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aylor Dynamometer

TD-3100/3102 Engine Dynamometer Operation & Maintenance Manual Z-EM-MNT-TD31 Revision G

Everything you need to succeed

Everything You Need to Succeed Serving customers. Solving problems. Driving productivity. These are among the reasons you need a robust dynamometer system. What you don’t need, however, is to have to go it alone when installing, optimizing or troubleshooting your system. That’s why you need Taylor Dynamometer – your partner for superior dyno system performance. Everything we do is about making it easy for you to turn your testing challenges into success. How do you know we can deliver on this promise? 1. A complete, proven product line. Get the right engine, chassis or towing dyno for your needs, as well as advanced controls, instrumentation and all the auxiliary systems for a complete solution. 2. Exceptional technical and applications knowledge. Look to our experts not only to help you select your optimal system, but also to provide design, configuration, installation and training for a total solution that integrates seamlessly with your operation. 3. Proactive service and enduring support. Count on us as the champions of your dynamometer system, taking full responsibility for the performance, ease of use and longevity of our equipment – so you can focus on what you do best. By applying these strengths, we’ve been helping companies like yours get greater performance, durability and return on investment in engine and equipment testing since the 1920s. The result is the best overall value for you today – in terms of both your testing performance and your company’s bottom line. Taylor Dynamometer www.taylordyno.com Phone: (414) 755-0040 Fax: (414) 755-0041 E-mail: [email protected]

© 2015 Taylor Dynamometer, Inc. All rights reserved. No part of this manual may be reproduced in any form or by any means without permission of Taylor Dynamometer, Inc. All trademarked product names referenced in this manual remain the property of their respective trademark owners. Taylor Dynamometer reserves the right to make changes in the specifications of the product described in this manual at any time and without any obligation to provide notification of such changes. No representations or warranties of any kind are provided with respect to the content of this manual. Note: Product photographs and graphics within this manual are examples and may not be actual representations of the product received. FEN0877 Revision G

Taylor Dynamometer’s Warranty Policy Taylor Dynamometer warrants its products against defects in materials and workmanship for a period of 18 months (1.5 years) from the date of shipment from our facility or 12 months (1 year) from the date of installation, whichever comes first, provided the equipment is properly installed and maintained, correctly lubricated and operated under normal conditions with competent supervision. This warranty does not cover calibration or normal maintenance. The foregoing is Taylor Dynamometer’s sole warranty with respect to its products. THIS DISCLAIMER AND WARRANTY AGREEMENT IS EXPRESSLY IN LIEU OF AND EXCLUDES ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE AND ALL OTHER EXPRESS OR IMPLIED REPRESENTATIONS AND WARRANTIES. The foregoing warranty shall be void if the product has been damaged by accident, misuse, negligence, or use not in accordance with instructions furnished by Taylor Dynamometer, or if the product has been serviced or modified by an agent other than an authorized representative of Taylor Dynamometer. No claim for service or adjustment by others will be allowed except for work done with the written consent of Taylor Dynamometer. The foregoing warranty is expressly limited to: 1) The repair, replacement or adjustment of Taylor-supplied parts or products, which upon examination shall be found defective. Such items must have been returned, freight prepaid, to the factory or repaired, replaced or adjusted onsite by an authorized representative of Taylor Dynamometer. Transportation and daily living expenses incurred by an onsite authorized representative of Taylor Dynamometer are expressly not covered by the warranty. Repaired, replacement and adjusted items will be shipped, freight prepaid, to the customer. The warranty DOES NOT include express shipping. 2) At Taylor Dynamometer’s discretion, the purchase price will be refunded once such items have been returned, freight prepaid, to the factory. Such remedy shall be buyer’s sole and exclusive remedy. Buyer agrees that no other remedy shall be available to him and that TAYLOR DYNAMOMETER SHALL NOT, IN ANY EVENT, BE LIABLE FOR INCIDENTAL DAMAGES OR FOR CONSEQUENTIAL DAMAGES, INCLUDING LOSS OF INCOME, LOSS OF TIME, LOST SALES, INJURY TO PERSONAL PROPERTY, LIABILITY BUYER INCURS WITH RESPECT TO ANY OTHER PERSON, LOSS OF USE OF THE DYNAMOMETER, ITS ACCESSORIES OR ITS INSTRUMENTATION OR FOR ANY OTHER TYPE OR FORM OF CONSEQUENTIAL DAMAGE OR ECONOMIC LOSS. The salespersons of Taylor Dynamometer are not authorized to make warranties about Taylor Dynamometer’s products. Taylor Dynamometer’s salespersons’ ORAL STATEMENTS DO NOT CONSTITUTE WARRANTIES, shall not be relied upon by the buyer, and are not part of any contract for sale. All of the warranties of Taylor Dynamometer are embodied in this writing and NO OTHER WARRANTIES are given beyond those set forth herein. Any action for breach of this contract for sale or any other action otherwise arising out of this contract must be commenced within one (1) year from the date the right, claim, demand or cause of action shall first occur, or be barred forever. Any component claimed to be defective during the warranty period should be reported to Taylor Dynamometer at (414) 755-0040 for return authorization or replacement. Authorized returns should be directed to Taylor Dynamometer at 3602 W. Wheelhouse Rd, Milwaukee, Wisconsin 53208. For diagnostic assistance or field service, contact Taylor Dynamometer at (414) 755-0040 by telephone or (414) 755-0041 by fax.

