Technical Specification Hydraulic Dynamometers Type D · In this case, the pendulum body is supported by eight rollers instead of four flexure strips which is usual for large dynamometers

Technical SpecificationHydraulic DynamometersType D2001-05-02

© SCHENCK PEGASUS GmbH • Technical Specification Hydraulic Dynamometer Type D

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C O N T E N T S

1. A Schenck Pegasus Product withConvincing Features1.1 Fields of Application1.2 Multi-Purpose and Flexible in Design1.3 Your Advantages

2. How it Works2.1 Principle of Function2.2 Torque Acquisition2.3 Speed Acquisition2.4 Frame2.5 Power Supply2.6 Test Stand Controller x-act2.7 Interfaces

3. What we Deliver3.1 Scope of Supply3.2 Order Numbers

4. Figures, Data, Facts4.1 Type Key4.2 Technical Data4.3 Power Ranges4.4 Electric Power Components4.5 Dimensions4.6 Fluctuating Torque

5. Things you Should Observe5.1 Planning Assistance

6. Product Options6.1 Trunnion Bearings6.2 Second Coupling Flange6.3 Shaft Connection6.4 Starter System6.5 Calibration System6.6 Pressure Control System6.7 Inlet Servo Valve6.8 Special Sizes


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1. A Schenck Pegasus Product withConvincing Features

1.1 Fields of ApplicationThe type D hydraulic dynamometers are mainly used as loading units for pro-duction testing of combustion engines, mainly Diesel engines, on engine teststands. Furthermore, they are used as loading unit for powertrain and gear-box test stands as well as chassis dynos. In this function, they absorb themechanical energy of the driving motor and allow its being loaded withtorque. The mechanical energy is converted into warmed-up cooling water.

The hydraulic dynamometers are available in different sizes and construc-tions so that a great variety of combustion engines can be tested, e.g.:

• Combustion engines for passenger cars and commercial vehicles• Aircraft engines and turbines• Large engines for trains and ships• Hydraulic motors• Electric motors

1.2 Multi-Purpose and Flexi-ble in Design

Great Variety of Power RangesThe type D hydraulic dynamometers are available for a great variety of powerranges from 230 kW up to 12600 kW. The type designation consists of a Dfollowed by the maximal power in kW. Thus, D400 represents a dynamometerwith a maximal power of 400 kW.

One and Two Directions of RotationUsually, the dynamometers are designed for one direction of rotation. In thisdirection, they are adjusted for an optimal torque at different speeds. How-ever, we are also able to supply dynamometers for two directions of rotation.The maximal torque of these, however, is slightly lower than one of the dy-namometers with one direction of rotation. In the type designation, the num-ber of directions of rotation is represented by the figure behind the size of thedynamometer. That means, D400-1 is a dynamometer for one direction ofrotation.

One and Two RotorsIf high power at high speed is required from fast-running dynamometers, e.g.for fast-running Diesel engines, Dynabar dynamometers with two rotors areavailable. These dynamometers allow the same maximal speed as the oneswith one rotor, however, the maximal torque doubles.By that, the double maximal braking force is available as well. In the typedesignation, dynamometers with two rotors are characterised by a “2” directly


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behind the D: D2-4200-1 is a hydraulic dynamometer with two rotors for onedirection of rotation and a maximal power of 4200 kW.

1.3 Your AdvantagesThe hydraulic dynamometers type D stand out for essential features:

• High measuring accuracy• Simple construction• Robust design• High-quality materials (water bearing parts: sea-water resistant!)• Reliable operation even in case of not optimal cooling water conditions• Wide range of standard sizes for different engine power• Many variants for a great variety of applications• Excellent ratio between price and power (DM/kW)• High power density• Compact construction for low requirement of space• Low power requirement• No remarkable reactive current• Extensive accessories, also for the adjustment to different cooling water

supplies


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2. How it Works

2.1 Principle of FunctionThe hydraulic dynamometer type D is connected with the engine to be testedby a shaft. It converts the mechanical energy of the engine existing at theshaft of the dynamometer as torque and speed into warming-up of the coolingwater. During that, the water serves as working medium for the creation of thebraking moment and, at the same time, as cooling medium for dissipating thekinetic energy converted into heat.

The cooling water supplied by the customer is conducted into the dyna-mometer, accelerated by the rotor of the dynamometer and decelerated againby the stator. The inner friction occurring in the water during that converts thekinetic energy of the water into heat.

Inside Construction of the Type D Hydraulic Dynamometers

The braking power of the dynamometer is water-controlled via the fill factor.For that, a control valve driven by a fast controlling motor is installed at thecooling water outlet at the bottom of the dynamometer. Optionally, the water


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supply can additionally be controlled by inlet servo valve. With that, thetorque response times can still be reduced.

