Instruction
Manual
RoaDyn S220
Measuring hub for
tire test stands
Type 9289A103
9289A_002-494e-07.21
Foreword
9289A_002-494e-07.21 Page 1
Foreword
Thank you for choosing a Kistler quality product
characterized by technical innovation, precision and long
life.
Information in this document is subject to change without
notice. Kistler reserves the right to change or improve its
products and make changes in the content without
obligation to notify any person or organization of such
changes or improvements.
©2010 … 2021 Kistler Group. All rights reserved. Except
as expressly provided herein, no part of this manual may
be reproduced for any purpose without the express prior
written consent of Kistler Group.
Kistler Group
Eulachstrasse 22
8408 Winterthur
Switzerland
Tel. +41 52 224 11 11
Kistler Instrumente GmbH
Umberto-Nobile-Str. 14
71963 Sindelfingen
Deutschland
Tel. +49 7031 3090 0
info.de@kistler.com
www.kistler.com
RoaDyn S220 Measuring hub for tire test stands Type 9289A103
Page 2 9289A_002-494e-07.21
Content
1.Introduction .................................................................................................................................. 4
2.Important notes ........................................................................................................................... 5
2.1For your safety .................................................................................................................... 5
2.2Warnings ............................................................................................................................. 7
2.3How to treat the instrument ................................................................................................. 8
2.4What happens after modifications? ..................................................................................... 8
2.5Disposal instructions for electrical and electronic equipment ............................................. 8
2.6Software upgrades and updates ......................................................................................... 8
3.General description of the instrument ...................................................................................... 9
3.1Field of application of a multi-component measuring hub S220 ......................................... 9
3.2RoaDyn S220 measuring chain digital and analog ........................................................... 10
3.3Technical data ................................................................................................................... 11
3.4Additional Documents ....................................................................................................... 11
4.Installation .................................................................................................................................. 12
4.1Preparation and tools ........................................................................................................ 12
4.2Preparation for mounting the measuring hub on the test bench ....................................... 13
4.2.1Measuring hub mounting location ........................................................................ 14
4.2.2Mounting on the test stand ................................................................................... 15
4.3Preparation of oil connection ............................................................................................ 16
4.3.1Connection of RoaDyn S220 with digital electronics KiRoad TT Type 9820A... .. 17
4.3.2Connection of RoaDyn S220 with analog electronics Type 5633A ..................... 17
5.Oil lubrication ............................................................................................................................ 19
5.1Oil connection ................................................................................................................... 19
5.2Oil circulating lubrications ................................................................................................. 20
5.3Oil lubrication system ........................................................................................................ 21
5.4Mounting oil hoses from the rear side of the test stand .................................................... 22
5.4.1Plug in the 5 oil hoses into the oil lubrication unit according Fig. 10 ................... 25
5.5Run the system ................................................................................................................. 26
5.5.1Oil lubrication ........................................................................................................ 26
5.5.2Final check ........................................................................................................... 26
5.5.3Mount adapter onto the RoaDyn S220 (if needed) .............................................. 26
5.5.4Mount the wheel ................................................................................................... 27
5.5.5Set Measuring values to zero ............................................................................... 27
6.Operation .................................................................................................................................... 28
6.1Permissible loads on the measuring hub .......................................................................... 28
6.2Service life of bearings ...................................................................................................... 28
6.3Setup DAQ ........................................................................................................................ 29
6.3.1With digital electronics Type 9820A… ................................................................. 29
6.3.2With analog electronics Type 5633A1 .................................................................. 29
6.4Run the system ................................................................................................................. 30
7.Maintenance ............................................................................................................................... 31
7.1On-side Fx calibration by the use of dead weights ............................................................ 31
7.1.1Preparation of Equipment .................................................................................... 31
7.1.2Deadweight calibration procedure ........................................................................ 32
7.2Checking calibration, function test and recalibration ........................................................ 37
Content
9289A_002-494e-07.21 Page 3
7.2.1Checking calibration and function test .................................................................. 37
7.2.2Recalibrating the measuring hub .......................................................................... 37
7.3Maintenance work .............................................................................................................. 37
7.3.1General ................................................................................................................. 37
8.Troubleshooting ......................................................................................................................... 38
8.1Fault location and rectification ........................................................................................... 38
8.2Technical support ............................................................................................................... 39
9.Appendix ..................................................................................................................................... 40
Total pages: 43
Introduction
9289A_002-494e-07.21 Page 4
1. Introduction
Please take the time to thoroughly read this instruction
manual. It will help you with the installation, maintenance,
and use of this product.
