USER MANUAL B. Chassis
Release 6.0 / 2010
INDEX 1.CHASSIS ........................................................................................................... 4 GENERAL AGREEMENT AND WARRANTY ............................................................ 5 FIXED PARTS .................................................................................................. 5 SAFETY WHEEL TETHERS ..................................................................................... 6 SET-UP .............................................................................................................. 7 MICHELIN TIRE INFORMATION .......................................................................... 7 SUGGESTED SETUP.......................................................................................... 7 SETUP ADJUSTMENT ........................................................................................ 8 SETTING THE VERTICAL SPRING PRE-LOAD......................................................... 9 FRONT ANTI ROLL DEVICE AND ROLL PRELOAD ................................................. 10 BELLEVILLE STACK CONFIGURATIONS .............................................................. 11 SETTING THE FRONT ROLL PRELOAD................................................................ 12 CASTOR ....................................................................................................... 13 FRONT SUSPENSION PICK-UP POINTS .............................................................. 14 STEERING WHEEL: .......................................................................................... 15 STEERING ASSEMBLY ..................................................................................... 15 STEERING WHEEL HEIGHT .............................................................................. 16 REAR SUSPENSION ......................................................................................... 18 ROLL CENTER AND ANTISQUAT OPTIONS.......................................................... 18 FLOOR EXTENSION MODIFICATION .................................................................. 20 FLOOR EXTENSION MODIFICATION .................................................................. 21 REAR ANTIROLL BAR STIFFNESS...................................................................... 22 REAR SUSPENSION PICK-UP POINTS ................................................................ 24 SET-UP ............................................................................................................ 25 RIDE HEIGHT CHECK AND REFERENCES............................................................ 25 DRAWINGS ................................................................................................... 26 NOSE FITTING ................................................................................................ 29 AERODYNAMICS.............................................................................................. 30 DEFINITIONS ................................................................................................ 30 AERODYNAMICS FEATURES OF THE CAR ........................................................... 30 FRONT WING ASSEMBLY................................................................................. 31 MAIN BODY AND UNDERWING ......................................................................... 34 REAR WING ASSEMBLY................................................................................... 36 LOW DOWNFORCE AERODYNAMIC CONFIGURATION (LAC) .................................. 42 POLAR DIAGRAM OF THE CAR.......................................................................... 43 AERO MAPS .................................................................................................. 44 COOLING INLET BLANKING ............................................................................. 46 POLAR DIAGRAM OF THE MAIN ADJUSTABLE DEVICES ........................................ 47 OIL SYSTEM .................................................................................................... 48 OIL LEVEL AND CHARACTERISTICS .................................................................. 48 HYDRAULIC OIL SYSTEM................................................................................. 49 ENGINE COMPARTMENT COOLING .................................................................. 50 EXTRACTABLE SEAT ........................................................................................ 52 CARBON SHELL AND LEG STRAP POSITION ....................................................... 52
B-2
Release 6.0 / 2010 BLACK SOCKET POSITION............................................................................... 54 SIDE BELTS .................................................................................................. 54 DRIVER SEAT DIMENSION .............................................................................. 55 FUEL SYSTEM .................................................................................................. 56 EXTINGUISHER SYSTEM LAY-OUT ................................................................... 56 EXTINGUISHER SYSTEM LAY-OUT ................................................................... 57 DETAILS....................................................................................................... 57 TESTING ...................................................................................................... 58 PRECAUTIONS............................................................................................... 58 SBS 30 – DRY BATTERY................................................................................... 59 CHARGING PROCEDURE.................................................................................. 59 SAFETY NOTES .............................................................................................. 59 SWITCH PLATE................................................................................................ 60 SWG & CONVERSION TABLE............................................................................ 61 SHEET METAL THICKNESS .............................................................................. 61 UNIT CONVERSION TABLE .............................................................................. 61
B-3
Release 6.0 / 2010
1.CHASSIS
B-4
Release 6.0 / 2010 GENERAL AGREEMENT AND WARRANTY Motor racing is not covered by warranty due to the intentional choice of drivers to race in a dangerous environment DALLARA indicates that, under normal operating conditions, this model of car, when new, would not show failure in structural components before it has completed around 10 000 Km. This holds true if necessary maintenance and checks are provided and if the car has no previous accidents. DALLARA is not responsible for incorrect chassis repairs, if made outside its factory or in centres not authorized by DALLARA. Chassis should be checked for structural failure not later than two years after delivery from the DALLARA factory, and after each major accident. After the first check or after any major accident it is mandatory to check the chassis every year in a centre authorized by DALLARA.
FIXED PARTS Teams are not allowed to use, test or run chassis parts not supplied by “Magasin Pièces détachées Compétition Renault Sport” except for the parts related to driver comfort in the cockpit. Main fixed parts are the following ones:
Springs (front: between 900 and 1600 lb/in, rear: between 900 and 1700 lb/in). ZF SACHS Race Engineering Dampers FBT23 (front) and FBT24 (rear) Differential ramps: 20°/60°; 45°/80°; 45°/45° and 45°/20° only allowed Front anti roll bar with 2mm Belleville springs. Rear T-shaped anti roll bar: 20x2.25, 25x1.5, 30x1.5, and 30x5 mm only are allowed Carbon / Carbon Clutch (140mm diameter) Carbon discs and carbon brake pads Brake master cylinders Seat harness
B-5
Release 6.0 / 2010
SAFETY WHEEL TETHERS
FRONT TETHERS – WHEEL SIDE
FRONT TETHERS – CHASSIS SIDE
REAR TETHERS – WHEEL SIDE
REAR TETHERS – CHASSIS SIDE
Wheel side installation: Front and rear: eyelet trapped around the brake calliper bosses. Chassis side installation: Front: front tether eyelet trapped around lower wishbone front leg central bracket; Rear: Tether eyelet trapped around the suspension brackets. Use a specific washer create enough space for the tether eyelet as described below: Renault Sport and Dallara recommend replacing wheel tethers if one or more of the following conditions are met:
The cable has been on the car for 12 months The car has been in an accident. The cable has been damaged, i.e. the braid, tape or mould have been damaged exposing the fibre, the cable or cover has been cut, the cable has been over-tensioned (cables are not designed to be exposed to any load prior to an accident
B-6
Release 6.0 / 2010 SET-UP
MICHELIN TIRE INFORMATION Tire dimensions depend on tyre pressure, rim width and camber angle. The stiffness values are based on the recommended inflating pressure (hot tyres). FRONT 26/64/13 1994 317.4 295.2 329.5 8.7 1.5
Specification Static circumference (mm) Unloaded radius (mm) Average loaded radius (mm) Width Weight (kg) Hot tire pressure (bar)
REAR 32/66-13 2060 327.8 308.5 382.5 10.2 1.5
SUGGESTED SETUP The set-up considers the complete car, with all liquids [water, oil], driver and 30 kilograms of fuel, ready to race. The front anti-roll setting pre-load is ‘double stiffness’ pre-load, for details look at the FARB pages.