TAYLOR DYNAMOMETER INC.

CONTENTS 1.0 

Product and Safety Information ................................................................... 1  1.1  Purpose ............................................................................................................. 1  1.2  Manual Scope ................................................................................................... 1  1.3  Safety................................................................................................................. 1  1.3.1  Warnings, Cautions and Notes in the Text ......................................................... 1  1.3.2  General Safety Precautions ................................................................................ 2  1.4  Principles of Operation .................................................................................... 4  1.5  Product Description ......................................................................................... 7  1.6  Specifications ................................................................................................... 7  1.6.1  Ratings Limits ..................................................................................................... 7  1.6.2  Physical Specifications ....................................................................................... 7  1.6.3  Water Specifications ........................................................................................... 8 

2.0 

Mounting Instructions................................................................................. 11  2.1  Engine Preparation ........................................................................................ 11  2.2  Coupling Section ............................................................................................ 17  2.3  Adapter Plates ................................................................................................ 17  2.4  Couplings ........................................................................................................ 17  2.5  Spacer Plates .................................................................................................. 17  2.5.1  Drive Coupling Spacers .................................................................................... 18  2.5.2  SAE Flywheel Housing Spacers ....................................................................... 18  2.5.3  Trunnion Housing Spacer ................................................................................. 19 

3.0 

Operation ..................................................................................................... 24  3.1  Water Flow Requirements ............................................................................. 24  3.2  Manual Control System ................................................................................. 24  3.3  Startup ............................................................................................................. 24 

4.0 

Maintenance and Lubrication..................................................................... 26  4.1  Daily ................................................................................................................. 26  4.1.1  Hoses and Connections.................................................................................... 26  4.1.2  Outer Gear Coupling......................................................................................... 26  4.1.3  Trunnion Housing/Bearing Housing .................................................................. 27  4.2  Maintenance Every 200 Hours or 3 Months (whichever is less) ................ 31  4.2.1  Shaft Bearings .................................................................................................. 31  4.2.2  Inner Gear Coupling ......................................................................................... 31  4.2.3  Load Cell and Linkage ...................................................................................... 32  4.2.4  Magnetic Speed Pickup .................................................................................... 34  4.3  Calibration ....................................................................................................... 35  4.4  Maintenance every 400 Hours or 6 Months (whichever is less)................. 36  4.4.1  Check drive hub internal spline to the main shaft fit. ........................................ 36  4.4.2  Check gear fit on outside diameter of drive hub and flange. ............................ 36 

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5.0 

Accessories ................................................................................................. 37  5.1  Small Cooling Column ................................................................................... 37  5.2  Charge Air Cooler (1000 HP) ......................................................................... 38 

6.0 

Troubleshooting .......................................................................................... 39 