The lowest torque of the dynamometer, the so-called idling characteristics,results from minimal water filling. This characteristics is not zero if there is nowater in the dynamometer because in this case air whirls instead of waterwhirls develop. With minimal water filling neither air nor water whirls can de-velop completely which causes the lowest torque. This so-called “idlingpower” is highest at maximal speed of the dynamometer and correspondinglylower at lower speeds. The idling power, please take from the power rangesin chapter “Technical Data”. These values vary depending on the inlet coolingwater quantity.

2.2 Torque Measurement

Torque Measurement Via Load Cell With Pendulum Body Support, Here Witha Dynamometer With Flexure Support


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The test piece is connected with the rotor of the dynamometer via shaft andflange. Due to the rotating movement of the shaft, the body of the dyna-mometer “oscillates” as well. The special flexure support of the dynamometeronly takes up the weight of the pendulum body and the counterforce to theload cell. Thus, the total torque is effective via a lever arm on the load cell in-stalled by the side of the pendulum body. The measured force is proportionalwith the braking torque. The flexure strips are almost friction- and mainte-nance-free. They provide a quick response, allow almost hysteresis-freemeasurement of the torque and keep theses features permanently.

Principle of Torque Measurement With Pendulum Support

Large dynamometers from D9800 on can exclusively be supplied with rollersupport. In this case, the pendulum body is supported by eight rollers insteadof four flexure strips which is usual for large dynamometers.

As alternative for flexure/roller support, the hydraulic dynamometers areavailable with trunnion bearings in which the dynamometer is supported byone rolling bearing each at both ends.

2.3 Speed AcquisitionThe speed is acquired digitally at the shaft of the dynamometer via a toothedwheel and a pulse generator.

DrivingTorque

Load cell

Flexure Support

Swivelingpendulum body

(Housing)


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2.4 FrameThe dynamometer is installed on a stable welded frame. In this frame, coolingwater outlet and connection point for the electric lines are integrated as well.

2.5 Power SupplyPower supply and electronic control of the control valve is made by a powercomponent. The entire electronics of power component LED 2000 is pooledin a 19” module. Due to the required higher adjustment torques of the throttlevalve, for dynamometers larger than D3600, the adjustment motor and thusthe power component is reinforced and designed as additional mounting plate“SIMODRIVE”.

Power Component LED 2000 as 19“ Module for all Dynamometer Sizes

Additional Power Component as Mounting Plate for Dynamometers LargerThan D3600 (Control Cabinet Can Be Supplied Optionally)


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2.6 Test Stand Controllerx-act

The digital test stand controller x-act by Schenck Pegasus GmbH controls thespeed and the desired torque. The unit is optimally matched to operation withthe power component of the hydraulic dynamometer. Further information,please take from the corresponding technical specification “Digital Test StandController x-act”.

Digital Test Stand Controller x-act


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2.7 Interfaces

Interface 1 Coupling flange, for connection data, please see chapter "Dimen-sions"

Interface 2 Speed signal from pulse generator, 60 pulses/revolution

Interface 3 Torque signal from load cell prepared for measurement with 6-wire technology.Nominal range supply voltage 0...10 V;Input resistance at reference temperature 350 ± 2 Ohm;Output resistance at reference temperature 350 ± 1.5 Ohm

Interface 4 Power supply for servo motor of the outlet throttle valve

Interface 5 Actual value 0...10 V throttle valve angle of the outlet valve of thehydraulic dynamometer

Interface 6 Demand value 0...10 V for throttle valve angle of the outlet valveof the hydraulic dynamometer

Interface 7 Power supply LED 2000; 1 ~ PEN, 230/115 V, 50/60 HzCurrent consumption: approx. 2 ACable diameter 3 * 1.5 mm², protected with 10 A

Interface 8 Operating modes and demand values:Analog values ± 10 V; Bit-parallel signals 0 / 24 V DC

Interface 9 Current demand value 0...10 V to SIMODRIVE

Interface 10 Signal of rotor position sensor and tachometer generator

Interface 11 Supply SIMODRIVE: 3 AC 400 V ± 10% or3 AC 415 V ± 10% or 3 AC 480 V ± 10% /50/60 Hz ± 10%,Cable diameter 5 * 2.5 mm², protected with 20 A

Interface 12 Water inlet, connection data see chapter "Dimensions"

Interface 13 Water outlet, connection data see chapter "Dimensions"


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Interfaces of the Type D Hydraulic Dynamometers Larger Than D3600

Interfaces of the Type D Hydraulic Dynamometers Larger Than D3600

SIMODRIVE

(modified)


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3. What we Deliver

3.1 Scope of SupplyThe following is included in the basic scope of supply

The dynamometer including:

• Pendulum body• Pendulum bearing (flexure strips)*• Pulse generator speed measurement• Load cell for torque acquisition• Frame• Electrically controlled control valve in the cooling water outlet

* for large dynamometers roller support

Power electronics

• 19“ module LED 2000• For dynamometers larger than 3600 kW modified LED 2000 and addi-

tional mounting plate SIMODRIVE

Test stand controller

• x-actD

Cable set

Technical documentation

Options

Further components and services completing the standard scope of supplycan be ordered additionally as well. For a description of the options, pleasesee chapter "Product Options".