Ride height Camber Castor (apparent) Toe (total two wheels) Springs Vertical pre-load Damper free gap Damper setting LS Damper setting HS Roll centre setting Anti Roll setting Roll pre-load Ramps Differential setting Plates Preload
mm deg deg deg Lb/in mm mm
FRONT 23 -3.5° 0.0° 40’° OUT 1600 5.5 turn 4 B8 R10 B10 R6 STD <<<<>>>>
notches
mm
B-7
2 -
REAR 38 -2.5° 20’ IN 1300 0 turn 11 B10 R2 B8 R8 3-A 20x2.25 Titan P3 Acc 20° Bra 60° 8 0.4
Release 6.0 / 2010
SETUP ADJUSTMENT POSITIVE CHANGE IN: Ride Height Toe Camber Castor
PUSHROD ADJUSTER Ride Height change +1 barrel Camber change (deg) TURN Thread size TOE ADJUSTER (PER WHEEL) toe change (deg) thread step CAMBER +1mm SHIM toe change (deg) CASTOR ADJUSTER Castor change (deg) Thread step & size Ride height change +1TURN Camber change (deg) Toe change (deg) SPRING PLATFORM thread step (mm) +1TURN height change (mm) RATIOS WHEEL/SPRING RATIO (vertical) WHEEL/BELLEVILLE RATIO (lateral) WHEEL/DROP LINK RATIO (roll) ROLL CENTRE HEIGHT [from ground]
MEANS: car moves up toe-out upper part of rim outward lower part of rim points ahead FRONT
REAR
6.00mm
7.56mm
0.1°
0.16°
M20x2R+7/16UNF20L=3.27mm
M20x2R+1/2UNF20L=3.27mm
0.6° (per turn) 1/4UNF-24 0.28° 0°
0.31° (per 1mm shim)
0.34° 1.06mm-1/4UNF-24 +0.20 mm +0.19° 0°
0.42° 1.27mm-1/2UNF-20 +0.42 mm +0.14° 0.05°
1.5 1.31
1.5 1.72
0.874 1.704 --
1.15 ---1.61
7.4 mm [down]
STD: 32mm [up]
0.24° 0°
Spacers to adjust camber and rear toe are available in the following thickness. FRONT: 1.0, 1.5 and 2.0 mm REAR: 0.5, 0.8, 1.0, 1.2, 1.5 and 2.0mm. Combine these spacers to make fine adjustments. At the rear, you can adjust toe with differential spacers. At the front, because of the “mono” geometry, when the axle moves vertically by 1mm, the vertical spring is compressed by 1/0.87 mm. When the difference in wheel vertical movement, from side to side, is 2 mm, the Belleville stack is compressed by 1/1.704 mm.
B-8
Release 6.0 / 2010 FRONT SUSPENSION
SETTING THE VERTICAL SPRING PRE-LOAD
Mount the spring with the spring platform C just in contact with the spring. Mount the damper-spring assembly on the car and put the car with the driver seated on the set-up floor. Bounce the car a few times to settle it down. Be sure that the droop-stop A is not in contact with the plate B. Set the desired ride height with the pushrod adjusters. Turn the droop-stop A in contact with plate B and tighten with its counter-nut. Turn spring platform C by the amount of turns to get the desired pre-load force
B-9
Release 6.0 / 2010
FRONT ANTI ROLL DEVICE AND ROLL PRELOAD There are three different ways of setting the front anti-roll Belleville washers. The platform thread step is 1.5 mm. There are 15 notches per turn, hence 0.1 mm preload per notch. [1] Select a stack configuration and turn the platforms (both sides) until just in contact with the stack. In this configuration there is no pre-load and the roll stiffness is the nominal stack stiffness. For example: the configuration <<>><< gives 761kg/mm stack stiffness. [2] By turning both platforms (use notches as a reference) you preload the system. The roll stiffness below the pre-load threshold is twice the nominal stack stiffness. The roll stiffness above the pre-load threshold is the nominal stack stiffness For example:” >><<>> + 5 notches “ has 0.5mm of roll preload and, up to 0.5 mm of side rocker movement, the stack stiffness is 761x2=1522kg/mm. [3] By turning both platforms (use notches as reference) and by locking the two extra locknuts the system is infinitely stiff, this means the rocker will not move as long as the force is lower than the pre-load. Once the side force overcomes the pre-load, the stiffness is the nominal stack stiffness. Both pre-load settings (2 and 3) generally help for sharper turn-in. No pre-load settings (1) can make the tyres last longer and make the car easier to drive. Above the pre-load, the stiffness gets back to the nominal stack stiffness. The driver may prefer not to overcome the pre-load in certain conditions (turn-in…) and to overcome the pre-load in some other conditions (mid corner, curbs…). Set accurately the transition point of ‘pre-load / no pre-load’ since the consequently stiffness variation is sudden and reflects immediately on the balance You can combine different stacks in series to achieve a progressive load / displacement characteristic. Pay attention to the following:
Total length of the combined stack should never be more than 28mm. The clearance between the platform and the rocker (B) should not be more than 6.5mm when the platform just touches the Belleville stack, with no pre-load. For any Belleville stack, in running conditions, the total of the rocker lateral displacement plus the chosen pre-load must never reach the "Maximum Deflection" (see Table below), to avoid the side of the rocker to “bottom-out” suddenly. Belleville thickness is 2.0 mm
B-10
Release 6.0 / 2010
BELLEVILLE STACK CONFIGURATIONS Stack configuration
Stack stiffness [kg/mm]
Stack stiffness (preload) [kg/mm]
Stack length [mm]
Max deflection [mm]
<<<<>>>> <<<>>> <<<>>><<< <<>><< <<>><<>> <<>><<>><< <>< <><> <><>< <><><> <><><><
2504 1796 1197 761 571 457 362 272 218 181 155
5008 3592 2394 1522 1142 914 724 544 436 362 310
17.50 13.50 20.25 14.25 19.00 23.75 8.25 11.00 13.75 16.50 19.25
1.12 1.12 1.69 1.69 2.25 2.81 1.69 2.25 2.81 3.37 3.93
Max notches
Do not exceed maximum notches with preloaded configurations
8 8 12 12 17 22 14 17 22 26 28
FRONT ANTI-ROLL BAR
MRarb
[-/-]
1,704
Track
[m]
1,630
Stack configuration
Stack Stiffness
Stack Stiffness AntiSymmetric Model
Stiffness @ Ground
Stiffness @ Ground
[kg/mm]
[kg/mm]
[kg/mm]
[kgm/deg]
<<<<>>>>
2504
1252
431
10008
<<<>>>
1796
898
309
7177
<<<>>><<<
1197
599
206
4786
<<>><<
761
381
131
3041
<<>><<>>
571
286
98
2272
<<>><<>><<
457
229
79
1820
<><
362
181
62
1443
<><>
272
136
47
1087
<><><
218
109
38
873
<><><>
181
91
31
726
<><><><
155
78
27
615
B-11
Release 6.0 / 2010
SETTING THE FRONT ROLL PRELOAD DOUBLE STIFFNESS PRE-LOAD
Select and mount the stack and turn the platforms to contact the Belleville stack Turn the platforms until distance A is the same on both sides Check distance B to be less than 6.5mm, if it is more, replace the adjustment spacer Mark this platform position as the “zero pre-load” notch Turn both left and right platforms by the same amount of notches to set the desired pre-load. (1 notch = 0.1mm) The platform has 15 notches per turn
INFINITE STIFFNESS PRE-LOAD Set the pre-load as described for the double stiffness procedure described above Mount nut D in contact with the platform Tighten lock nut E against nut D, (1 notch = 0.1mm)
B-12
Release 6.0 / 2010
CASTOR FRONT When the car is flat ( front and rear ride height are identical ) and the front upright inclination is 0.00° [APPARENT CASTOR ] the effective castor angle is 7.60° [ BUILT-IN CASTOR ]. With different front to rear ride heights, castor angle changes because of the pitch angle of the car. For instance, with 20 mm front and 35mm rear ride heights, measured at wheel axis, (wheelbase is 3125 mm) the pitch angle is 0.27° and castor angles (both apparent and total) are reduced. Pitch angle : [(35-20)/3125] 57.296 = 0,27° Total Castor angle : 7,60° - 0,27° = 7,33° Apparent Castor angle : 0,00° - 0,27° = -0,27°
B-13
Release 6.0 / 2010
FRONT SUSPENSION PICK-UP POINTS
REFERENCE POINT: X0: FRONT WHEEL AXIS Y0: LONGITUDINAL AXIS Z0: BOTTOM OF THE CHASSIS (NOT THE WOODEN SKID)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Front suspension coordinates X Y Z 267,0 18,0 147,1 -370,0 15,0 161,5 112,0 155,0 350,0 -296,5 192,5 349,8 170,0 170,0 353,5 -37,7 691,0 368,0 -11,1 724,6 167,7 57,3 720,5 369,5 0,0 815,0 -27,0 0,0 798,7 283,4 -10,3 676,5 195,4 0,0 70,0 542,5 75,0 60,0 539,0 155,0 0,0 562,0 275,0 0,0 249,1 75,0 -60,0 539,0
B-14
Release 6.0 / 2010 STEERING WHEEL: For safety reason Dallara allows a minimum distance between the steering wheel assembly and the chassis (as in the following picture). Please check accurately. For distances close to 59 mm, the optional steering column support for taller drivers must be used (it is fixed on the front face of the bulkhead).