APPENDIX A – MAINTENANCE LOG APPENDIX B – DRAWINGS

Figures Figure 1 - TD-3100; English Horsepower, Torque Curve ........................................................ 5  Figure 2 - TD-3100; Metric Power, Torque Curve ................................................................... 5  Figure 3 - TD-3102; English Horsepower, Torque Curve ........................................................ 6  Figure 4 - TD-3102; Metric Power, Torque Curve ................................................................... 6  Figure 5 - TD-3100 Detail........................................................................................................ 9  Figure 6 - TD-3102 Detail...................................................................................................... 10  Figure 7 - Detent Pin ............................................................................................................. 13  Figure 8 - Absorber Module Gear; remove plug; put in zerk fitting and grease [5 pumps].... 14  Figure 9 - Trunnion Housing Key Lubrication........................................................................ 15  Figure 10 - Speed Sensor and Torque Cable Connection .................................................... 16  Figure 11 - Flywheel Housing Bolts and Dimensions, mm (in.) ............................................ 19  Figure 12 - Trunnion Housing Spacer Location When Using a Hub ..................................... 21  Figure 13 - SAE Flywheel Housing Adapter Bolt Sizes ......................................................... 21  Figure 14 - Measurement of Dimension X ............................................................................ 22  Figure 15 - TD-3100 Lubrication, Section View .................................................................... 27  Figure 16 - TD-3102 Lubrication, Section View .................................................................... 28  Figure 17 - Required Lubrication – Main Bearing Grease Points (3 pumps) ........................ 29  Figure 18 - Required Lubrication – Key ................................................................................ 30  Figure 19 - Trunnion Alignment............................................................................................. 32  Figure 20 - Trunnion Alignment Tool Use ............................................................................. 33  Figure 21 - Magnetic Speed Pickup Air Gap [gear shown is representative only]) ............... 34  Figure 22 - Calibration Arm Installed..................................................................................... 36  Figure 23 - Small Cooling Column ........................................................................................ 37  Figure 24 - Charge Air Cooler (1000 HP).............................................................................. 38 

Tables Table 1 - Ratings Limits .......................................................................................................... 7  Table 2 - Physical Specifications ............................................................................................ 7  Table 3 - Average Properties for Inlet Cooling Water ............................................................. 8  Table 4 - Drive Coupling Spacers ......................................................................................... 18  Table 5 - SAE Flywheel Housing Spacers ............................................................................ 18  Table 6 - Trunnion Housing Spacer ...................................................................................... 19  Table 7 - Flywheel Housing Dimensions (refer to Figure 7) .................................................. 20  Table 8 - X Dimensions for SAE Housings ........................................................................... 23 

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1.0 Product and Safety Information 1.1

Purpose This manual provides information necessary for the safe, efficient installation of the TD-3100/3102 engine dynamometer. The manual is intended for use by individuals who understand and are able to perform the procedures described. Where indicated, maintenance procedures must be performed by a qualified service engineer. Failure to perform the procedures as described may void the warranty on your Taylor dynamometer. Refer to the Warranty Policy at the front of this manual. When planning your test cell, minimum requirements are provided in this manual. Local codes and building requirements may also apply. The customer should contract with qualified electrical, masonry, plumbing, and HVAC contractors to ensure that all requirements are met.

1.2

Manual Scope This manual is divided into six sections:

1.3



Section 1.0 provides (a) important safety instructions, and (b) product specifications;



Section 2.0 provides important preliminary steps prior to use;



Section 3.0 provides dynamometer operation instructions;



Section 4.0 describes maintenance, lubrication and service requirements;



Section 5.0 describes accessories to optimize your engine testing facility; and



Section 6.0 contains troubleshooting information.

Safety 1.3.1 Warnings, Cautions and Notes in the Text Symbols and safety messages in the text are used to emphasize important and critical instructions. The meaning and importance of each is noted below. It is imperative these safety messages be read and thoroughly understood before performing any procedure described in this manual.

WARNING

STOP

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A procedure, practice, condition, etc., which, if not strictly and correctly followed, could result in severe personal injury.

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CAUTION

!

A procedure, practice, condition, etc., which, if not strictly and correctly followed, could result in damage to or destruction of equipment.

NOTE:

!

A procedure, practice, condition, etc., which is essential for safe and effective installation and operation.