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3.2 Order NumbersBasic scope of supply

Hydraulic dynamometers with flexure strips and one rotor

Dynamometers with one direction of rotation Dynamometers with two directions of rotationType Order no. Type Order no.D230-1 M0058593.01 - -D400-1 M0058594.01 D400-2 M0058602.01D700-1 M0058595.01 D700-2 M0058603.01D900-1 M0058596.01 D900-2 M0058604.01D1200-1 M0058597.01 D1200-2 M0058606.01D2100-1 M0058599.01 D2100-2 M0058607.01D3600-1 M0058600.01 D3600-2 M0058608.01D6300-1 M0058601.01 D6300-2 M0058609.01

Hydraulic dynamometers with roller support and one rotor

Dynamometers with one direction of rotation Dynamometers with two directions of rotationType Order no. Type Order no.D9800-1 on request D9800-2 M0067165.01

Hydraulic dynamometers with flexure strips and two rotors

Dynamometers with one direction of rotation Dynamometers with two directions of rotationType Order no. Type Order no.D2-800-1 on request D2-800-2 on requestD2-1400-1 on request D2-1400-2 on requestD2-2400-1 on request D2-2400-2 on requestD2-4200-1 on request D2-4200-2 on requestD2-7200-1 M0082250.01 D2-7200-2 on request

Hydraulic dynamometers with roller support and two rotors

Dynamometers with one direction of rotation Dynamometers with two directions of rotationType Order no. Type Order no.D2-12600-1 on request D2-12600-2 M0073988.01


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Options

3.2.1 Trunnion Bearings

Hydraulic dynamometers with trunnion bearings and one rotor

Dynamometers with one direction of rotation Dynamometers with two directions of rotationType Order no. Type Order no.D230-1 on request - -D400-1 on request D400-2 on requestD700-1 on request D700-2 on requestD900-1 M0085114.01 D900-2 on requestD1200-1 on request D1200-2 on requestD2100-1 on request D2100-2 on requestD3600-1 on request D3600-2 on request

Hydraulic dynamometers with roller support and one rotor

Dynamometers with one direction of rotation Dynamometers with two directions of rotationType Order no. Type Order no.D6300-1 on request D6300-2 on request

Hydraulic dynamometers with trunnion bearings and two rotors

Dynamometers with one direction of rotation Dynamometers with two directions of rotationType Order no. Type Order no.D2-800-1 on request D2-800-2 on requestD2-1400-1 on request D2-1400-2 on requestD2-2400-1 on request D2-2400-2 on requestD2-4200-1 on request D2-4200-2 on requestD2-7200-1 on request D2-7200-2 on request


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3.2.2 Second Coupling Flange

Second coupling flange for dynamometers with one rotor

For Dynamometer Type Order Number

D230 M0038224.01

D400 M0038224.02

D700 M0038224.03

D900 M0038224.04

D1200 M0038224.05

D2100 M0038224.06

D3600 M0038224.07

D6300 On request

Second coupling flange for dynamometers with two rotors

For Dynamometer Type Order Number

D2-800 On request

D2-1400 On request

D2-2400 On request

D2-4200 On request

D2-7200 On request

D2-12600 M0075058.01


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4. Figures, Data, Facts

4.1 Type KeyThe type D hydraulic dynamometers by Schenck Pegasus GmbH are char-acterised by the letter “D”:

D 2 xxx 1 Number of directions of rotation Braking power in [kW] Number of rotors Hydraulic dynamometer type D

4.2 Technical Data

Torque / Speed Measuring SystemMeasuring AccuracySpeed [U/min] ± 1, not smaller than 0.025 % of final value of measuring range

Measuring AccuracyTorque [%] 0.2 , specific to final value of measuring range

Control AccuracySpeed * [U/min] ± 10

Control AccuracyTorque * [%] ± 1 , specific to final value of measuring range

Color of Dynamometer Pebble gray RAL 7032

Color of Frame Umbra gray RAL 7022

* specific to the system hydraulic dynamometer, power component and test stand controller


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4.2.1 Hydraulic Dynamome-ters with one Rotor and oneDirection of Rotation