STEERING ASSEMBLY Pinion primitive diameter [ mm ] Static steering ratio
B-15
13.7 14.6 steering wheel/wheel
Release 6.0 / 2010
STEERING WHEEL HEIGHT To manage the steering wheel height two steps must be followed: A. Use the support for tall drivers B. Add spacer between the second column support and the tub Use support for tall drivers
Add the spacers here to raise the steering wheel further
The support for tall drivers (77 11 165 330) will raise the steering wheel of 5 mm approximately. To further raise the steering wheel, spacers can be added between the support and the tub. Make sure that the screws (M6 8.8) are long enough to maintain the support. You must use Loctite on the screws. There are two types of spacers: 8 mm 1 mm The maximum height of the spacer stack is 14 mm
B-16
Release 6.0 / 2010 Procedure: 1. Un-tighten the nuts that keep the steering box in place
2. Insert spacers (up to 14 mm) between the monocoque and the intermediate support 3. By doing this, you will change the inclination of the steering box; it is allowed to grind the Magnesium bulkhead in case the steering box touches in the area shown below (picture A); it is allowed as well to remove material from the leg padding in case the steering column touches in the area shown below (picture B)
Picture A
Picture B
4. Once you get the position you want for the steering wheel, be sure that the steering column can turn freely.
B-17
Release 6.0 / 2010 REAR SUSPENSION
ROLL CENTER AND ANTISQUAT OPTIONS Roll center height is measured from the ground with the car at design ride height (35 mm).
DO NOT USE COMBINATIONS NOT LISTED BELOW !!!
OPTION 1-A 1-E 1-I 2-A 2-E 2-I 3-A 3-E 4-A 4-E (STD) 4-I 5-E 5-I 6-A 6-E 7-E 7-I
Roll centre height (Variation [mm] from STD) +22.5 +49.5 +74.0 Shorten 1turn to adjust Bump Steer +5.0 Lengthen 2turns to adjust Bump Steer +32.0 Lengthen 2.5turns to adjust Bump Steer +58.0 Lengthen 3turns to adjust Bump Steer -10.0 Shorten 1.5turns to adjust Bump Steer +17.0 Shorten 2.5turns to adjust Bump Steer -28.5
Camber change for 10mm wheel travel -0.20° -0.30°
/ +26.5 Shorten 1turn to adjust Bump Steer -24 Lengthen 3 turns to adjust Bump Steer +3.3 Lengthen 3 turns to adjust Bump Steer -55 Shorten 3turns to adjust Bump Steer -27 Shorten 2.5 turns to adjust Bump Steer -51 -29.3 Lengthen by 3 turns to adjust bump steer
Antisquat %
Antilift %
27,0 27,0
12,1 12,1
-0.39°
27,0
12,1
-0.17°
11.1
-18.3
-0.27°
11.1
-18.3
-0.37°
11.1
-18.3
-0.15°
42.8
42.5
-0.25°
42.4
42.5
-0.12°
27.0
12.1
-0.22°
27.0
12.1
-0.32°
27.0
12.1
-0.19°
11.6
-18.6
-0.29°
11.6
-18.6
-0.06°
42.6
41.8
-0.16°
42.6
41.9
-0.13°
27.0
12.1
-0.24°
27.3
12.3
Rear roll centre height in STD configuration is 32 mm from ground (with a static rear ride height of 35 mm). OPTIONS IN BLUE: The modification of the floor extension is compulsory (see page B21)
B-18
Release 6.0 / 2010
1-E
1-A
2-A
1-I
2-E
2-I
3-A
3-E
B-19
Release 6.0 / 2010
4-A 4-E
4-I
5-I
5-E
6-E 6-A
7-I
7-E
B-20
Release 6.0 / 2010
FLOOR EXTENSION MODIFICATION To comply with the lowest position of the lower wishbone used in options 5E, 5I, 7E, 7I, it is compulsory to perform the following modification to the floor extension.
The modification consists in cutting off a 15 mm stripe from the existing cut in the part. THIS MODIFICATION IS NOT COMPULSORY WHEN NOT USING THE MENTIONED POSITIONS When the rear lower wishbone is mounted on the gearbox using the upper position of the front mounting (configuration 1A, 1E, 1I, 3A and 3E), the forward leg of the wishbone is touching on the diffuser. In order to avoid any interference problem it is allowed to grind the underwing in the area shown in the picture. Furthermore, check that the brake line can’t be damage because of the contact with the diffuser.
B-21
Release 6.0 / 2010
REAR ANTIROLL BAR STIFFNESS There are four different T shaped anti roll bars: 20x2.25 mm 25 x 1.5 mm. 30 x 1.5 mm 30 x 5 mm And two blades: one made of steel, one made of titanium.