1.3.2 General Safety Precautions

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Each facility should have a safety policy and emergency action plan in place. Employees should be trained on all aspects of safety procedures, including lockout/tagout. Inspect the facility for hazards regularly, and enforce all safety policies and procedures.



Any employee involved in dynamometer testing must be trained in equipment inspection, operation, troubleshooting, and emergency shutdown procedures. Shutdown procedures are different for diesel and other types of engines.



Because dynamometer testing involves running engines, follow normal safety precautions regarding engine operation and moving parts, fluids under pressure, flammable liquids, high voltage, ventilation and exhaust extraction, and noise exposure.



Before startup, inspect connections, hoses, cables, and wires for damage and tightness.



Ensure that proper safety guards are secured in place around the dynamometer and the engine being tested. All rotating parts should be guarded, including but not limited to the driveshaft and flywheels.



Clearly designate the dynamometer testing room as a “No Smoking” area.



Do not store flammable materials in the test cell.



If flammable or combustible liquids are transferred between containers, both containers must be bonded and grounded.



Train employees on stopping fuel and other leaks, as well as proper cleanup.

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

Have a fire blanket and fire extinguisher readily accessible.



Routinely test fire detection, alarm, containment, and extinguishing systems/equipment.



Conduct refueling and dynamometer testing with adequate ventilation. If velocity- or motor-operated shutters of sufficient area are not installed, the test cell door(s), except the personnel door to the control room, must remain open during a test.



All fuel supplies must have a positive shutoff valve.



A sump should be regarded as a confined space which can collect fumes and cause illness or asphyxiation.



Use safety glasses, gloves, hearing protection and safety shoes.



Tie back long hair.



Prohibit loose clothing and dangling jewelry in the testing area.



Require that clothing contaminated with flammable, combustible, or skin-irritating agents be temporarily stored in a safe manner and then properly cleaned.



Provide eyewash and first aid station(s), and train employees in emergency procedures. Gloves and protective eyewear should be available for employees rendering first aid or cleaning up biohazards (such as, blood or bodily fluids).



Personnel should avoid being in the test cell during testing. During maintenance, personnel should not be alongside rotating machinery, because thrown parts usually fly radially.



Use lockout/tag out procedures. Note: Some machines may require re-energizing before removal of lockout device(s).



Disconnect spark plugs, close fuel lines, and disable any other ignition sources to prevent accidental startup while working on an engine.



After mounting an engine to the dynamometer, check alignment by manually rotating the engine. Use a strap or chain wrench wrapped around the coupling or companion flange on the dynamometer shaft. Do not use a bar inserted through the driveshaft yoke as a crank.

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1.4

Principles of Operation The TD-3100/3102 Dynamometer act essentially as a turbulent action water brake and operates on a momentum exchange, raw water waste principle. This system converts the rotational torque of the engine to stationary torque that can be measured and displayed. Simply stated, as the amount of water within the dynamometer is increased, the load, or the resistance on the engine, is also increased. The resistance developed by the dynamometer increases with the speed of the engine. This resistance is exactly measured and is calculated in terms of horsepower. Figures 1-4 show the operating limits for the TD-3100/3102 dynamometers. The dynamometers can be operated continuously. Specifically, resistance is created by the momentum exchange principle. Water is introduced into the dynamometer through an inlet control valve. A spinning rotor, with vanes, picks up this water. The engine under test drives the rotor. The rotor then accelerates the water to a high velocity. The high velocity water is directed by the rotor vanes into the stator, which has stationary vanes. These vanes slow the water down. This exchange of energy creates heat, which is carried away and out the outlet of the dynamometer. The load on a dynamometer, of this type, is controlled by the volume of water in the dynamometer. This volume is controlled by the amount of water flowing through the dynamometer. Because the water flowing through the dynamometer carries away the energy (heat), it is important to realize that if the inlet water is too hot, the consequent rise in water temperature from the energy being absorbed by the dynamometer could in some cases boil the water. Usually, outlet temperatures should be 140°F or less. However, sometimes this is not possible. An absolute maximum outlet water temperature of 190°F should be observed. Under certain water conditions, water that is higher than 140°F will deposit a mineral “scale” on the inside of the dynamometer. Under prolonged running under these conditions, the scale can become a deterrent to efficient dynamometer performance.