Type Pnom

MaximalSpeednmax

Rated TorqueMnom

Max. Share ofCouplingMass at

nmax

ΘRotor

Torsion-springconstant up tomiddle of dy-namometer

Weight

kW 1/min Nm kg kgm2 106 Nm/rad kg

D230-1 230 13000 600 2.35 0.02 0.154 110

D400-1 400 10000 1300 5 0.08 0.374 200

D700-1 700 7500 3000 10 0.3 0.923 310

D900-1 900 6500 4000 16 0.6 1.310 500

D1200-1 1200 5500 7500 24 1.2 2.546 650

D2100-1 2100 4000 15000 73 3.9 5.193 1300

D3600-1 3600 3000 35000 188 18.4 11.929 3200

D6300-1 6300 2500 80000 350 50.5 26.793 6600

D9800-1 9800 1500 180000 985 200.0 63.615 11500


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4.2.2 Dynamometers withOne Rotor and Two Direc-tions of Rotation

Type Pnom

MaximalSpeednmax

Rated TorqueMnom

max. Share ofCoupling Mass

atnmax

ΘRotor

Torsion-spring con-stant up to middle of

dynamometerWeight

kW 1/min Nm kg kgm2 106 Nm/rad Kg

D400-2 400 10000 1000 5 0.08 0.374 200

D700-2 700 7500 2600 10 0.3 0.923 310

D900-2 900 6500 4000 16 0.6 1.310 500

D1200-2 1200 5500 6000 24 1.2 2.546 650

D2100-2 2100 4000 15000 73 3.9 5.193 1300

D3600-2 3600 3000 30000 188 18.4 11.929 3200

D6300-2 6300 2500 70000 350 50.5 26.793 6600

D9800-2 9800 1500 170000 985 200.0 63.615 11500

4.2.3 Dynamometers withTwo Rotors and one Direc-tion of Rotation

Type Pnom

MaximalSpeednmax

Rated TorqueMnenn


atnmax

ΘRotor


dynamometerWeight


D2-800-1 800 10000 2600 on request 0.16 On request 360

D2-1400-1 1400 7500 6000 10 0.6 On request 760

D2-2400-1 2400 5500 15000 24 2.4 2.820 1350

D2-4200-1 4200 4000 30000 73 7.8 5.920 2300

D2-7200-1 7200 3000 70000 188 36.8 12.838 4000

D2-12600-1 12600 2500 160000 277 101,0 36,307 8500


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4.2.4 Dynamometers with twoRotors and two Directions ofRotation

Type Pnom

MaximalSpeednmax

Rated TorqueMnom


at nmax

ΘRotor


dynamometerWeight


D2-800-2 800 10000 2000 on request 0.16 On request 360

D2-1400-2 1400 7500 5000 10 0.6 On request 760

D2-2400-2 2400 5500 10000 24 2.4 2.820 1350

D2-4200-2 4200 4000 30000 73 7.8 5.920 2300

D2-7200-2 7200 3000 60000 188 36.8 12.838 4000

D2-12600-2 12600 2500 150000 277 101,0 36,307 8500

4.3 Power RangesThe power ranges of the hydraulic dynamometers, please take from the dia-grams on the following pages.


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Power ranges of the dynamometers with one rotor and one direction of rota-tion

Power Ranges Dxxx-1

D2100-1D1200-1

D700-1D400-1

D230-1

D900-1

D6300-1D9800-1

1

10

100

1000

10000

n [1/min]


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Power ranges of the dynamometers with one rotor and two directions of rota-tion

Power Ranges Dxxx-2

D9800-2

D1200-2

D400-2D700-2

D900-2

D2100-2D3600-2

1

10

100

1000

10000

n [1/min]


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Power ranges of the dynamometers with two rotors and one direction of rota-tion

Power Ranges D2-xxx-1

D2-12600-1D2-7200-1

D2-4200-1D2-2400-1

D2-1400-1

1

10

100

1000

10000

100000

n [1/min]


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Power ranges of the dynamometers with two rotors and two directions of rota-tion

Power Ranges D2-xxx-2

D2-1400-2D2-2400-2

D2-4200-2D2-7200-2

D2-12600-2

1

10

100

1000

10000

100000

n [1/min]


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4.4 Electric Power Compo-nents

Power Componentfor Dynamometer

TypeDesign Size

Up to/andD3600 19“ Module

2HE, 450 mm deep(incl. plug)

Larger than D3600Additional

Mounting Plate500 * 1500 mm

Cable Lengthsbetween dynamometer and power component 15 mbetween power component and controller 2 mbetween mounting plate and 19” module 15 m

Please note the additional space requirement as well as the environmentalconditions for the digital test stand controller x-act, please see specification x-act.