Important: The titanium blade can exclusively be used with the Ø20 X 2.25 bar. At Full soft (Position 1) the blade is vertical. At Full Stiff (Position 5) the blade is horizontal. REAR ANTI-ROLL BAR MRarb Track
Ø 20 x 2.25 Ti Blade Ø 20 x 2.25 Ø 25 x 1.5 Ø 30 x 1.5 Ø 30 x 5
Ø 20 x 2.25 Ti Blade Ø 20 x 2.25 Ø 25 x 1.5 Ø 30 x 1.5 Ø 30 x 5
Ø 20 x 2.25 Ti Blade Ø 20 x 2.25 Ø 25 x 1.5 Ø 30 x 1.5 Ø 30 x 5
[m]
1,614 1,529
P1
P2
P3
P4
P5
Component Stiffness
Component Stiffness
Component Stiffness
Component Stiffness
Component Stiffness
[kg/mm]
[kg/mm]
[kg/mm]
[kg/mm]
[kg/mm]
13
15
18
22
24
20 25 29 38
21 27 32 43
24 33 40 59
28 39 49 80
29 40 55 93
P1
P2
P3
P4
P5
Stiffness @ Ground
Stiffness @ Ground
Stiffness @ Ground
Stiffness @ Ground
Stiffness @ Ground
[kg/mm]
[kg/mm]
[kg/mm]
[kg/mm]
[kg/mm]
10
11
14
17
18
15 19 22 29
16 21 24 33
18 25 31 45
21 30 38 61
22 31 42 72
P1
P2
P3
P4
P5
Stiffness @ Ground
Stiffness @ Ground
Stiffness @ Ground
Stiffness @ Ground
Stiffness @ Ground
[kgm/deg]
[kgm/deg]
[kgm/deg]
[kgm/deg]
[kgm/deg]
206
229
280
341
372
308 393 454 598
328 429 496 678
374 509 626 921
431 608 766 1251
457 632 861 1461
[-/-]
B-22
Release 6.0 / 2010 Rear anti-roll stiffness ranges:
Rear ARB Stiffness - WSbR 1600
1400
Ground Stiffness [kgm/deg]
1200
1000
800
600
400
200
0 Ø 20 x 2.25 Ti Blade
Ø 20 x 2.25
Ø 25 x 1.5
B-23
Ø 30 x 1.5
Ø 30 x 5
Release 6.0 / 2010
REAR SUSPENSION PICK-UP POINTS
REFERENCE POINT : X0: REAR WHEEL AXIS Y0: LONGITUDINAL AXIS Z0: BOTTOM OF THE CHASSIS (NOT THE WOODEN SKID) Rear suspension coordinates (4E –STD) X Y Z 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
355.405 -157.179 355.531 -155.232 -155.232 75.829 28.593 -96.334 0.000 0.000 33.685 66.066 117.500 74.381 368.000 117.500
B-24
128.508 118.497 157.023 134.490 134.490 586.991 664.923 587.332 764.500 753.262 608.773 151.997 132.874 30.864 85.000 92.998
148.786 133.570 331.576 316.402 316.402 379.000 158.300 373.500 -42.000 279.804 184.091 395.943 404.258 448.613 425.000 312.552
Release 6.0 / 2010 SET-UP
RIDE HEIGHT CHECK AND REFERENCES Front and rear ride heights are fundamental for setting and changing the aerodynamic performance of the car. It might be difficult to measure them directly, so we provide alternative references. The example shows the design configuration with front ride 20mm and rear ride height 35mm (at the wheel axis). Pitch angle in the design configuration is 0,275°. (3125 wheelbase) Measuring front ride height: [ 1 ] A flat surface (skid) about 286 mm behind the front wheel axis. You can calculate the ride height at the wheel as follows: measured 22 - tan (pitch angle) · 286 = 20mm Measuring rear ride height: [ 1 ] Two machined areas, at 382 mm from car bottom, on the gearbox aligned with the wheel axis. Their distance from the ground is 417 – 382 = 35mm. [ 2 ] Under the flat bottom, 314mm ahead of the rear wheel axis, you can easily measure the ground clearance and calculate the ride height at the rear axis as follows: measured 34mm + tan ( pitch angle ) · 314 = 35 mm For a more
general procedure Define your desired ride heights, front and rear ( F & R ) [mm] Calculate the pitch angle ( R – F ) / 3125 · 57.29 Calculate which value you should measure in the reference you choose FRONT [ mm ] REAR [ mm ]
NOTES
A
20
35
DESIGN DIMENSIONS
B
22
34
UNDERTRAY DIMENSIONS
B-25
Release 6.0 / 2010
DRAWINGS
B-26
Release 6.0 / 2010 The drawing underneath represents the car with no tyre deformation.
B-27
Release 6.0 / 2010
B-28
Release 6.0 / 2010 NOSE FITTING The nose fitting pins can be pre-adjusted by mounting them on the nose respecting the dimension illustrated below; which is 43,4mm from the top of the head of the pin to the nose counterbore hole on the nose in contact with the steel bush of the tub. After that, a fine tuning is required, in order to guarantee a good lock on each cam; by using the Allen key hole on the head of the pin.
B-29
Release 6.0 / 2010 AERODYNAMICS
DEFINITIONS Aero values are given @ the following ambient conditions; Temperature = 15°C Pressure = 1013 mb Humidity = 0% (dry air) Aeroloads are function of air temperature, pressure and humidity because they affect the air density. Typically, Higher Air Temperature Higher Air Pressure Higher Air Relative Humidity
by 5.5 °C (10° F) by 1” Hg by 50%
reduces downforce and drag by 3.0 % increases downforce and drag by 3.0% increases downforce and drag by 0.5%
Drag number includes front and rear wheels contribution Front Downforce is meant at the front axle Rear Downforce is meant at the rear axle Efficiency is Total Downforce / Drag Balance is the Downforce split percentage on front (=100*Lf /Lt).
AERODYNAMICS FEATURES OF THE CAR The 2008 Formula Renault 3.5 car was deeply inspired by the style of the most recent Renault F1 cars: the R27 was taken as example in the design process. As a result, more aerodynamic devices were present in this new Formula Renault 3.5: more profiles on the front wing assembly, extra wings on the body and various aerodynamic devices on the side pods, all of them giving their contribution to the generation of downforce and drag. As a consequence of the changes on aerodynamics that F1 cars will have since in 2009, the Formula Renault 3.5 has been updated in order to follow F1’s moves. In the following pages it is possible to find all the details concerning the aero devices installed in the car, together with the basic data needed for the definition of a complete aero set-up.
B-30
Release 6.0 / 2010
FRONT WING ASSEMBLY
Mainplane Design mainplane HEIGHT (from reference plane) 61 mm Design mainplane INCIDENCE (relative to reference plane) 1.1°
B-31
Release 6.0 / 2010 Flap Flap angle is measured: - at the plane where the chord is maximum - on upper surface (drawing a line above the flap) - from the reference plane (with zero rake) The flap angle can be between 3 and 32 degrees. Nominal SLOT GAP is 13.0 mm. Nominal OVERLAP between the flap and the main plane is : 22.0 mm.
Gurney (Nolder) 10 mm height front flap Gurneys are increasing the front downforce of 3% approximately. To balance front flap Gurney, the front flap incidence must be reduced of 7 holes. Each Gurney must be fitted with M3 bolts (We recommend the use of domed head screws with the nut on the top for aerodynamic efficiency). The flaps must be drilled accordingly to the holes present on the Gurneys. Important information: The use of the front flap Gurneys is not compulsory Flaps can remain without holes if the Gurneys are not used New flaps will be sold without holes
B-32
Release 6.0 / 2010 Endplate The endplate is divided into two parts: the lower part is more subject to wear and damages (e.g. on kerbs) and it’s easier to replace if separated from the main upper part. Furthermore, this lower part is shaped in a way that the possibility of damage to other cars in case of contact is minimum.
