The Experts in Turbomachinery

VAROC® Air Dynamometers

For load testing gas turbine engines

• Engineering • Software • Manufacturing • Training

Concepts NREC
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VAROC Air Dynamometers
The VAROC Air Dynamometer is used worldwide by both military and commercial organizations to test
a broad range of gas-turbine engines. The patented design is a VAriable-geometry, Radial Outflow Com-
pressor (VAROC) that provides significant advantages over all other types of dynamometers. The VAROC
can operate in any climate and is designed to be highly reliable, simple to operate, easy to maintain, com-
pact, and lightweight. VAROC dynamometers are now being used by military and commercial organizations
throughout the world and are the dynamometers preferred by the defense agencies of many countries.

No Complex Water Systems and Support Equipment Needed

The VAROC uses ambient air for power absorption and does not
need the substantial water systems required by conventional dy-
namometers. VAROC dynamometers completely eliminate the
need for fixed plumbing installations, heat exchangers, cooling
towers, and electrical load banks. Using air as the working fluid
also eliminates environmental pollution caused by oil contamina-
tion of the water system.

Can Be Used in Fixed Test-Cell Installations or

Mobile Field Applications in Any Climate
Using ambient air to absorb engine output greatly enhances porta-
bility and allows the VAROC to operate in any climate. This can be
a significant advantage in fixed test-cell operations and is essen-
tial for practical remote engine testing. The VAROC can be used
anywhere, regardless of climate.

Stable Operation and Precise Control

The unique VAROC design uses a two-sided impeller to create a
balanced double air-entry arrangement. Power absorption is pre-
cisely controlled by a moving shroud which exposes a portion of
the rotating impeller blades to the flow path. This variable-length
blade system is accurately regulated by a precision high-speed
servo motor. The high inertia of the impeller provides very stable
control and eliminates the need for a separate flywheel.

Simple to Operate, Easy to Maintain, and Very

Reliable
No special training is required to use a VAROC dynamometer,
and the simplicity of the design substantially reduces mainte-
nance. Moving parts are limited to the impeller, bearings, and the
shroud-actuating mechanism. The V series dynamometer utilizes
oil-damped ball bearings while the S series incorporates fluid film
bearings to extend bearing life. VAROC dynamometers require
minimal maintenance between overhauls and have decades of
proven reliability in the most challenging applications.
Applicable to a Wide-Range of Engine Types
The VAROC comes in four models and can test more than forty engine types. Engine shafts can be
coupled to either end of the VAROC for rotation in either engine direction. When used with optional
torque-sensor instrumentation, the VAROC dynamometer can test an entire series of engines with a single
dynamometer/sensor combination.

Turnkey Test Packages Available

Concepts NREC can supply only the VAROC dynamometer or work with proven test-system manufacturers
to produce a turnkey VAROC test cell. Concepts NREC can also supply all shafting, torque measurement
systems, dynamometer control equipment, instrumentation, and special accessories.

Service
Concepts NREC maintains extensive overhaul and maintenance facilities to service the VAROC family
of air dynamometers.

Dynamometer Operating Envelope

Dynamometer Design Comparison
Dynamometer type VAROC V Series VAROC S Series Hydraulic Dynomometer

Working Fluid Air Air Water

Infrastructure Exhaust Duct Exhaust Duct Supply water tank

Requirements (Optional) (Optional) Water treatment system
Water filtration system
Booster pumps, motors
Water pressure regulator
Load control valve
Cooling system
Water plumbing

Operating Cost Low Low High

Portability High Moderate Limited

Cavitation Risk None None Potential

Load Stability High High Moderate

Flywheel None None Yes

Overhaul Interval Up to 2,000 hours Up to 10,000 hours Up to 10,000 hours

Regular Maintenance Minimal Minimal Significant

Types of Dynamometers
Air Dynamometer

The VAROC air dynamometer uses a unique patented radial-outflow compressor with sliding shrouds
that effectively modify the geometry of the flow path to vary engine load. The simple VAROC design pro-
vides stable operation over a wide range of speed and power, and permits low weight, small size, minimal
maintenance, and high portability, in any climate.