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4.5 Dimensions

Connection data of dynamometer DYNABAR with horizontal water supply andcalibration system (optional)Y1 Coupling flangeY2 Cooling water outletY3 Cooling water inlet

Type A G F J P B E D ØL K M H N S C T

mm mm mm mm mm mm mm Mm mm mm mm mm mm mm mm mm

D230 450 460 190 450 248 370 - 21 23 320 - -22 360 63 0 56

D400 540 500 230 540 293 470 - 21 27 375 - -5 480 73 0 71

D700 640 550 285 680 365 580 - 21 27 500 - 20 665 88 0 83

D900 710 630 330 740 394 640 - 21 27 520 - 30 750 95 0 20

D1200 800 700 360 850 460 720 - 21 2722

640750 - 40 806 107 0 20

D2100 1000 800 450 1050 570 900 - 21 27 750 - 65 1015 112 0 20

D3600 1260 835 545 1300 625 810 150 97 36 1200 1100 44 1295 132 170 20

D6300 1696 1100 900 1640 970 1006 240 115 36 1500 1400 9 - 170 160 20

D2-800 790 498 230 750 335 690 - 65 27 680 610 5 710 88 50 83

D2-1400 945 550 285 930 430 845 - 65 27 860 790 21.5 884 107 60 20

D2-2400 1210 635 360 1000 470 840 130 97 30 900 800 68 1167 122.5 190 20


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Connection data of dynamometer type D with vertical water supply and cali-bration system (optional)Y1 Coupling flangeY2 Cooling water outletY3 Cooling water inlet

Type A G F J P B E D ØL K M H S C T

mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm

D9800 2130 1450 ~1070 2030 1100 1490 180 125 38 1900 1770 100 225 0 18

D2-4200 1500 835 ~845 1050 535 1150 130 95 27 950 850 65 145 350 20

D2-7200 1890 835 ~990 1300 850 1440 150 97 36 1200 1100 44 157 315 20

D2-12600 2460 1100 ~1180 1685 1000 1770 240 115 36 1500 1400 45 170 400 20

The dynamometers D9800, D2-4200, D2-7200 are equipped with two trans-versally opposite cooling water outlet connection pieces - the ones of D2-12600 are directly opposite - which can be used alternatively.


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Connection data (all D dynamometers except D9800) ofY1 Coupling flangeY2 Cooling water outletY3 Cooling water inlet

Coupling flange Y1 Cooling water outlet Y2 Cooling water inletY3

Type A b c d e f g h i k l n o p q

mm mm mm mm mm mm mm mm mm mm mm mm

D230 120 101.5 8*M8 2 10 75 R2“ Diameter 3/4“

D400 150 130 8*M10 2 15 90 R3“ Diameter 1“

D700 180 155.5 8*M12 2 18 110 R4“ Diameter 1½“

D900 225 196 8*M16 3 20 140 125 200 240 85 7*M16 Diameter 2“

D1200 225 196 8*M16 3 23 140 150 225 265 95 7*M16 Diameter 2“

D2100 290 245 8*M20 5 30 175 160 225 265 95 7*M16 Diameter 2 ½“

D3600 355 310 8*M20 5 35 220 200 280 320 122 7*M16 Diameter 3“

D6300 435 385 8*M27 6 50 280 250 335 375 160 7*M16 125 210 250 8*M16

D2-800 180 155 8*M12 2 18 110 R4“ Diameter 1½“

D2-1400 225 196 8*M16 3 23 140 150 225 265 95 7*M16 Diameter 2“

D2-2400 290 245 8*M20 5 30 175 175 225 295 117.5 7*M16 Diameter 2 ½“

D2-4200 355 310 10*M20 5 35 220 200 280 320 125 7*M16 100 180 220 8*M16

D2-7200 435 385 10*M27 6 50 280 250 335 375 147 7*M16 125 210 250 8*M16

D2-12600 690 600 30*M30 6 45 280 250 335 375 160 7*M16 200 295 340 8*M20


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Connection data D9800 ofY1 Coupling flangeY2 Cooling water outletY3 Cooling water inlet

Coupling flange Y1 Cooling water outlet Y2 Cooling water inlet Y3

Type a b c d e f g h i k l n o p q

mm mm mm mm mm mm mm mm mm mm mm mm

D9800 700 615 18*φ38 10 60 400 350 445 490 215 10*M16 150 240 285 8*M20

4.6 Fluctuating TorqueThe overload fluctuating torque must not exceed 20% of the rated torque(overload mechanical vibrations). The center load over several seconds,however, must not exceed 100% of the rated torque.


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5. Things you Should Observe

5.1 Planning AssistanceIn this chapter, you will find additional information you require for planning theinstallation of the dynamometers. The mechanical dimensions of the dyna-mometers are stated in chapter "Dimensions", the electric interfaces arestated in chapter "Interfaces". Further general information regarding founda-tion, cooling water quality and cooling water consumption, you will find in thischapter.

5.1.1 FoundationAll dynamometers are supplied with processed frame bottom and can befixed on clamping rails or groove plates as well as on a concrete foundation.

Installation positionTransversal slope max. ± 15°Longitudinal slope max. ± 15°

For foundation fixing, the dynamometer has to be aligned with water level onthe correspondingly prepared concrete foundation, underpoured and an-chored with stone bolts.