The holes on the endplate allow a flap angle range between 3 and 32 degrees (1 deg step). 1 2 3 4 5 A 3 9 15 21 27 B 4 10 16 22 28 C 5 11 17 23 29 D 6 12 18 24 30 E 7 13 19 25 31 F 8 14 20 26 32
B-33
Release 6.0 / 2010
MAIN BODY AND UNDERWING
B-34
Release 6.0 / 2010 Underwing and skirts The underwing with its diffuser and the skirts placed on each side play a major role in the generation of downforce. Be aware that the skirts have been designed to work with their lower point 5 mm above the reference plane: set the skirts’ heights carefully in order to get the best performance out of them. Remember also that skirts wear down quite easily: there is no need to destroy them during warm up laps, when the tyres are not ready. A worn skirt is producing less downforce because the “sealing” effect between the car and the ground is reduced; furthermore, if the skirts wear down unevenly (e.g.: the rearmost part of the skirt is destroyed and the foremost is almost untouched, or vice-versa), the aerodynamic balance can move significantly to the front / rear of the car.
B-35
Release 6.0 / 2010
REAR WING ASSEMBLY
B-36
Release 6.0 / 2010 Mainplane Design mainplane HEIGHT (from reference plane) 337 mm Design mainplane INCIDENCE (relative to reference plane) 10° Sideplate Design mainplane HEIGHT (from reference plane) 337 mm
Biplane The rear biplane can be installed in the car in three different configurations, depending on the type of track and on the grip conditions: - high downforce (HFD) - medium downforce (MDF) - low downforce (LDF)
B-37
Release 6.0 / 2010 High downforce (HDF): The “high downforce” biplane assembly is made of: - the STD mainplane - the HDF flap - the two STD steel sideplate (in order to allow adjustments) Nominal OVERLAP between the flap and the main plane is : 36.0 mm Angle between mainplane and flap is 49 degrees. Biplane angle is measured: - on the upper surface (drawing a line above the flap and tangent to the mainplane) - from the reference plane (with zero rake)
B-38
Release 6.0 / 2010 Medium downforce (MDF): The “medium downforce” biplane assembly is made of: - the STD mainplane - the MDF flap (it is the STD flap used in the T05 biplane) - the two STD steel sideplate (in order to allow adjustments) Nominal OVERLAP between the flap and the main plane is : 31.0 mm Angle between mainplane and flap is 38 degrees.
B-39
Release 6.0 / 2010 Low downforce (LDF): The “low downforce” biplane assembly is made of: - the STD mainplane - the two STD steel sideplate (in order to allow adjustments)
B-40
Release 6.0 / 2010 Biplane adjustment The holes machined on the steel sideplates allow biplane angles between 11 and 28 degrees.
A B C D E F
1 11 12 13 14 15 16
B-41
2 17 18 19 20 21 22
3 23 24 25 26 27 28
Release 6.0 / 2010
LOW DOWNFORCE AERODYNAMIC CONFIGURATION (LAC) Here are the restrictions that must be observed when “LAC” is required: Skirts cannot be used MDF rear profile must be used on the first line of holes exclusively
Other information: The skirt supports (77 11 165 315 & 316) must be removed when the skirts are not used. No restriction is made on the front wing A specific adhesive covering lines 2 & 3 must be applied when LAC is required to ensure a quick control The specific adhesive will be distributed by Renault Sport during preliminary scrutineering LDF cannot be used when LAC is required
B-42
Release 6.0 / 2010
POLAR DIAGRAM OF THE CAR FRH: 15 mm / RRH: 25 mm T09 Polar Diagram
3,600
3,400
3,200
Downforce
11
12
3,000
8 5
9
10
6 7
2,800
4 2,600
1 2
3
2,400
2,200 0,900
0,950
1,000
1,050
1,100
1,150
1,200
1,250
Drag
Downforce Level Point Low Downforce
Middle Downforce
High Downforce
1 2 3 4 5 6 7 8 9 10 11 12
Configuration Only rear main plane
Rear biplane MDF
Rear biplane HDF
Data provided without the use of front flap Gurney.
B-43
Front Flap 3 5 7 10 11 12 14 16 25 26 27 28
Rear Flap 18 23 28 11 13 15 18 22 11 15 19 22
Drag D/force 0,941 0,956 0,967 1,028 1,042 1,060 1,082 1,106 1,140 1,177 1,211 1,230
2,518 2,528 2,552 2,751 2,781 2,811 2,851 2,871 2,942 3,007 3,066 3,081
Release 6.0 / 2010
AERO MAPS Low downforce CxT
CzT
FRH/RRH
5
10
15
20
25
30
35
5
0,952
0,958
0,961
0,962
0,965
0,966
0,970
10
0,955
0,957
0,958
0,958
0,960
0,965
0,966
0,970
15
0,948
0,948
0,949
0,954
0,956
0,960
0,962
0,964
0,968
0,945
0,949
0,952
0,956
0,957
0,959
0,961
0,961
20
0,946
0,950
0,951
0,953
0,955
0,956
0,958
25
0,948
0,949
0,950
0,951
0,952
0,953
30
0,947
0,948
0,949
0,950
0,951
35
20 25 30 35
40
45
FRH/RRH
5
10
15
20
25
30
35
5
2,823
2,809
2,792
2,784
2,788
2,800
2,806
10
2,677
2,645
2,646
2,646
2,651
2,689
2,660
2,640
15
2,522
2,491
2,489
2,513
2,528
2,541
2,507
2,477
2,448
2,373
2,377
2,400
2,428
2,414
2,376
2,343
2,298
2,289
2,316
2,321
2,303
2,264
2,225
2,187
2,231
2,229
2,194
2,164
2,121
2,087
2,138
2,109
2,061
2,029
2,011
40
45
CzF 5
10
15
20
25
30
35
5
1,203
1,202
1,199
1,203
1,210
1,218
1,222
10
1,104
1,098
1,107
1,112
1,118
1,138
1,130
1,128
15
1,007
1,005
1,012
1,026
1,036
1,047
1,037
1,031
0,929
0,936
0,951
0,968
0,965
0,956
0,949
0,877
0,892
0,898
0,894
0,886
0,832
0,836
0,831
0,782
0,778
20 25 30 35
40
45
FRH/RRH
5
10
15
20
25
30
35
5
1,620
1,607
1,594
1,581
1,579
1,581
1,584
10
1,573
1,547
1,539
1,535
1,533
1,551
1,530
1,512
1,028
15
1,515
1,487
1,477
1,486
1,492
1,495
1,470
1,446
1,421
0,937
20
1,443
1,441
1,449
1,460
1,449
1,421
1,394
1,360
0,877
0,869
25
1,411
1,424
1,424
1,408
1,379
1,348
1,319
0,825
0,814
0,807
30
1,398
1,393
1,363
1,339
1,307
1,281
0,765
0,759
0,759
35
1,356
1,332
1,296
1,270
1,252
40
45
Eff
R.A.%
FRH/RRH
5
10
15
20
25
30
35
40
5
2,966
2,933
2,904
2,895
2,891
2,898
2,891
10
2,804
2,765
2,762
2,763
2,761
2,788
2,754
2,722
15
2,660
2,627
2,621
2,633
2,645
2,648
2,605
2,568
2,510
2,507
2,522
2,539
2,523
2,479
2,419
2,438
2,440
2,416
2,371
2,354
2,349
2,308
2,259
2,224
25 30
45
CzR
FRH/RRH
20
40
35
45
FRH/RRH
5
10
15
20
25
30
35
5
42,6%
42,8%
42,9%
43,2%
43,4%
43,5%
43,6%
10
41,2%
41,5%
41,8%
42,0%
42,2%
42,3%
42,5%
42,7%
2,530
15
39,9%
40,3%
40,7%
40,8%
41,0%
41,2%
41,3%
41,6%
42,0%
2,439
2,392
20
39,2%
39,4%
39,6%
39,9%
40,0%
40,2%
40,5%
40,8%
2,328
2,283
25
38,3%
38,5%
38,7%
38,8%
39,1%
39,4%
39,7%
2,275
2,229
2,190
30
37,3%
37,5%
37,9%
38,1%
38,4%
38,6%
2,171
2,135
2,113
35
36,6%
36,9%
37,1%
37,4%
37,7%
Configuration: Front : Front flap @ 5° Rear: LDF @ 23° Data provided without the use of front flap Gurney.
