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1.0 Introduction

1.1 About This Manual

This manual is provided as a reference to explain the operation of the SuperFlow dynamometer system as

used on an engine test system and also covers the operation and maintenance of the SF-902S engine test

stand.

An electronic PDF copy of this manual is provided on the system configuration thumb-drive sent with the

SuperFlow system.

Please read the complete manual in

detail, prior to operating the

dynamometer. Contact SuperFlow

immediately if you experience

problems to avoid any warranty

issues.

IMPORTANT

1.2 Target Audience

This manual is intended to be used by skilled operators trained in the operation of the equipment by a

SuperFlow representative.

1.3 Product Features

•  A system consists of two major components:
    - Dynamometer stand with a Power Absorption Unit (PAU).
    -  Data Acquisition and Control (DAC) system – Computer system with

WinDyn software.

Содержание SF- 902S

Страница 1: ...Pub No 191204 Rev 2 April 2020 Operator Manual www SuperFlow com Original Instructions SF 902S Engine Dynamometer...

Страница 2: ...Flowbenches 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 W227...

Страница 3: ...2 Sensor Panel Modules 13 3 4 Accessories and Options 16 4 0 Installation 22 4 1 Location 22 4 2 Plumbing Diagram 23 4 3 Unpacking 24 4 4 Engine Docking Cart 24 4 5 Absorber Stand 25 4 6 Sensor Box 28...

Страница 4: ...alog 52 WinDyn Prep 52 WinDyn Setup Dialog 52 ValPos Adjustment 53 Running a Test 54 Post Test 55 Shutdown 55 5 8 Analyzing the Test Results 56 6 0 Maintenance 58 6 1 Maintenance Schedule 58 6 2 SF 90...

Страница 5: ...sent with the SuperFlow system Please read the complete manual in detail prior to operating the dynamometer Contact SuperFlow immediately if you experience problems to avoid any warranty issues IMPORT...

Страница 6: ...ors and at least two stators or end bells The rotors spin freely inside the absorber housing in the absence of water When water is introduced into the absorber the spinning rotor accelerates the water...

Страница 7: ...er is applied to the system DO NOT open any panels while power is applied to the system DO NOT make any plumbing connections without shutting down all water supplies and pumps DO bleed air pressure fr...

Страница 8: ...nel should never attempt electrical work Electrostatic Discharge Printed Circuit Boards PCBs and other electronic devices contain static sensitive parts Observe the following precautions to prevent da...

Страница 9: ...s properly ventilated If anyone shows signs of carbon monoxide poisoning get them to fresh air Fumes can cause headache dizziness lack of consciousness and or death DANGER Take care that the dynamomet...

Страница 10: ...will clearly note 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...

Страница 11: ...uisition and Control DAC system with its associated accessories The absorber stand also holds auxiliary equipment such as a flow measurement system and an engine cooling system The DAC system is made...

Страница 12: ...tem keep the test cell safe organized and attractive while allowing rapid engine changes Additional mounts for ignition boxes and work tools can be added if desired Optional features include cooling f...

Страница 13: ...outes water from the engine to the cooling tower and organizes transducer cables Boom mounted sensor box Versatile docking engine cart Industrial grade heavy duty baseframe Rugged high torque power ab...

Страница 14: ...ance is essential to efficient operation consult a water system specialist to create the proper program to monitor your system Filters For both open water and recirculating systems install a filter to...

Страница 15: ...es and records all data and generates control signals then broadcasts this data over an Ethernet network to display on the WinDyn computer software The sensor box has slots for expansion panels such a...

Страница 16: ...ecommends using an Uninterruptible Power Supply UPS that has a minimum rating of 750 VA or a high quality surge suppressor for the sensor box and computer This may protect the electronics from damage...

Страница 17: ...gine speed sensor input May also be used for frequency type devices RJ 45 Category 5 Cat 5 serial connectors Sensor Interconnect Panel AMP The sensor interconnect panel provides the primary connection...

Страница 18: ...54 to 2 300 F 270 to 1260 C linearized Universal panel jacks accept both standard and miniature connectors Pressure Input Panel The pressure panel provides up to 10 channels of pressure measurements o...

Страница 19: ...t 14 amps on the starter and fuel pump outputs and 5 amps on the auxiliary output Emergency stop functions when used with WinDyn limits or emergency stop switches Provides one unswitched 10 amp fused...

