SuperFlow SF-1020I Operator'S Manual Download Page 67 | Manualshive

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8.0 Appendix

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Summary of Contents for SF-1020I

Page 1: ...Pub No 1058319 Rev 7 August 2022 Operator Manual www superflow com Original Instructions SF 1020i FLOWBENCH SF 1020i SF 1020i...

Page 2: ...nches All rights reserved No part of this publication may be reproduced transcribed or translated by any means without the prior written permission of SuperFlow Dynamometers Flowbenches N60 W22700 Sil...

Page 3: ...Adapters and Fixtures 9 4 0 Installation 10 4 1 Installation 10 4 1 1 Room Requirements 10 4 1 2 Unpacking 10 4 1 3 Electrical 10 4 2 Modbus Communication Connection 11 4 2 1 Modbus List 11 5 0 Operat...

Page 4: ...30 6 2 Troubleshooting 31 6 3 Flowbench Flow Tests 33 6 4 Service 36 6 4 1 Blower Belt Replacement 36 6 4 2 Blower Motor Replacement 37 6 4 3 Temperature Probe 39 6 4 4 Orifice Stepper Motor Assembly...

Page 5: ...ronments Castors allow for easy movement The flowbench utilizes a Modbus TCP IP network via the internal PLC controller Once properly connected and configured to consumer control system the flowbench...

Page 6: ...to the equipment Read and understand all instructions in the user guides Keep the air ducts free of dust or dirt Keep loose material away from the inlet and exhaust ducts Always wear eye and hearing...

Page 7: ...u have any questions about the safe operations of our equipment and for service and advice The following universal warning decals can be found in the appropriate locations on your equipment A descript...

Page 8: ...e that repairs are under way and state who is responsible for the lockout condition Tagout devices have to be constructed and printed so that exposure to weather conditions or wet and damp locations w...

Page 9: ...rly connected and configured machine calibration operation and troubleshooting can done via a web interface Can communicate with computers equipped with optional airflow analysis software 3 1 2 Option...

Page 10: ...approach What is the largest diameter part tested on a SuperFlow bench Over 18 inches in diameter and 6 feet tall The component is for a very large gas turbine that drives a stationary electrical powe...

Page 11: ...gh accuracy over a wide range of flows The SF 1020i has ten unique flow ranges this insures the highest accuracy flow measurements from near 0 to 1000 cfm 0 to 470 lps 3 3 1 Baseplate The SF 1020i flo...

Page 12: ...Assembly The muffler assembly replaces the rear panel on the SF 1020i and has been designed to reduce the overall noise emitted by the exhaust air flow of the machine Figure 3 5 Exhaust Muffler 3 0 S...

Page 13: ...nto the cavity beneath the test baseplate and becomes part of the baseplate The washable filter has low restriction to ensure minimal effect on the flowbench capacity The assembly has a 13 inch 33 02...

Page 14: ...room after a while the flowbench may heat the area Conditioning the air for temperature or humidity is not necessary but would be more comfortable for the operators 4 1 2 Unpacking 1 The SuperFlow SF...

Page 15: ...Version Int 16 R Firmware Version 40002 Servo_Mode Int 16 R W 0 Test pressure mode 1 Flow rate mode 40003 Intake_Exhaust Int 16 R Not Used 40004 AutoZeroNow Int 16 R W Enables Auto zero of pressure c...

Page 16: ...e setpoint CFM None 40039 40 ReadyToTest Float 32 R 0 NotReady 1 Ready Stable 40041 42 SerialNumber Float 33 R SerialNumber of flow bench 40043 44 MotorSpeedCmd Float 32 R Returns current VFD speed co...

Page 17: ...age Float 32 R W Analog averaging 1 40109 110 AI3_Adder Float 32 R Analog adder value 40111 112 AI3_Gain Float 32 R Analog multiplier value 40113 114 AI3_Raw Float 32 R Unfiltered analog data 40115 11...

Page 18: ...OpRangeVal_3 Float 32 R W Value 3 40169 170 OpRangeVal_4 Float 32 R W Value 4 40171 172 OpRangeVal_5 Float 32 R W Value 5 40173 174 OpRangeVal_6 Float 32 R W Value 6 40175 176 OpRangeVal_7 Float 32 R...

Page 19: ...rate In test pressure mode the air pressure is set and the flow rate measured In flow rate mode the airflow is set and the test pressure measured Servo Mode Register Register Function Data Type Read W...

Page 20: ...ves commands The register can be set to the desired test pressure in the unit of measurement InH2 O Example 25 A test pressure of 25 H2 0 5 1 3 Setting the Flow Rate If the 40002 Servo_Mode register h...