Dynamometer sizes D230 to D1200 with one rotor and dynamometer sizesD2-800 to D2-2400 with two rotors are designed for a standard shaft height of700 mm above normal level, for larger dynamometers, the centerline ishigher.


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Connection data foundation with anchor bolts

Type A A1 B E J J1 K M R Z� Z1

mm mm mm mm Mm mm mm mm mm mm Mm

D230 450 570 370 - 450 570 320 - 240 85 250

D400 540 660 470 - 540 660 375 - 202 100 250

D700 640 760 580 - 680 800 500 - 150 100 250

D900 710 830 640 - 750 870 520 - 70 120 250

D1200 800 920 720 - 850 970 640 - 0 120 250

D2100 1000 1120 900 - 1050 1170 750 - 0 120 350

D3600 1260 1380 810 150 1300 1420 1200 1100 0 120 350

D6300 1696 1820 1006 240 1640 1760 1500 1400 0 120 350

D9800 2130 2260 1490 180 2030 2160 1900 1770 0 120 350

D2-800 910 790 690 - 750 870 680 610 202 100 250

D2-1400 945 1065 845 - 930 1050 860 790 150 100 250

D2-2400 1210 1350 840 130 1000 1140 900 800 65 120 250

D2-4200 1500 1630 1150 130 1050 1180 950 850 0 120 350

D2-7200 1890 2020 1440 150 1300 1430 1200 100 0 120 350

D2-12600 2460 2590 1870 240 1640 1770 1500 1400 0 120 350


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Foundation Pit Load

Type Stone bolt Number fortype...

FixingTorque

Pre-loadper bolt

D-xxxx D2-xxxx DIN 529(4.6)

D-xxxx

D2-xxxx

Nm kN

D230 - M20*250 4 - 145 42D400 D2-800 M24*320 4 4 265 60D700 D2-1400 M24*320 4 4 265 60D900 - M24*320 4 - 265 60

D1200 D2-2400 M24*320 4 8 265 60D2100 D2-4200 M24*400 4 8 265 60D3600 D2-7200 M30*320 8 8 520 96D6300 D2-12600 M30*320 8 8 520 96D9800 - M30*320 8 - 520 96

5.1.2 Transportation, Un-packing, Storage

For transportation and loading/unloading of the dynamometer, the corre-sponding safety regulations for the operation of lifting devices and materialhandling equipment must be observed.

Transporting, loading and unloading of the dynamometerThe dynamometer is carefully packed by the manufacturer and thus exten-sively protected against mechanical damages and atmospheric exposure.Anyway, harsh impacts and extreme weather conditions should be avoidedduring transportation. The packaging containers must neither be turned onedge nor tipped nor piled up. When packed, the dynamometer should pref-erably be loaded and unloaded with fork lift truck or similar lifting devices.

Unpacking of the dynamometerWhen unpacking, take care that the dynamometer does not get damaged. Incase the dynamometer is boxed for foreign shipment, first of all the steelstrips, then the cover and the side walls of the packaging have to be re-moved. After having unpacked, please check the dynamometer for beingcomplete and undamaged.

Storage of the dynamometerPerfect storage conditions are provided by an air-conditioned room. Baremetal parts must additionally be coated with an anticorrosive. The dyna-mometer and all parts of the facility must be protected against soiling anddust. For storage outside air-conditioned rooms, the dynamometer has to beheat-sealed into a polyethylene foil of at least 0.2 mm together with a desic-cant (e.g. Silicagel). For that, the air inside the cover has to be sucked off anda humidity indicator has to be installed visibly. Due to the danger of corrosion,the desiccant must not get in contact with bare metal parts. The cover has tobe protected against mechanical damages. The cover has to be checked


32 H. J. Dadt • D______E.doc • V4 •02.05.2001

regularly approx. every four weeks and, if required, the desiccant or the hu-midity indicator have to be exchanged. Furthermore, the transportation pro-tection has to be removed and the rotor has to be turned by 15 to 20°.

5.1.3 Cooling WaterThe working principle of the hydraulic dynamometer requires flow-off of thecooling water without hindrance and counter-pressure. The cooling waterflows through the control valve into the collection tank arranged inside theframe of the dynamometer. From there, it flows through the pressure-free re-turn pipe into the outlet duct in case of once-through flow or into the coolingsystem in case of re-cooling systems. Thus, cooling water can be suppliedalternatively from the normal water system with pressure control valve (once-through flow through the dynamometer, then into the sewage canal) or froman overhead water tank (multiple flow through the dynamometer via re-cooling and pumping back into the overhead water tank). Directly in front ofthe dynamometer, a simple shut-off valve and additionally, as an option, acontrolled inlet servo valve for the adjustment of the required flow has to beprovided.