B-44
Release 6.0 / 2010 Medium downforce CxT
CzT
FRH/RRH
5
10
15
20
25
30
35
5
1,050
1,053
1,060
1,064
1,068
1,073
1,080
10
1,048
1,050
1,054
1,058
1,062
1,069
1,077
1,082
15
1,044
1,046
1,050
1,054
1,060
1,066
1,076
1,076
1,079
1,046
1,049
1,052
1,059
1,063
1,071
1,074
1,079
20
1,048
1,052
1,058
1,062
1,068
1,071
1,073
25
1,050
1,056
1,060
1,067
1,067
1,072
30
1,056
1,058
1,066
1,068
1,071
35
40
45
FRH/RRH
5
10
15
20 25 30 35
40
45
FRH/RRH
5
10
15
20
25
30
35
5
3,167
3,116
3,085
3,077
3,090
3,105
3,138
10
2,965
2,942
2,901
2,897
2,926
2,957
2,964
2,953
15
2,805
2,774
2,777
2,779
2,811
2,840
2,838
2,805
2,779
2,672
2,658
2,693
2,733
2,726
2,711
2,687
2,655
2,577
2,613
2,628
2,625
2,598
2,570
2,541
2,520
2,530
2,523
2,498
2,457
2,444
2,454
2,440
2,414
2,384
2,350
20
25
30
35
40
45
CzF 5
10
15
20
25
30
35
5
1,356
1,341
1,335
1,337
1,346
1,354
1,369
10
1,227
1,229
1,219
1,219
1,237
1,251
1,256
1,260
15
1,128
1,123
1,132
1,136
1,151
1,169
1,173
1,166
1,057
1,052
1,070
1,089
1,090
1,089
0,995
1,014
1,021
1,024
1,016
0,955
0,960
0,959
0,909
0,906
20 25 30 35
5
1,811
1,774
1,750
1,740
1,744
1,751
1,768
10
1,738
1,713
1,683
1,678
1,689
1,706
1,708
1,693
1,163
15
1,678
1,650
1,646
1,643
1,660
1,671
1,665
1,639
1,617
1,086
1,079
20
1,615
1,606
1,623
1,643
1,636
1,622
1,601
1,575
1,011
1,006
25
1,582
1,600
1,607
1,601
1,582
1,558
1,535
0,954
0,944
0,944
30
1,566
1,570
1,564
1,544
1,513
1,500
0,901
0,895
0,887
35
1,545
1,534
1,513
1,489
1,463
40
45
Eff
R.A.%
FRH/RRH
5
10
15
20
25
30
35
5
3,016
2,960
2,910
2,892
2,893
2,892
2,905
10
2,828
2,802
2,754
2,739
2,754
2,766
2,752
2,730
15
2,686
25 30
45
CzR
FRH/RRH
20
40
40
45
FRH/RRH
5
10
15
20
25
30
35
5
42,8%
43,1%
43,3%
43,4%
43,6%
43,6%
43,6%
10
41,4%
41,8%
42,0%
42,1%
42,3%
42,3%
42,4%
42,7%
40,2%
40,5%
40,7%
40,9%
41,0%
41,2%
41,3%
41,6%
41,8%
39,6%
39,6%
39,7%
39,9%
40,0%
40,2%
40,4%
40,7%
38,6%
38,8%
38,8%
39,0%
39,1%
39,4%
39,6%
37,9%
37,9%
38,0%
38,2%
38,4%
38,6%
37,1%
37,1%
37,3%
37,5%
37,7%
2,650
2,645
2,637
2,651
2,664
2,638
2,607
2,575
15
2,555
2,534
2,558
2,582
2,566
2,532
2,502
2,460
20
2,460
2,484
2,484
2,473
2,433
2,399
2,368
25
2,399
35
2,396
2,380
2,342
2,303
2,281
30
2,325
2,305
2,265
2,232
2,195
35
Configuration: Front : Front flap @ 12° Rear: MDF @ 15° Data provided without the use of front flap Gurney.
B-45
Release 6.0 / 2010 High downforce CxT
CzT
FRH/RRH
5
10
15
20
25
30
35
5
1,204
1,208
1,216
1,228
1,235
1,240
1,248
10
1,217
1,221
1,219
1,224
1,235
1,241
1,246
1,249
15
1,217
1,215
1,222
1,228
1,230
1,241
1,243
1,249
1,251
1,217
1,220
1,224
1,228
1,234
1,239
1,243
1,249
20
1,218
1,223
1,229
1,233
1,235
1,241
1,245
25
1,219
1,225
1,231
1,236
1,238
1,242
30
1,227
1,227
1,232
1,236
1,241
35
40
45
FRH/RRH
5
10
15
20 25 30 35
40
45
FRH/RRH
5
10
15
20
25
30
35
5
3,395
3,327
3,317
3,306
3,308
3,334
3,346
10
3,238
3,186
3,175
3,175
3,194
3,220
3,213
3,187
15
3,097
3,075
3,067
3,073
3,081
3,120
3,092
3,073
3,052
2,980
2,969
2,978
3,006
3,001
2,987
2,951
2,927
2,883
2,906
2,924
2,919
2,881
2,857
2,823
2,833
2,833
2,825
2,795
2,756
2,729
2,767
2,725
2,700
2,671
2,651
20
25
30
35
40
45
CzF 5
10
15
20
25
30
35
5
1,445
1,421
1,423
1,420
1,421
1,435
1,441
10
1,340
1,331
1,326
1,328
1,340
1,351
1,352
1,346
15
1,254
1,251
1,249
1,257
1,262
1,278
1,272
1,267
1,186
1,183
1,190
1,205
1,206
1,204
1,129
1,138
1,147
1,148
1,140
1,092
1,089
1,090
1,042
1,033
20 25 30 35
5
1,950
1,905
1,894
1,886
1,887
1,899
1,906
10
1,898
1,854
1,848
1,847
1,855
1,869
1,861
1,842
1,267
15
1,843
1,824
1,818
1,816
1,819
1,843
1,821
1,805
1,786
1,195
1,187
20
1,794
1,786
1,787
1,801
1,794
1,784
1,756
1,740
1,132
1,124
25
1,754
1,768
1,776
1,772
1,742
1,725
1,699
1,082
1,071
1,065
30
1,741
1,744
1,735
1,713
1,685
1,664
1,026
1,018
1,015
35
1,725
1,692
1,674
1,653
1,636
40
45
Eff
R.A.%
FRH/RRH
5
10
15
20
25
30
35
5
2,820
2,754
2,727
2,692
2,679
2,689
2,681
10
2,661
2,609
2,605
2,593
2,587
2,594
2,579
2,551
15
2,545
2,529
2,511
2,503
2,505
2,514
2,488
2,461
2,448
2,434
2,432
2,447
2,432
2,412
2,374
2,368
2,375
2,379
2,367
2,333
2,325
2,313
2,295
2,255
2,221
25 30
45
CzR
FRH/RRH
20
40
35
40
45
FRH/RRH
5
10
15
20
25
30
35
5
42,6%
42,7%
42,9%
42,9%
43,0%
43,0%
43,1%
10
41,4%
41,8%
41,8%
41,8%
41,9%
42,0%
42,1%
42,2%
2,440
15
40,5%
40,7%
40,7%
40,9%
41,0%
40,9%
41,1%
41,2%
41,5%
2,343
20
39,8%
39,9%
40,0%
40,1%
40,2%
40,3%
40,5%
40,6%
2,303
2,268
25
39,2%
39,2%
39,2%
39,3%
39,5%
39,6%
39,8%
2,261
2,226
2,197
30
38,5%
38,4%
38,6%
38,7%
38,9%
39,0%
2,192
2,161
2,136
35
37,7%
37,9%
38,0%
38,1%
38,3%
Configuration: Front : Front flap @ 28° Rear: HDF @ 22° Data provided without the use of front flap Gurney.
