EC997 Dynamometer Calibration Routine

To be done monthly
 

The Speed Calibration routine verifies the EC997's ability to measure Speed and RPM to 1/2048th accuracy.

The Load Cell Calibration routine verifies the EC997's ability to measure torque to better than 1/100th of a pound.

The Speed / Load Calibration routine verifies the EC997's firmware and software settings to calculate power based on the verified Speed and verified Load Cell values.
 

1. Turn OFF PAU box power.
    
2. Turn ON black box (DAQ unit) power, computer and EC997 software (as normal).
3. Stay on Graph Screen.
4. Unscrew mil spec connector from the dyno's speed sensor and unplug cable.
   1. Unscrew the CENTER threaded ring (not the two outer rings, or you will twist and short the cables) - click here.
      
5. Install Factory Pro Speed Calibration Unit (SCU) to sensor cable (replacing the dyno's speed sensor).
6. Select any Reference File and click "Go to Test".
7. On the "Test Setup" screen,
   Change "Starting RPM" to 5000 rpm (anything over 3000 rpm is ok).
   Set "Tach Ratio" to "1.0" (the reason for the "1.0" will be apparent later)
8. Now, go to the Test Screen.
9. If the EC brake comes on, you missed step 1.
10. The SCU is generating a calibrated or 2048 and the Speed readout on Test Screen should read: ~77.62 mph (if you are using a tach ratio of 1.0).
11. Tach should read 2048 rpm. (if you are using a tach ratio of 1.0)
12. ~77.62 and 2048 rpm? Good!
13. Remove SCU and reattach cable to the dyno speed sensor.
14. Replace EC brake cover and turn on power at PAU box.

If you have the SCU installed to the speed sensor connector, using a tach ratio of 1.0 and you do not see 2048 rpm and ~77.62 mph, write down what is displayed and call Tech Support at 800 869-0497. It is important that you write down what rpm and speed is displayed.

If it's a new installation, you can call Tech Support and then proceed to the Calibration Routine. If existing setup, DO NOT recalibrate the Speed Sensor before contacting Tech Support.

If it's a new

Dyne Speed Calibration:

1. Turn OFF PAU box power.
    

2. Turn ON black box (DAQ unit) power, computer and EC997 software (as normal).
3. Unscrew mil spec connector from center and unplug cable from dyno's speed sensor.
4. Install Factory Pro Speed Calibration Unit (SCU) to sensor cable (replacing the speed sensor).
5. Go to Graph Screen
6. On Main menu, click Tools / "Calibrate DAQ unit".
7. On the RH side of the box that pops up, write:  2048  in the data entry box to the right of "Span to:".
8. Then click on the "Span to:" button. It will take a few moments to get several thousand samples and arrive at a value.
9. You will see ~2048 and 77.62 mph appear to the left.
10. If you see ~2048 and 77.62, good - now click on "Write INI" and the calibration will be saved permanently.
11. Close that box. Now.....
12. Select some reference file and click "Go to Test".
13. On the "Test Setup" screen,
    Change "Starting RPM" to 5000 rpm (anything over 3000 rpm is ok).
    Set "Tach Ratio" to "1.0" (the reason for the "1.0" will be apparent later)
14. Now, go to the Test Screen.
15. If the EC brake comes on, you missed step 1.
16. Speed readout on Test Screen should read: ~77.62 mph.
17. ~77.62? Good!
18. Remove SCU and reattach cable to the dyno speed sensor.
19. Replace EC brake cover and turn on power at PAU box.

1. Turn OFF PAU box power.
2. Remove the cover of the Factory pro eddy current brake.
3. Go to Test Screen, main menu / setup
4. Click on Calibrate Load cell.
5. Check that the top green box contains the number that is stamped on your calibration weight.
   1. Sometimes an update will change it to a default value.
6. With no calibration weight on the brake's torque arm, click ZERO.
   1. The red box in the bottom right should read .000 and flicker a few thousandths of a pound.
      1. It's a raw, unaveraged readout of the load cell, hence the "alive" appearing reading.
7. Calibration weight: Carefully set the calibration weight on the torque arm of the brake.
   1. Do NOT drop the weight on the arm or you will damage the load cell.
8. Go to he program and click "Span". The red box should read the calibration weight (with a few thousandths of flicker).
9. Remove the calibration weight and the red box should read approx. the Zero weight again.
10. When you verify that you can place and remove the calibration weight, click: Save and return to test.
11. Replace the EC brake cover and turn PAU box power back on.

1. Calibrate Load cell with calibration weight (above)
2. Calibrate Speed Calibration with (above)
    
3. With calibration weight OFF the torque arm, PAU power OFF and SCU installed, speed should read 77.62mph and parasitic generated power should read:
   1. On single roller, 12.875 diameter drive roller MC dyne:   aprox.  1.7 +/- .1 hp
   2. On dual coupled roller, direct drive MC/Quad dyne:   xxhp
   3. On belt drive, dual coupled, drive roller MC/Quad dyne:   xxhp
      
       
4. With calibration weight, YES ON on the torque arm, PAU power OFF and SCU installed, speed should read 77.62 mph and parasitic generated power should read:
   1. On single roller, 12.875 diameter drive roller MC dyne:   aprox.  21 +/- .5 hp
   2. On dual coupled roller, direct drive MC/Quad dyne:   xxhp
   3. On belt drive, dual coupled, drive roller MC/Quad dyne:   xxhp
       

I would do this monthly:

Load Cell Calibration

Speed Sensor Calibration

Grease bearings (Mobilith AW2 grease avail. direct from Factory)