Страница 20: ...ront panel connections for sensors or other devices 5F 5VDC 100 mA poly fused at 0 1A 12F 12VDC 500 mA poly fused at 0 5A Air Fuel Kit AEM s 4 Channel Wideband UEGO Controller allows users to simultan...

Страница 21: ...1 40 Fuel Canister Designed to measure fuel consumption of fuel injected engines Mid flow unit available in 20 720 lb hr High flow unit available in 30 1070 lb hr Available for gas or alcohol Electri...

Страница 22: ...cially during endurance tests Figure 3 15 shows a multi pass heat exchanger with the water inlet controlled by a mechanical thermostat valve It can be mounted on the absorber stand the engine cart or...

Страница 23: ...urized CT300P CT700 or CT1001 cooling towers for higher temperatures 160 230 F 71 110 C or with antifreeze mixtures Pressurized cooling towers have separate chambers for engine cooling water and heat...

Страница 24: ...0 Volumetric Blow by The JTEC VF563 series flow meter provides exceptional accuracy The sensor measures blow by in Actual cubic feet per minute ACFM units Figure 3 17 Blow by Sensor 3 0 System Overvie...

Страница 25: ...ngines The SuperStarter can be configured for several applications Dual starters clockwise or counterclockwise rotation Single starter clockwise or counterclockwise rotation Dual starters bidirectiona...

Страница 26: ...lt your specific room layout drawings for additional details Contact your Power Test representative should any questions arise concerning the location or installation of your equipment Dimensions show...

Страница 27: ...N TANK TO MAIN TANK EITHER 1 1 2 OR 2 SCHEDULE 80 PVC OR GALVANIZED SUPPLY SIDE PLUMBING 2 1 2 SCHD 80 PVC 30 ft MAX EFFECTIVE LENGTH IF LONGER THAN 30 ft SIZE ACCORDINGLY TO ALLOW NECESSARY INLET PRE...

Страница 28: ...hat all circuit cards are secure and cables are properly seated in their connectors 5 Position the sensor box on a stable surface Locate the sensor box door key Carefully open the sensor box door and...

Страница 29: ...e tank between the chambers is closed Figure 4 2 Dynamometer Stand Sump Tank 4 Place the absorber vent tube and throttle drain tube outlets in the outlet or drain side of the tank These are the two sm...

Страница 30: ...osition Figure 4 3 Water Supply Connections 9 Connect the water inlet and outlet ports on the rear of the tank to the appropriate sources You may need to slide the tank out a little to allow access to...

Страница 31: ...cess inside the tank for maintenance 12 Install pressure hoses to the appropriate connectors on the rear panel of the absorber stand Figure 5 9 using the supplied hardware Tee adapters are provided to...

Страница 32: ...to the bottom of the box Electrical power for the sensor box should come from a dedicated protected line If desired a long power cord can be routed into the control room and plugged into the same out...

Страница 33: ...nnection of the water inlet and outlet hoses to the CT700 NOP cooling tower can pressurize the system and blow the hoses off the engine which can result in serious equipment damage or bodily injury WA...

Страница 34: ...30 Figure 4 6 CT700P Pressurized Cooling Tower 4 0 Installation...

Страница 35: ...d and connected Close the box lock it and put the keys in a safe place NOTE The power supply used in the sensor box and the console is 12 volt switching power supply Voltage checkpoints for both power...

Страница 36: ...ir 1 Calibration tables for each flow turbine are entered in the configuration file Other TTL or MAG frequency devices can be connected here as well but require modification to the definition of chann...

Страница 37: ...a system ES action initiates 1 Connect a Cat 5 serial cable supplied from the RJ 45 connector J2 on the back of the console to the Console J2 connector on the sensor box system interconnect panel Mak...

Страница 38: ...34 Electrical Diagram 4 0 Installation...

Страница 39: ...tered in the configuration file Aux 1 Aux 2 The Auxiliary 1 and Auxiliary 2 inputs are direct not multiplexed analog voltage inputs These inputs are designed for a 0 10 VDC signal and configured for t...

Страница 40: ...ressure Connections Connect the hose to the appropriate pressure source SuperFlow recommends using reinforced rubber Stainless steel hoses can be used but have the potential to conduct Radio Frequency...

Страница 41: ...the thermocouple into an extension cable if needed or directly into the thermocouple panel The panel will accept standard or miniature plugs The system is typically supplied with 12 closed tip 1 8 the...

Страница 42: ...Expansion Receptacles are color coded All are keyed the same and use the same pin out The channels are configured in the software as to the type of sensor used Prefabricated cables are available to co...