To the extent permitted by law, Kistler does not accept
any liability if this instruction manual is not followed or
products other than those listed under Accessories are
used.
Kistler offers a wide range of products for use in
measuring technology:
Piezoelectric sensors for measuring force, torque,
strain, pressure, acceleration, shock, vibration and
acoustic emission
Strain gage sensor systems for measuring force and
torque
Piezoresistive pressure sensors and transmitters
Signal conditioners, indicators and calibrators
Electronic control and monitoring systems as well as
software for specific measurement applications
Data transmission modules (telemetry)
Kistler also develops and produces measuring solutions
for the application fields of engines, vehicles, manufac-
turing, plastics and biomechanics sectors.
Our product and application brochures will provide you
with an overview of our product range. Detailed data
sheets are available for almost all products.
If you need additional help beyond what can be found
either on-line or in this manual, please contact Kistler's
extensive support organization.
Page 4 9289A_002-494e-01.12
Important notes
9289A_002-494e-07.21 Page 5
2. Important notes
It is essential for you to study the following information,
compliance with which is for your personal safety during
use and will ensure long, fault-free operation of the
instrument.
2.1 For your safety
This product has been manufactured in compliance with
current valid safety regulations. It has been thoroughly
tested, leaving the factory in a perfect, safe condition. In
order to maintain this condition and ensure safe
operation, compliance is required with the instructions
and warning notes contained within this manual.
Compliance with local safety regulations, which apply to
the use of power line operated electrical and electronic
equipment, is strongly recommended.
Compliance with the following precautionary
measures is vital to ensure safe and reliable
operation.
The measuring hub must be installed, operated and
serviced only by qualified persons who are familiar
with this kind of instruments
If there is evidence that safe operation is no longer
possible, the instrument must be powered off and
rendered safe against accidental start-up. Safe
operation is no longer possible when the product:
shows visible signs of damage
is no longer operating
has been subjected to prolonged storage under
unsuitable conditions
has been subject to rough transit conditions
When utilizing an external AC/DC power adapter, be
certain to use the proper input line voltage and proper
output DC voltage prior to power-up
Never expose the instrument to contamination or oil
mist
RoaDyn S220 Measuring hub for tire test stands Type 9289A103
Page 6 9289A_002-494e-07.21
Never operate or store the instrument outside the
specified temperature range
Never exceed the maximum stated voltage
Connect the instrument only to equipment for which it
was designed to be used
Never allow the product to drop
The environment should be as dry, clean and free
from vibrations as possible
Never operate the instrument if there are visible signs
of damage
For wheel force measurements, secure the
measuring hub to the test bench correctly!
Secure all parts mounted on the shaft according to
the anticipated forces!
Important notes
9289A_002-494e-07.21 Page 7
2.2 Warnings
The measuring hub is designed and manufactured by
Kistler Instrumente AG according to the best enginee-
ring knowledge and the latest state of technology.
These components, however, are not designed for
indefinite use. They are highly stressed high-perfor-
mance products and as such have a limited life, since
they are subjected to wear and tear and in extreme
cases to fatigue stress.
For this reason, the following safety measures must be
strictly observed:
The loading for the measuring hub and its accessories
must basically not exceed the overload ranges
specified in the Type 9289A data sheet
If the user has reason to believe that these overload
ranges have been exceeded, he must have the parts
tested (according to the situation, for example: visual
inspection, crack analysis etc.)
All parts must be subjected to a visual inspection on
each occasion before use
As soon as any signs of damage (crack, deformations
etc.) are visible, further use is prohibited
Strict compliance is required with the operating
instructions during mounting, in particular concerning
tightening torques for screws, the correct fitting of
parts, adequate clearance for the fixation arms and
safe cable installation
A crack test must be carried out after the first 100
hours operating time
After 500 hours operating time, the instrument wheel
and the accessories must be subjected to a crack test
periodically
RoaDyn S220 Measuring hub for tire test stands Type 9289A103
Page 8 9289A_002-494e-07.21
2.3 How to treat the instrument
The measuring hub may only be used under specified
environmental and operating conditions
Protect the signal output of the instrument against
contamination and do not touch it with your fingers. Fit
the cover supplied when the connection is not used
Protect the measuring hub while it is not in use by
keeping it in the transport and storage box supplied
2.4 What happens after modifications?
Modifications to instruments result in alterations of the
operating instructions as a rule. In such cases, enquire at
your Kistler distributor about the possibilities of updating
your documentation.
