired color and confirm with OK Use F5 STORE to import the settings 11 2 3 New Profile Use the button F7 NEW PROFILE to create a new profile Enter the name and confirm with ENTER ...

Page 110: ... the profile 11 3 Backup Restore Database 11 3 1 Backup Database 1 Enter the file name and if necessary select a path 2 Confirm with STORE The database backup file is stored on the hard disk under C MAHA Dyno Model Backup 11 3 2 Restore Database 1 Select a database backup file 2 Confirm with OPEN The database backup file is opened from C MAHA Dyno Model Backup as standard path ...

Page 111: ...ER The following safety inquiry appears 3 To delete the database table select YES Select NO if the dataset is not to be deleted 11 3 4 Delete Database The following safety inquiry appears 1 To completely delete the database select YES Select NO if the database is not to be deleted ...

Page 112: ...zed by MAHA or after consultation and approval by MAHA The manufacturer warranty becomes invalid at non compliance Inform the operating personnel before doing maintenance work 12 2 Annual Inspection The maintenance interval prescribed by the manufacturer is 12 twelve months This maintenance interval refers to normal workshop usage If the equipment is used more frequently or under severe operating ...

Page 113: ...ved 12 5 Maintenance by the Operator 12 5 1 Roller Set The LPS 3000 roller set should be inspected and serviced every 200 hours of operation or once per year Inspection of the roller set includes its anchorage and all screw connections The cover plate screws must be inspected before each start up of the dynamometer 1 Eddy current brake 2 Cardan shaft 3 Encased bearings of rollers and eddy current ...

Page 114: ...114 BA052301 en 1 2 3 ...

Page 115: ...au Haldenwang GmbH Co KG herewith declares as a manufacturer its sole responsibility to ensure that the product named hereafter meets the safety and health regulations both in design and construction required by the EC directives stated below This declaration becomes void if any change is made to the product that was not discussed and approved by named company beforehand Model LPS 3000 Designation...

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