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TD-3100 (English) 1100 1000 900

700

Torque (lb-ft)

Horsepower (HP)

800

3800 3600 3400 3200 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000

600 500 400 300 200 100 0 0

200

400

600

RPM TD-3100 (HP)

TD-3100 (lbft)

Figure 1 - TD-3100; English Horsepower, Torque Curve

TD-3100 (Metric) 5000

800

4500

700

4000 3500

500

3000

Torque (Nm)

Kilowatts (kW)

600

2500

400

2000

300

1500 200 1000 100

500

0 0

200

400

600

0 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000

RPM TD-3100 (kW)

TD-3100 (Nm)

Figure 2 - TD-3100; Metric Power, Torque Curve

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TD-3102 (English) 1100 1000 900

700

Torque (lb-ft)

Horsepower (HP)

800

3800 3600 3400 3200 3000 2800 2600 2400 2200 2000 1800 1600 1400 1200 1000 800 600 400 200 0 6000

600 500 400 300 200 100 0 0

400

800

1200

1600

2000

2400

2800

3200

3600

4000

4400

4800

5200

5600

RPM TD-3102 (HP)

TD-3102 (lbft)

Figure 3 - TD-3102; English Horsepower, Torque Curve

TD-3102 (Metric) 5000

800

4500

700

4000 3500

500

3000

Torque (Nm)

Kilowatts (kW)

600

2500

400

2000

300

1500 200 1000 100

500

0 0

400

800

1200

1600

2000

2400

2800

3200

3600

4000

4400

4800

5200

5600

0 6000

RPM TD3102 (kW)

TD3102 (Nm)

Figure 4 - TD-3102; Metric Power, Torque Curve

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1.5

Product Description The TD-3100/3102 engine dynamometer is a portable, engine-mounted, water brake dynamometer designed for the testing of industrial engines to 1000 hp (746 kw). The standard speed rating for the TD-3100 dynamometer is 4000 rpm. The standard speed rating for the TD-3102 is 6000 rpm. The TD-3100/TD-3102 is assembled as a unidirectional dynamometer with a capacity of 3000 ft-lb (4068 Nm) at 1500 rpm. The TD-3100/3102 is normally assembled for right hand rotation engines. The TD-3100/3102 can, however, be reassembled to handle left hand rotation engines. This is accomplished by removing the inboard and outboard stators and the rotor and reassembling them in reverse order. This reverses the vane direction and consequently capacity direction.

1.6

Specifications 1.6.1 Ratings Limits Maximum Continuous Torque

3000 ft-lb [4068 Nm)

Maximum Continuous Power

1000 hp [746 kw] 4000 rpm TD-3100 6000 rpm TD-3102

Maximum Operating Speed Minimum Controllable Torque

32 ft-lb [24 Nm] @ 1800 rpm

Minimum Controllable Power

11 hp [5 kw] @ 1800 rpm Lb*In2

Weight Moment of Inertia Table 1 - Ratings Limits

1.6.2 Physical Specifications TOTAL Length

18.5 inches [47 cm]

Width

27.5 inches [70 cm]

Height

23.5 inches [60 cm]

Weight

312 lbs. [142 kg]

Load Cell

3000 lbf, 3 mV/V [133,450 N, 3 mV/V]

Magnetic Speed Pickup

Magnetic Pickup 220 ohms impedance

Water Inlet Size Water Outlet Size

1.50 in. [38 mm] pipe 1.25 in. [31.75 mm] pipe Table 2 - Physical Specifications

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1.6.3 Water Specifications A water supply of 100 gpm [378 lpm] at 60 psi [420 kPa] is required to allow full range testing with the TD-3100. Water inlet temperature should not exceed 90°F.

PH Total Hardness Total Salinity Nitrates Chlorides Sulphate (SO3) Manganese Organic Substances Coarse Solids Solids in Suspension Free Oxygen Free Carbon Dioxide Iron Oils Algae Growth Silicates

Unit of Measurement Deg. dH * mg/liter mg/liter mg/liter mg/liter mg/liter mg/liter

Open Circuit

Closed Circuit

7–9 < 30 < 2500 < 150 < 0.15