2.5 Disposal instructions for electrical and electronic equipment
Do not discard old electronic instruments in municipal
trash. For disposal at end of life, please return this
product to an authorized local electronic waste
disposal service or contact the nearest Kistler
Instrument sales office for return instructions.
2.6 Software upgrades and updates
Kistler may occasionally supply upgrades or updates for
embedded software. Such upgrades or updates must
always be installed.
Kistler declines any liability whatsoever for any direct or
consequential damage caused by products running on
embedded software which has not been upgraded or
updated with the latest available software.
General description of the instrument
9289A_002-494e-07.21 Page 9
3. General description of the instrument
3.1 Field of application of a multi-component measuring hub S220
The RoaDyn S220 measuring hub is used for rolling
resistance measurements according the commonly used
global regulations (ISO 28580, SAE J1269, ECE R117)
for passenger car tires up to tire load index 121.
Therefore, two of the orthogonal components (Fx and Fz)
which are acting on the shaft respectively on the tire
patch will be measured.
The measuring hub has a high accuracy with lowest
crosstalk and thus the ability to measure smallest
longitudinal forces (Fx) while a high normal force (Fz) acts
simultaneously. As a result of the ability to measure Fz,
the measuring hub is perfectly suited also to be used for
the test-stand controlling. It mea measures the active
wheel force independently of its point of application. Both
the average force and dynamic force changes can be
measured. The useful frequency range depends mainly
on the resonant frequency of the entire test rig.
The main application of use for the multi-component
measuring hub is:
Rolling resistance measurement
As a result of the specific construction, lowest longi-
tudinal forces (Fx) applied on the tire patch could be
precisely measured at a high nominal force (Fz).
Fig. 1: Measuring hub Type 9289A103
RoaDyn S220 Measuring hub for tire test stands Type 9289A103
Page 10 9289A_002-494e-07.21
3.2 RoaDyn S220 measuring chain digital and analog
Below are the measuring chains with single
measuring hub and digital and analog electronics.
Fig. 2: Digital measuring chain RoaDyn S220
Fig. 3: Analog measuring chain RoaDyn S220
In case any problems occur during the setup, please
contact your local Kistler office.
Measuring Hub
RoaDyn S220
Type 9289A103
Analog
Electronic
Type 5633A1
DAQ
Fz UAFxi (i= a...c)
UAFzi (i= a...c)
AD-converter
10 channels
±10V
Cable L= 4m
Type 1795A14
Cable
Lmax= 25m
DC 10...36V
(5...10W)
UAFyi (i= a...c) Calculation algorithms
according specifications
A
D
Fx
Fz
Temp
D
A
Supplied by customer
T
General description of the instrument
9289A_002-494e-07.21 Page 11
3.3 Technical data
Specifications
Measuring range Fx
Fz
N
N
–400 … 400
15 000
Instrumentation accuracy Fx
Fz
N 1)
or
% 1)
N 1)
or
% 1)
±0,5
±0,5
±10
±0,5
Max. Load Fx
Fy
Fz
N
N
N
±1 500
±500
0 … 20 000
Calibrated range Fx
Fz
N
N
0 … 400
0 … 15 000
Operating temperature range °C 5 … 80
Degree of protection (cable mounted) DIN40050 IP65
1) dependent upon which value is higher
For detailed specifications please refer to data sheet
9289A_000-761e. The actual document is available on
the Kistler website: www.kistler.com
3.4 Additional Documents
Calibration data sheet
Data sheet 000-761e
RoaDyn S220 Measuring hub for tire test stands Type 9289A103
Page 12 9289A_002-494e-07.21
4. Installation
4.1 Preparation and tools
The work surface must be clean and dry. Use appropriate
storage surfaces and lifting gear.
The measuring hub must be fitted only by trained
personnel. Make sure screws and bolts are never
over-tightened beyond their specified torques.
Use suitable lifting gear when fitting a measuring hub.