COOLING INLET BLANKING Vrad V0
Description
CxT S
CzF S
CzRS
No blanking
Ref
Ref
Ref
Ref
50 mm horizontal
0.000
0.000
+0.005
-2.3%
100 mm horizontal
+0.001
+0.004
+0.023
-5.8%
B-46
(each side)
Release 6.0 / 2010
POLAR DIAGRAM OF THE MAIN ADJUSTABLE DEVICES FRH : 15 mm / RRH : 25 mm
FRONT FLAP Data provided without the use of front flap Gurney.
LDF (rear @15°)
MDF (rear @11°)
Front wing flap angle 3 5 8 12 3 6 13 18 22
CxT*S
CzF*S
CzR*S
BalFr%
6 13 18 23 28
Ref -0,002 -0,004 -0,001 Ref 0,001 0,004 0,009 0,013 Ref 0,001 0,002 0,005 0,008 0,012
Ref 0,012 0,052 0,095 Ref 0,027 0,104 0,163 0,191 Ref 0,042 0,168 0,227 0,266 0,306
Ref -0,045 -0,087 -0,159 Ref -0,061 -0,171 -0,239 -0,278 Ref -0,028 -0,109 -0,177 -0,218 -0,261
41,09 42,10 43,70 45,91 35,80 37,15 40,29 42,50 43,65 32,21 33,56 37,47 39,68 41,11 42,58
Wing angle 18 21 25 28 11 15 18 20 22 11 13 18 20 22 25
CxT*S Ref 0,008 0,020 0,024 Ref 0,0315 0,0506 0,0646 0,0749 Ref 0,018 0,061 0,073 0,090 0,095
CzF*S Ref 0,001 0,003 -0,003 Ref -0,0150 -0,0203 -0,0270 -0,0302 Ref -0,004 -0,007 -0,010 -0,009 -0,009
CzR*S Ref 0,030 0,055 0,077 Ref 0,0654 0,1174 0,1511 0,1693 Ref 0,033 0,115 0,132 0,157 0,154
BalFr% 43,0 42,5 42,1 41,6 42,0 40,4 39,8 39,2 38,9 39,8 39,4 38,1 37,8 37,5 37,5
3 HDF (rear @14°)
REAR BIPLANE
LDF (front @8°)
MDF (front @11°)
HDF (front @16°)
B-47
Release 6.0 / 2010 OIL SYSTEM
Keep the oil level at 40 mm above the inferior partition wall. Less oil may cause cavitation: air would get into the oil circuit, more oil may absorb more power. Typically you would need 9 -10 litres to fill the oil tank (including oil lines).
OIL LEVEL AND CHARACTERISTICS Name Engine oil (mandatory)
Capacities 10.0L
Gearbox oil
3.5 L
Fuel
110 L
Cooling Fluid
9.0 L
Brake Fluid
0.7 L
Hydraulic fluid
0.8 L
Clutch Fluid
0.15 L
Characteristics ELF XT 3818 Elf HTX 755 or Castrol SAF XJ SAE 75W140 98 Unleaded or Elf E85 Glaceol RX Type D ELF XT DOT5 DOT 5 Mini ELF MATIC G3 Dextron 3 or G3 SYN ELF XT DOT5 DOT 5 Mini
Remarks With radiators With radiators Maximal capacity With radiators High pressure system -
PLEASE NOTE THAT THE USE OF THE SPECIFIED ENGINE OIL IS MANDATORY
B-48
Release 6.0 / 2010 HYDRAULIC OIL SYSTEM Keep the hydraulic oil level at the top of the plate (see image) to avoid any problems with the clutch and gear box release system.
B-49
Release 6.0 / 2010 ENGINE COMPARTMENT COOLING 4 areas must be cooled by bring a tube directly on the element: - Fusebox - Alternator - Hydraulic block - Hydraulic pump For all these areas, make sure that the extremity of the tube is in contact with the body of the element that needs cooling. Fusebox
Alternator
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Release 6.0 / 2010 Hydraulic pump and hydraulic block
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Release 6.0 / 2010 EXTRACTABLE SEAT
CARBON SHELL AND LEG STRAP POSITION Please keep in mind that, in case of an important crash, the driver should be extracted with no harm and no difficulties. On this purpose you should be sure that the following points are respected when you make your driver’s seat. B
A
C
D
Make sure that the seat is correctly fitted in the carbon shell (A). Make sure that the holes for the leg straps (D) in the carbons shell (A) and in the seat are in front of each others. Make sure that the leg straps (D) are exiting in front of the driver’s crotch. Make sure that, the driver doesn’t sit on the leg straps (D) when he is sitting in the car.
In order to be able to place the straps correctly, the following modification must be performed on all carbon shell:
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Release 6.0 / 2010 Here are some illustrations of these points (sources: F.I.A.):
The hole made in the driver seat to pass the lower seat belts must be large enough. Some tape can be added on the lower belt in order to avoid any friction during the extraction. The non respect of this rule will be considered as a non conformity
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Release 6.0 / 2010
BLACK SOCKET POSITION The black plastic sockets must be maintained in position on the edge of the carbon shell in order to allow a quick fitting of the extraction tools. You can use one piece of black tape for this purpose. The tape should not prevent the belt from extension.
Socket Black Tape Carbon shell
Belt
We would like to remind you that no other modification is allowed on the carbon shell (category A). Please modify the driver’s seat instead in case of problem.