Cooling water supply from the overhead water tank, alternatively from thepressure water system with options

Overhead watertank


H. J. Dadt • D_____E.doc • V4 • 02.05.2001 33

Once-through flowFor designing the outlet pipe for free outlet of the cooling water from the dy-namometer, please take care that the pipe has a sufficient gradient and thatthe connection pipe is dimensioned according to the size of the connectionpiece or the flange at the frame of the dynamometer. In case one commonoutlet is used for several dynamometers together, the outlet pipe has to bedimensioned larger according to the common inlet in order to avoid a backdraught.

Multiple flowDue to the fact that the cooling water has to flow off without pressure, the dy-namometer must not be operated in a closed circuit. However, it is possible tochannel the free water outlet into a container installed at a lower level and toreturn it into the cooling circuit via pumps. For monitoring the water flow, flowcontrol units can be installed in the outlet pipe and connected with the safetycircuit of the control unit. In case of a lack of water, the test stand will beswitched off.

Laying the pipesFor free outlet of the cooling water from the dynamometer, the outlet pipemust be laid with sufficient gradient in order to avoid a back draught in thecollecting containers. If the dynamometer is connected to a closed coolingcircuit, the permitted counter-pressure must not be exceeded. Prior to con-necting the dynamometer, please rinse the pipes thoroughly, no matter if thecooling water pipes are new or reconditioned.

Cooling water quality

Requirements to the water qualityPermitted size of solid ingredients max. 1 mmViscid ingredientse.g. components containing oil, tar and resin not allowed

Cooling water system type once-through flow re-cooling system

Total water hardness dH* < 30 < 40Carbonate hardness dH* < 10 < 5Non-carbonate hardness dH* < 28 < 35Total salt content mg/l (solid residue from evaporation) < 1200 < 1200Algae growth not allowed

* 1 dH = 10 mg CaO/l = 1.787 French hardness = 1.25 British hardness.The figures stated refer to concentrated circuit water not to make-up water tobe conditioned.


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Cooling water pressure

Cooling water pressure required for type D dynamometers depending on thecooling water heating ∆t

The maximally allowed water pressure of 0.6 bar in front of the dynamometermust not be exceeded. Dynamometer bearings failing as a result of waterdamages due to excessive inlet pressure cannot be replaced within theframework of our warranty.

Pressure variations in the cooling water inlet: < 5 %

Cooling water requirementThe cooling water requirement depends on the size of the dynamometer aswell as on the combustion engine to be tested. Basically, the dynamometershould be connected in a way that it can dissipate its maximal braking poweras heat via the cooling water with permissible cooling water temperatures andpressures. For examinations with combustion engines with lower power, thecooling water quantity can be reduced to the minimal water quantity for thesetests.

The cooling water quantity required Q (m³/h) depending on the temperaturedifference ∆t in °C (∆t = cooling water outlet tA minus cooling water inlet tE )and the power to be braked P (kW) is

Q = 0,86 ·P

∆t


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Cooling water requirement type D dynamometers

Cooling water outlet temperature:For a carbonate hardness of the water up to 5° dH, cooling water outlet tem-peratures up to 80°C are allowed. Due to the fact that, depending on thecooling water composition, the formation of scale will be increased, 50°Cmust not be exceeded for a carbonate hardness of the water >5° dH.

Minimal cooling water quantityThe idling characteristics (see power range) cannot be reached with the waterquantity required for heavy duty, it can only be reached with the minimalcooling water quantity. The minimal cooling water quantity is approx. 20 to25% of the cooling water quantity required for the rated power of the dyna-mometer and a cooling water heating of ∆t = 44.5 °C. The cooling waterquantity must not be lower than this, not even for low testing power.


36 H. J. Dadt • D______E.doc • V4 •02.05.2001

Minimal cooling water quantity required

Dynamometers with one rotor Qmin (m³/h) Dynamometers with two rotors Qmin (m³/h)

D230-1 1 - -

D400-1, D400-2 1.6 D2-800-1, D2-800-2 3.2

D700-1, D700-2 3 D2-1400-1, D2-1400-2 6

D900-1, D900-2 4 - -

D1200-1, D1200-2 5 D2-2400-1, D2-2400-2 10

D2100-1, D2100-2 9 D2-4200-1, D2-4200-2 18

D3600-1, D3600-2 16 D2-7200-1, D2-7200-2 32

D6300-1, D6300-2 27 D2-12600-1, D2-12600-2 54

D9800-1, D9800-2 47 - -

5.1.4 Shaft Connection PartsAll connection parts you manufacture or supply yourself (e.g. intermediatedisks, flywheels, ring gears etc.) must be balanced with a balancing quality ofat least Q 6.3. Lateral and axial run-out of the centering of these parts mustnot exceed 0.01% of the outside diameter. For drive and clutch shafts asconnection between engine to be tested and dynamometer, a shaft guard isrequired. Furthermore, we recommend to carry out a corresponding shaft cal-culation.