Page 21: ...g Register Register Function Data Type Read Write Value Units Scale 40023 RangeSetting Int 16 R W Display current and set flow range 1 10 Register 40023 RangeSetting provides the status state that the...

Page 22: ...t in CFM CFM x10 Register 40026 Leakage provides the status state that the flowbench leakage value is currently in when read It also allows operator to change set states when this register receives co...

Page 23: ...g Leakage on page 18 Use the same mode and test pressure that will be used in the normal test On flowbench range 1 leakage is usually from 0 5 to 2 cfm 0 50 to 1 0 l s If no leakage occurs the test fl...

Page 24: ...ays use a flow inlet guide on the intake side of the head and always use the same guide and cylinder adapter 5 As nearly as possible conduct all tests with the same equipment used in the same way 6 Wh...

Page 25: ...the Wago PLC through an Ethernet Local Area Network LAN cable Follow the steps below to connect the computer to the Wago PLC i For direct connection set the computers Ethernet Port Static IP Address t...

Page 26: ...n settings This login is considered an Administrator s login Username SETUP Password PWRTSTCAL 4 Once logged in click the Control Page button to open the Control Page page See section 5 2 2 Wago Webvi...

Page 27: ...iscussed in detail on the following pages The screen appears slightly different depending on the login credentials USER or SETUP used as illustrated in Figures 5 4 and 5 5 below Administrator function...

Page 28: ...ervo Mode is set to Pressure the operator should verify and if necessary set the test pressure setpoint in the unit of measurement InH2 O prior to testing Example 10 A test pressure of 10 H2 0 4 Flow...

Page 29: ...2 Allow Pressure PID Adjust Allows an administrator to select if the PID values for pressure are on LOCK selected in Figure 5 8 or UNLOCK If UNLOCK is selected the PID values can be changed 3 Flow Pr...

Page 30: ...l open a popup window that allows the administrator to adjust the Orifice Position for each of the ten range settings 1 10 The SF 1020i has ten 10 flow ranges see Table 5 3 SF 1020i Nominal Flow Range...

Page 31: ...metric pressure transducer by pressing the UNLOCK button 2 Enter the obtain accurate uncorrected barometric pressure reading in inches Hg value by writing it in the APPLIED section 3 With obtained val...

Page 32: ...ibration of the appropriate pressure transducer by pressing the ADJUST button 7 Slowly bleed off calibration pressure to zero pressure and disconnect the calibrated vacuum pressure source from the tra...

Page 33: ...Offset value to open a popup window that allows the administrator to enter the new value 5 Allow Temp 2 Calibration Allows an administrator to select if the calibration values of Temp 2 are on LOCK se...

Page 34: ...om inaccessible locations with compressed air Keep ventilation openings clear to allow the free passage of air Wipe away grease or oil with a rag and petroleum solvent Refer to motor name plate or pro...

Page 35: ...port in head Line voltage varying Motor is failing Motor controller malfunction The range selected cannot be set The range orifice stepper motor is defective see section 6 4 4 Orifice Stepper Motor A...

Page 36: ...ng to the procedure in section 6 3 Flowbench Flow Tests The back vent is open is too much No communication between flowbench and the computer Disconnected or defective cable Modbus TCP IP connection i...

Page 37: ...e flowbench running This is the normal leakage of the flowbench itself and a small amount is acceptable If the leakage exceeds 3 cfm 1 43 lps record the flow meter reading and try to locate the source...

Page 38: ...ation is on the calibration sheet shipped with the flowbench or can be read from the flowbench reading register 40022 FullScaleFlow It will return the full scale reading for the current flow range 6 S...

Page 39: ...H2 0 Example If the Full Scale Range Value for Range 10 on your SF 1020i 1000 and you measured a Flow Pressure of 14 0 in H2 O at 25 inH2 O test pressure then Maximum Capacity 14 0 14 5 x 1000 982 6 c...

Page 40: ...t tensioner arm counter clockwise CCW At the same time wrap the replacement belt around the blower pulley then along the right side of the idler pulley and finally around the motor pulley 7 Slowly rot...

Page 41: ...to blower bracket 13 Using a inch deep socket remove the bolts securing the motor to the frame 14 Using proper lifting aids carefully remove the motor 15 Remove the seal tight and motor wiring harness...

Page 42: ...ap and the alignment must be within 1 32 inch Repeat steps 16 and 17 to readjust shaft bushing until pulley alignment is within specification 28 Using a 9 16 inch box end wrench rotate the belt tensio...

Page 43: ...th the plates attached and two limit switches The PLC is programmed with a position for each range When a range is selected on the PLC the motor will drive the plates until the reading matches the pro...