Hydraulic Dynamometers

Hydraulic dynamometer systems are heavy, not easily transportable, and typically limited to low speeds.
The water must be cooled for reuse and can become contaminated with chemicals that pose an environ-
mental threat which is expensive to treat. Water impurities and corrosion can also cause poor reliability,
premature rotor erosion, and the need for frequent maintenance.

Eddy Current Dynamometers

Eddy current dynamometers are large, heavy devices for fixed installations with cooling systems that
generally require water treatment. Besides not being portable, eddy current dynamometers are expen-
sive to operate and maintain, and have a relatively narrow operating range which limits the number of
engine models that can be supported by any one unit.
Specifications
V Series S Series

Dimensions
A B C D E F
V35 13.5 28.7 40.2 35.2 33.3 23.7
Inches (cm) (34.3) (72.9) (102.1) (89.4) (84.6) (60.3)
V35-85 13.5 28.7 40.2 35.2 33.0 23.7
Inches (cm) (34.3) (72.9) (102.1) (89.4) (83.8) (60.3)
V250 24.5 50.5 58.9 60.0 47.6 30.0
Inches (cm) (62.2) (128.3) (149.6) (152.4) (120.9) (76.2)
S35 15.5 33.8 41.0 35.0 31.6 22.5
Inches (cm) (39.4) (86.0) (104.1) (88.9) (80.3) (57.2)

Performance
V35 V35-85 V250 S35
Speed range (RPM) 24,000 24,000 16,000 24,000
Power Range 3,500 5,500 18,000 3,500
HP (kW) (2600) (4,100) (13,500) (2,600)
Weight 830 862 2,875 1,750
lbs (Kg) (376) (391) (1,304) (794)
Operating Voltage 100-440 100-440 100-440 100-440
VAC (Hz) (50-60) (50-60) (50-60) (50-60)
Lubrication System Integral Integral External External
Mass Flow 18.2 38.6 77.4 18.2
Lb/sec (Kg/sec) (8.3) (17.5) (35.1) (8.3)
Rotor Inertia 0.51 0.43 3.02 0.52
Slug-ft2 (Kg-m2) (0.69) (0.59) (4.10) (0.70)

Component Characteristics
V35 V35-85 V250 S35
Plenum Stainless Steel
Chassis Stainless Steel Cast Iron
Impeller Stainless Steel Titanium Stainless Steel
Seals Wear-Compensated Segment Carbon Labyrinth Seals
Bearings Pre-loaded Angular Contact Bearings Fluid Film Bearings
High Precision Torque Measurement System
The VAROC High Precision Torque
Measurement System (TMS) pro-
vides high speed torque measure-
ment for turboshaft engine testing.
It delivers accuracy, repeatability
and reliability, and the system can
be easily calibrated in the field.

The TMS uses a torquemeter man-

ufactured by Torquemeters LTD.
The Torquemeters LTD technolo-
gy is the state of the art in torque
measurement. The heart of the
system is a multi-pole sensor, uti-
lizing multiple pick-ups in the form
of internally toothed rings. The pick-
up/field coils are wound circumfer-
entially giving a toroidal flux path.
Radial shaft movement is compen-
sated with the circumferential sen-
sor as an early signal at one tooth
is compensated by a late signal from the opposite tooth making the phase output largely independent of
shaft radial position. This greatly improves the accuracy in the high-speed drive lines used in turboshaft
engine testing.

The integration of the torquemeter to the VAROC dynamometer eliminates external support systems,
such as a pedestal or oil supply system. The torquemeter is close coupled to the dynamometer, thereby
eliminating the coupling normally used between a torquemeter and dynamometer. Calibration of the
system is done with the torquemeter mounted on the dynamometer. Calibration is fast and accurate.

The improved accuracy of the

torque system (.5% FS) provides
a significant cost savings. Engine
acceptance criteria must consid-
er the system accuracy. A narrow
tolerance band results in fewer re-
jections of the items under test. In
addition, the ability to calibrate the
torque system serves to put to rest
any concerns related to test accu-
racy in the course of engine testing
and evaluation of the results. This
can save the costs of repeat testing and eliminate the costs spent in defending the test validity. Concerns
over test validity can delay repair action and tie up product in long periods of evaluation and resolution.
Field calibration and demonstration of an accurate test system saves time and money.
The Experts in Turbomachinery

London, UK

White River Junction, USA

Shanghai, China

Bangalore, India

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