SIDE BELTS It is recommended that the side belts of the carbon shell are attached together to avoid them being trapped between the shell and the chassis. Please use white paper tape easily tearable like shown in the picture underneath. Keep in mind that the socket must always be in the upper position.
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Release 6.0 / 2010
DRIVER SEAT DIMENSION The driver seat must not exceed the carbon shell length and width.
CARBON SHELL MODIFICATION The extractible seat must be modified only if the lower seat-belt position is used on the tub. Remove the material according to the drawing underneath.
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Release 6.0 / 2010 FUEL SYSTEM Formula Renault 3.5 uses twin electrical-submerged fuel pumps as a precaution in case one pump fails. Fuel Tank capacity High pressure fuel pump flow
110 L 200 L/h (5bar)
ENGINE
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Release 6.0 / 2010 EXTINGUISHER SYSTEM LAY-OUT
DETAILS The Formula Renault 3.5 estinguisher is filled with E85 compliant liquid. The Lifeline system is an electrically triggered Halon or foam spray fire extinguisher system. The system uses actuators to operate the valves located on the pressurised container, containing the extinguishing liquid. These are triggered remotely using a battery powered ‘power pack’. In order to guarantee reliability the actuators are of military specifications. The system/battery test electronics are integrated into the remote power pack. Connectors on the firing heads are also of military grade and use two contacts per lead to guarantee the best connections. Actuators are designed either to operate individually, or connected in series if two heads are used. All Lifeline Zero 2000 electrical extinguisher kits have a separate power pack to provide the current needed to operate the system. The power pack should be wired independently from the vehicle’s electrics as failure to do this may result in the actuation of the system due to electrical interference from the vehicle’s power source. Once the system has been wired a test check should be carried out to ensure that the system will fire properly. Before you start the check procedure, ensure that the bottle and the power pack are connected. On top of the power pack is a three position switch. This provides checking facilities for the battery and operation. If the switch is pulling against its spring towards the amber diode, the diode will light if there is sufficient current in the battery. IF THE DIODE DOES NOT LIGHT, OR IMMEDIATELY GOES OUT, IT SHOULD BE REPLACED. THE BATTERY SHOULD BE OF THE MANGANESE/ALKALINE TYPE ONLY.
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Release 6.0 / 2010 With the switch in the centre (‘’system isolated’’) position, and the centre position only, the wiring of the circuit can be checked. With the extinguisher(s) connected, press one of the firing buttons and the green diode should light. If it does not there is a break in the circuit. If the diode lights before the button is pressed, there is a short in the circuit and the system is permanently ‘’live’’. If this occurs, DO NOT PUT THE SWITCH INTO THE ‘’SYSTEM ARMED’’ POSITION, OR YOU WILL DISCHARGE THE SYSTEM. If, for any reason, the green LED does not illuminate when the system is tested, check the wiring. If the problem persists consult Lifeline. To arm the system place the switch in to the “SYSTEM ARMED’’ position. The red LED will illuminate to indicate the system is armed. To prolong battery life and prevent accidental activation it is recommended that the power pack switch be in the ‘’SYSTEM ISOLATED’’ position and the plug disconnected.
TESTING The power pack electronics can test the continuity of the electrical wiring, and provide a high current pulse test on the battery, to ensure system integrity before use. The battery test electronics do not excessively drain the battery during this test. The tests are carried out using a three-way switch on the power pack. Since the system is only as good as the battery that powers it and the integrity of the wiring and its connections, the tests should be performed before each race. To check the battery, press and hold up the power pack switch. Every 2 seconds you’ll see a YELLOW light flash. If the light flashes very dimly the battery should be replaced. In doubt change the battery. To check the wiring continuity, ensure that the power pack switch is on “SYSTEM INACTIVE” to ensure that the extinguisher is not fired. Press the internal firing button and check that the RED light comes on. Press the external firing button and check that this also makes the RED light comes on.
PRECAUTIONS Ensure that the electric ‘command’ cables are not laying next to or in the same loom as the car battery power cables or ignition cables. Ideally, all cables should lie next to the chassis (earth). Ensure that all plugs exposed to water spray are protected with rubber boots. If tubing is to be removed, push the orange collet in. While holding in the collet, pull out the tube. Avoid running any cable over sharp edges without protection. Do not fix the cables next to or onto any surface likely to exceed 200°C. Do not turn the firing heads when the system is activated.
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Release 6.0 / 2010 SBS 30 – DRY BATTERY
CHARGING PROCEDURE Only use specific DRY BATTERY chargers!!!! • The charger must give a constant tension of 14.7V • The charger must be able to charge with a current of at least 40% of the nominal capacity of 26-27Ah, which is about 10A.The current will come down during charging. • A complete charge can take up to 10 hours.
SAFETY NOTES • Never charge the battery when the battery is “HOT”. • Tighten the cable-nuts to no more than 4Nm. • Charge an empty battery immediately, do not leave it empty. • When the battery is stored do not let the tension come down under 12V but charge it again as soon as possible. • Store the batteries in an ambient temperature of about 25°C. Hotter conditions will reduce the life of the battery. • Make sure that all breather holes stay un-covered. • Fit the battery securely in its position, without fitting it too rigidly. Use some extra foam to reduce vibrations. SPARE BATTERY For security reasons, the “+” wire of the park battery loom must be plugged on the exit side of the master switch. In case of lateral crash when the master switch is off, this will prevent any current to run in the battery park loom. The thimble use on the master switch is Ø8 mm.
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Release 6.0 / 2010 SWITCH PLATE For driver comfort, it is allowed to remove material from both the switch plates according to the area shown in the drawing underneath.
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Release 6.0 / 2010 SWG & CONVERSION TABLE
SHEET METAL THICKNESS SWG Metric [mm]
8 4.064
10 3.251
12 2.642
14 2.032
16 1.626
18 1.219
20 0.914
UNIT CONVERSION TABLE 1 1 1 1
1 foot=304.8 mm=12 in 1 yard=914.4 mm=3 ft 1 mile=5280 ft=1.60934 km
millimetre=0.03937 in centimetre=0.3937 in meter=39.37 in kilometre=0.62137 miles
Volume 1 cubic inch (c.i.)=16.387 cubic centimetres
1 cubic centimetre=0.061 cubic inch 1 litre=1000 cc=61.0255 cubic inch
Pressure 1 psi=0.06894757bar
1 kg/cm2=1.019 bar 1 bar=105 Pa=0.1MPa 1 bar=14.503 psi
Weight 1 ounce (oz)=28.35 grams 1 pound (lb.)=16 ounces=453.592 grams
1 Kg=1000 grams = 2.205 lb
Speed 1 mph=1.609344 kilometres per hour 1 IPS (in/s)=25.4 mm/s
1 kilometre per hour=0.6213712 mph 1 mm/s=0.039 IPS
Specific weight Water = 1.000 kg/l Mineral Oil = 0.903 Kg/l Gasoline = 0.740 Kg/l Useful formulas Engine displacement = 0.7854 × bore × bore × stroke × no. of cylinders British horsepower (BHP) = RPM × torque (lbs ft)/5250 Km/h = RPM × tire diameter (mm)/(gear ratio × 5308) Lap speed (km/h) = track length (Km) × 3600/lap time (s) Average speed (km/h) = track length (Km) ×3600 × no. of laps/total time (seconds)
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