Page 44: ...upplied to the bench and the condition of the filters and motors Record the maximum test pressure reached when the bench and filters are new The maximum test pressure will decrease as the motors heat...

Page 45: ...NUT 1 4 28 NYLOCK PLTD 10 12 SF03UNC114X10X SHCS 10 24X1 1 4 11 2 SFE4320P 8940 CLAMP CABLE 1 8 BLK NYLON 12 1 3 625 SF3200P 0125 O RING MATERIAL 1 8 BUNA FT 13 1 SFINST F1030 INSTRUCTIONS FILTER INS...

Page 46: ...hich harm to the gauze filter media and shrink and harden the caps cleaning eaning leaning solutions etergents ssure car wash aning solvents inse off the element with low water pressure tap water ways...

Page 47: ...e off the element with low water pressure tap water Always flush from the clean side to dirty side This he dirt and does not drive it into the filter HINTS s dry naturally After rinsing shake off all...

Page 48: ...registers 6 5 1 Calibrating Sensors Pressure Calibration Calibrate the Test and Flow pressure channels using an accurate calibrated vacuum pressure source that reads in inches of water inH2 O Verify C...

Page 49: ...7 Once the calibration value has been applied in step 6 adjust calibration of the appropriate pressure transducer by setting either register 40089 90 AI2_Cal Flow Pressure Transducer or 400105 106 AI...

Page 50: ...not acceptable for calibrating the sensor The current Barometric Pressure can be read by reading register 40011 BarometricPressure NOTICE Calibration 1 Enable write access to calibration register for...

Page 51: ...nd development for many years Some of the first engine airflow studies using some type of flow testing date back to the early 1900s However the study of engine airflow and flowbench information and th...

Page 52: ...necessity of flow number comparison is something anyone involved in flow testing must endure Even if the number comparison is made on the same components and flowbench it is important to know how to...

Page 53: ...60 1 100 1 180 1 260 1 340 28 0 327 0 422 0 500 0 598 0 654 0 721 0 845 0 945 1 000 1 040 1 120 1 200 1 270 30 0 316 0 408 0 483 0 577 0 632 0 707 0 816 0 913 0 966 1 000 1 080 1 150 1 220 35 0 293 0...

Page 54: ...Q0 goes through the test plate at test pressure TP2 First we derive the measured flow for TP1 and then for TP2 These two readings will differ and they should be the same because Q0 is the same flow i...

Page 55: ...st equation expresses flowbench flow as a function of constants the intake flow the atmospheric pressure and test pressure We can perform the exact same steps for the diagram on the right hand side in...

Page 56: ...flow as follows Given Pa Actual measured pressure drop Pt Theoretical pressure drop Fa Actual Flow rate Ft Theoretical Flow Rate Pt Ft Fa 2 x Pa Example You tested an intercooler and found that it flo...

Page 57: ...is flowing through your part first If your flow bench is equipped with FlowCom then those measurements can be collected from the FlowCom Once you have the atmospheric conditions you can calculate the...

Page 58: ...and therefore the differential pressure across the test article changes then the differential pressure across the internal orifice changes a similar amount If the differential pressure at the test art...

Page 59: ...o assume that air is incompressible and p1 p2 This is true at speeds below 100 m s which is roughly the equivalent velocity of escaping air with a differential pressure of 25 inches of water At speeds...

Page 60: ...sition 1 25 5266272 2 50 4874796 3 100 4350105 4 150 3945465 5 200 3595657 6 300 3002954 7 400 2504226 8 500 2065429 9 700 1299986 10 1000 342827 Table 8 2 Default PID Settings Input Value Flow P 0 10...

Page 61: ...locity ft sec Flow Unit Area cfm sq in 1 66 2 27 6 3 114 7 47 8 5 148 0 61 7 7 175 1 72 9 10 209 3 87 1 12 229 3 95 6 15 256 4 106 9 20 296 0 123 4 25 331 0 138 0 28 350 3 146 0 30 362 6 151 1 35 391...

Page 62: ...per square inch Inches of water inH2 O 0 0737 Inches of Mercury inHg Inches of water inH2 O 2 54 Centimeters of water cmH2 O Inches of water inH2 O 0 2488 Kilo pascals per square cm kPa Centimeters o...

Page 63: ...minute ft3 min Cubic meters per hour m3 hr 0 589 Cubic feet per minute ft3 min Liters per second l s 2 12 Cubic feet per minute ft3 min Liters per second l s 3 60 Cubic meters per hour m3 hr Length Co...

Page 64: ...ea Conversions Table 8 11 Area Conversion Units Have Multiply By To Get Square inches sq in 6 4516 Square centimeters sq cm Square inches sq in 645 2 Square millimeters sq mm Square centimeters sq cm...