Support the measuring hub at all times to prevent it
from dropping.
Make sure that it is never exposed to any hard
strokes! The force of such shocks may exceed the
measuring range of the instrument and cause
permanent deformations.
Do not use inappropriate tools like, for example, a
hammer to position the rim adapter (hammer strokes
may cause deformation of the bearings or rim).
Use health and safety equipment (wear safety shoes
and gloves).
In the following chapters, you will find information on
installing the measuring hub and basic details for
setting up the test rig.
Installation
9289A_002-494e-07.21 Page 13
4.2 Preparation for mounting the measuring hub on the test bench
Please comply with the following notes for correct
mounting of the measuring hub:
The measuring hub must only be installed by persons
who are familiar with the instrument and are
adequately qualified for this work
Before connecting the cable to the measuring hub
clean both sides of the connector (measuring hub and
cable) with the cleaning and insulation spray Type
1003. Check orientation by bringing the mark on the
connector of the cable in line with the hole of the
metal sheet (Fig. 2). Plug in the cable until a proper
contact is made
Before mounting the measuring hub on a test bench
or another test device also connect the oil hoses as
explained in chapter 5.1
Before mounting the measuring hub on a test bench
or another test device, check that the mounting
surface is flat and clean. Uneven and dirty contact
surfaces cause internal distortions, which will expose
the individual force sensors to additional high shear
stresses and can increase crosstalk
Fig. 4: Connection
RoaDyn S220 Measuring hub for tire test stands Type 9289A103
Page 14 9289A_002-494e-07.21
4.2.1 Measuring hub mounting location
The measuring hub could be mounted either on the left or
the right side of the drum (Fig. 6).
Fig. 5: Horizontal drum axle with different positions of
the measuring hub
As the coordinates are in fixed relation to the measuring
hub, they remain for all positions the same:
Fx: Longitudinal force (rolling resistance)
Fz: Normal force
To avoid overload on the X direction, ensure that the
measuring hub is mounted in the correct orientation.
The measuring hub is provided with oil lubrication. It must
be performed with the specific oil-supply related
to the mounting position as described in Fig. 6.
Installation
9289A_002-494e-07.21 Page 15
4.2.2 Mounting on the test stand
Depending on the design of the tire test stand it is
recommended to mount all equipment on the rear side
(e.g. resolver, slip ring, oil hoses, etc.) before mounting
the RoaDyn S220 onto the tire test stand.
Standard mounting of the measuring hub by using six
M16x60 mm screws on pitch circle diameter of 280 mm.
Screws must be tightened with a torque of
180 … 190 Nꞏm.
The positioning is given by two 10 mm pins which are
also located on the pitch circle diameter 280 mm. These
positioning pins allow accurate mounting and remounting
of the measuring hub. Therefore, adjustment of position
according the regulations is recommended to be done on
a second layer.
Fig. 6: Measuring hub with wheel mounted on the tire
test stand
Ensure that the measuring hub makes absolutely flat
contact. Even the slightest gap will produce unwanted
elasticity and cause a reduction in the resonant fre-
quency of the measuring arrangement. Therefore,
examine all structures also for vibration
Wherever possible, the connecting cable should
remain permanently connected to the measuring hub
Fit the connecting cable and the oil tubes so that it
cannot shear off or be ripped out during operation
RoaDyn S220 Measuring hub for tire test stands Type 9289A103
Page 16 9289A_002-494e-07.21
4.3 Preparation of oil connection
The following instructions will give you a stepwise
explanation about the mounting of the RoaDyn S220 onto
the tire test stand.
To avoid any shunt-force measurement due to a strong
contact to the test stand, we strongly recommend taking
out the oil hoses at the rear side as shown in the
following picture. Therefore, the straight oil connectors
are already mounted.
Fig. 7: Check if sealing is correctly done by connecting
to oil lubrication system according instructions in
chapter 5.1
Installation
9289A_002-494e-07.21 Page 17
4.3.1 Connection of RoaDyn S220 with digital electronics KiRoad TT Type
9820A...
Fig. 8: Connection with digital electronics
4.3.2 Connection of RoaDyn S220 with analog electronics Type 5633A
Fig. 9: Connection with analog electronics
RoaDyn S220 Measuring hub for tire test stands Type 9289A103
Page 18 9289A_002-494e-07.21
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