5.1.5 Installation Power Elec-tronics

All 19” modules are designed for installation in 19” housings or 19” controlcabinets. Schenck Pegasus GmbH offers this measuring cabinet with a basiccabling, the measuring cabinet can be ordered separately. Control cabinetsfor the power electronics on the mounting plate can be offered as well.

5.1.6 Assembly and Commis-sioning

Commissioning cannot be carried out unless cooling water pipes have beenlaid and a test engine has been provided. Foundation fixings must have dried.For assembly and commissioning, we will be pleased to place experiencedfitters and commissioners from our house at your disposal (against invoicing).


H. J. Dadt • D_____E.doc • V4 • 02.05.2001 37

6. Product Options and Accessories

6.1 Trunnion BearingsAs standard, the hydraulic dynamometers type D are equipped with a pen-dulum body supported in flexure strips, alternatively, trunnion bearings can besupplied except for the dynamometers from size D6300 on. D6300 can besupplied with roller support as alternative for the flexure strips. The technicaldata and dimensions stated in chapter "Figures, Data, Facts" will not changeif trunnion bearings are used. The order numbers, please take from chapter"Order Numbers".

6.2 Second Coupling ShaftFor some applications such as for engines for starting and tractor operationsupplied by the customer, a connection to the rear shaft end of the dyna-mometer is required. For that, the protection cover of the rear end of the shaftwill be removed and an additional coupling flange will be installed. The con-nection drawing (centering diameter, hole circle etc.) as well as the projectionof the base frame correspond with the coupling flange of the engine.

For operation with two coupling flanges and connection of masses at bothsides, the following must be observed:

• for maintaining the masses coupled on, the speeds allowed have to bereduced to 90% of the corresponding values and

• for maintaining the speeds, the masses allowed on both sides reduce to81% of the corresponding values.

The order numbers for the coupling flanges of the various dynamometersizes, please take from chapter "Order Numbers".

Scope of supply:

• second coupling flange• protection cover for coupling flange (The protection cover for the rear

end of the shaft is not required)

6.3 Shaft ConnectionFor connecting the engine to be tested with the hydraulic dynamometer, adouble-cardanic shaft is required. Schenck Pegasus GmbH offers differentshafts for all applications. Further information, please take from the corre-sponding technical specification.


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6.4 Starter SystemFor test stands without starter system of the engine, we offer a starter systemwith different power ranges installed at the free shaft end of the dynamome-ter. Further information, please take from the corresponding technical specifi-cation.

6.5 Calibration SystemA calibration of the hydraulic dynamometer is recommended after each op-eration in the area of the load cell or the pendulum body receptacle. For con-trolling the torque measurement system, we recommend the Schenck Pega-sus GmbH calibration system. Further information, please take from the cor-responding technical specification.

6.6 Pressure Control SystemThe pressure control system type D is always a space-saving, good-valuealternative when an overhead water tank cannot be used for the cooling wa-ter. It is used to reduce and to control the pressure of the water supply inType D230 to Type D3600 hydraulic dynamometers. The system is easy toassemble and to connect to the normal water system. Integrated manometersare used to additionally control the inlet and outlet pressure. Easily accessibledirt traps guarantee the trouble-free operation of the system. If maintenancework is required on the dynamometers, the water supply can easily beblocked by ball cocks. Further information, please take from the correspond-ing technical specification.

6.7 Inlet Servo ValveThe inlet servo valve guarantees a quick and reliable supply of water to thetype D hydraulic dynamometers at high inlet pressures. A servo motor oper-ates a servo valve via tooth-belt and provides together with the serial outletservo valve for a torque response time reduced by 70%. The inlet servo valvealso guarantees the lowest torque when idling, despite an increased inletpressure. Further information, please take from the corresponding technicalspecification


H. J. Dadt • D_____E.doc • V4 • 02.05.2001 39

6.8 Special SizesType D hydraulic dynamometers can also be manufactured in sizes otherthan the standard sizes. If required, they will be manufactured to your specifi-cations. Combinations with additional flywheel masses or gear are possibleas well. Please, do not hesitate to contact us.

Special-size dynamometer type D with 50.000 kW


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Corporate Division

Development Test Systems

SCHENCK PEGASUS GmbHLandwehrstraße 55D-64293 DarmstadtPhone +49 (0) 61 51 / 32-20 34Fax. +49 (0) 61 51 / 32-38 65

http://www.schenck.netE-mail: [email protected]

All Rights reserved.Redistribution or reproduction of this technical specification or any parts of it, no matterby which method, is prohibited.Subject to technical alternations.

Copyright by SCHENCK PEGASUS GmbH, D-64273 Darmstadt

Documents

Technical Specification Hydraulic Dynamometers Type D · In this case, the pendulum body is supported by eight rollers instead of four flexure strips which is usual for large dynamometers