Page 65: ...Cambridge MA 1971 The Sports Car Engine Colin Campbell Robert Bentley Inc out of print Public Library The Theory and Practice of Cylinder Head Modification David Vizard 1973 Classic Motorbooks Osceol...

Page 66: ...Borgnakke and T Morel 900058 An Experimental Study of Velocity and Reynolds Stress Distributions in a Production Engine Inlet Port Under Steady Flow Conditions 1990 by R S W Cheung S Nadarajah M J Ti...

Page 67: ...63 NOTE Page left blank on purpose could be used for notes 8 0 Appendix...

Page 68: ...tion specific to the SuperFlow equipment ordered As specifications and part numbers change these documents will be updated to reflect the equipment and requirements for your machine at the time of shi...

Page 69: ...R VFD 460V 15KW 20HP FR F740 24 8 X 1635 RD HD MACH SCR 8 32 X 3 4 25 8 X 1691 LOCK WASHER 8 EXT TOOTH 26 4 H 0492 HEX HD CAP SCR 3 8 16 X 1 3 4 GD5 27 4 H 02614 HEX JAM NUT 3 8 16 GD 5 ZINC 28 4 1261...

Page 70: ...24 10 X 167 BTN HD SOC CAP SCR 8 32 X 3 8 25 10 X 172 LOCK WASHER 8 INT TOOTH 26 1 9 000 1066010 TUBING URETHANE 3 16 X 1 16W CLEAR 27 4 P 1125 FITTING 1 4NPTM X 3 16 H B STRT BRASS 28 5 11232 BULKHE...

Page 71: ...750 469 1 5 2 6 3 7 4 8 750 552 1 5 2 6 3 7 4 8 BLACK RED BLACK BLACK RED RED RED BLACK BLACK RED BRN 16AWG BLU 16AWG GRN 16AWG BLACK INLET AIR TEMP 112 AUX AIR TEMP 111 YELLOW RED YELLOW RED GREEN ET...

Page 72: ...SHER 1 4 X 1 2OD X 032THK NYLON 5 1 1065796 WELDMENT MUFFLER PANEL 1020i A 1 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF POWER TEST INC ANY REPRODUCTION IN PART OR WHOLE WITHOUT...

Page 73: ...OVER PLATE 13 1 1045050 COVER ORIFICE MOTOR ACCESS 14 3 SF3500P 2012 FITTING 1 8T X 1 8MPT THERMOCOUPLE SS 15 2 1045062 PITOT TUBE LOWER 1020i 16 1 1045109 BRASS TUBE NIPPLE 2 1 2IN 17 1 E 2815 COMP F...

Page 74: ...3100P 3054 BEARING SLEEVE 17 2 SFF4310P 5413 SWITCH LIMIT 18 4 SFF9 20 375 02B PHMS 2 56 X 3 8 PHIL PLTD 19 1 SFF2430Z 1021 LEVER LIMIT ADJUST 20 2 SF9 26 125 02C PHMS 4 40 X 1 8 PHIL SS 21 1 SFF9 26...

Page 75: ...INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF POWER TEST INC ANY REPRODUCTION IN PART OR WHOLE WITHOUT THE WRITTEN PERMISSION OF POWER TEST INC IS PROHIBITED 1 2 3 4 A B C D 3 2 1 4 B...

Page 76: ...IGHT BAYONET STYLE T3 1 4 24V WHT 1 12593 1 CONTACT BLOCK NO 22MM AB 1 14708 SWITCH E STOP NC NC PUSHTURN 1 SFHW1B V4F02 R 1 2 3 4 A B C D 3 2 1 4 D C A THE INFORMATION CONTAINED IN THIS DRAWING IS TH...

Page 77: ...R WHOLE WITHOUT THE WRITTEN PERMISSION OF POWER TEST INC IS PROHIBITED B FINISH MATERIAL APPROVED REVIEWED DETAILED APPROVALS CAD GENERATED DRAWING DO NOT MANUALLY UPDATE SCALE PART NO DATE REV UNLESS...

Page 78: ...ITOR 23in FLAT PANEL 11 1 1038011 USB TO ETHERNET ADAPTER 1000MBPS 12 1 C 0034 USB CABLE A B 10FT A 1 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF POWER TEST INC ANY REPRODUCTION...

Page 79: ...ated please contact your technical service representative for further information DOCUMENT DOCUMENT NAME MFG Blower Motor Manual Baldor Motor MN416A01 pdf MFG Blower Manual Operations_Manual_Sonic 150...

Page 80: ...N60 W22700 Silver Spring Drive Sussex WI 53089 USA Phone 1 262 252 4301 Fax 1 262 246 0436 www SuperFlow com...

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