Страница 43: ...the variety of fuel supply systems used on today s engines you may be required to fabricate special adapters to work with throttle systems Consult the documentation that accompanied the throttle syste...

Страница 44: ...calibrating the systems torque measurement sensor Refer to Calibrating the Sensors on page 63 in Chapter 6 IMPORTANT The system is now ready for use Proceed to Chapter 5 for operation instructions Co...

Страница 45: ...protection should be worn at all times when the equipment is operating WARNING Do not attempt to use the dynamometer without proper training from SuperFlow Severe injury or property damage may result...

Страница 46: ...mputer system Additional emergency stop switches can be installed in the test cell and control room In the event of an emergency press the nearest emergency stop switch The emergency stop command will...

Страница 47: ...t Access during warm up periods and when the engine is idling is permissible Power OFF the system during periods when the dynamometer is not in use Ensure good visibility of the complete test cell are...

Страница 48: ...engine on the stand before the headers are installed Refer to figure 5 1 when following this procedure 1 Support the engine from a lift at the angle it will be mounted on the Docking Cart Rotate the f...

Страница 49: ...in the same manner that a standard shift transmission connects to the engine First install an adapter plate to the flywheel or flex plate Engine Adapter Plates for many engines are available from Sup...

Страница 50: ...ired to open the inlet valve and let in more water to compensate for air purging out of the engine Both valves must be closed for normal operation SuperFlow CT300P CT700P and CT1001 pressurized coolin...

Страница 51: ...the variety of fuel supply systems used on today s engines you may be required to fabricate special adapters to work with throttle systems Consult the documentation that accompanied the throttle syst...

Страница 52: ...upply source Engine Connections 1 Attach thermocouples to the engine and connect them to the proper plugs on the sensor box temperature panel 2 Attach pressure lines to the engine and connect them to...

Страница 53: ...onnections and adjust throttle end stops insure you have idle and WOT Sensors are connected as required for the test 4 Ensure no sensor cables electrical wires or pressure lines interfere with the eng...

Страница 54: ...o computer keyboard Verify the torque system is at or near zero 2 verify weather conditions are current 7 System setup S key on dyno computer keyboard Set the data file name and beginning sequence num...

Страница 55: ...on on the desktop and double click the icon to load the program 2 Once NetDyn has been loaded locate the SuperFlow WinDyn program icon on the desktop and double click the icon to load the program a Th...

Страница 56: ...o be reading correctly See section 6 3 Calibration on page 63 if you feel calibration should be performed before testing WinDyn Setup Dialog WinDyn preferences can be set up to quickly prepare the sys...

Страница 57: ...rs may be used i e 2 5 or 3 3 etc The key is to observe outlet water temps from the absorber SuperFlow prefers to see temps no higher than 190 deg F Optimally use a ValPos and water pressure setting t...

Страница 58: ...to dyno warmed up and running 1 Press the START button to begin 2 Follow the on screen prompt and increase throttle setting and stabilize speed at 3 000 RPM 3 Once stabilized begin test by pressing th...

Страница 59: ...the location and with the filename specified in the Test Setup screen Press Shift F3 to select and view the saved test data Shutdown Let the engine cool down as necessary in idle mode then turn off f...

Страница 60: ...ccess the Channel Order Dialog Double click on data point to see its value Double click in left or right margins to customize the plot format or change plot titles Right click anywhere in graph to cha...

Страница 61: ...57 DATA SHEET 5 0 Operation...

Страница 62: ...se Inspect for wear or damage Pressure hoses fittings Inspect for wear or damage Other sensors Inspect for wear or damage Water Filter Strainers Every 3 months Inspect and clean Water System Add 1 gal...

Страница 63: ...float valve inside the tank The tank can possibly overflow the first time it is filled but should not happen again after the automatic valve is primed The control valve rarely fails to work properly...

Страница 64: ...sect parts If you are not testing with highly filtered fuel your fuel system will catch a large quantity of contaminants you may not realize are even present To clean the system remove the filter scre...

Страница 65: ...at the servo valve is wide open 2 Fully loosen the lock nut on capacity valve 3 Turn the capacity valve fully counterclockwise open 4 Remove the capacity valve from the back of the absorber pump housi...

Страница 66: ...between the rotor and stator area and the pump housing Failure of this seal can lead to absorber controllability issues such as reduced loading capacity surging and erratic changes in load This part...

Страница 67: ...isition and Control Software please refer to the software manual for additional calibration details Torque 15 Power on computer system 16 Power on dyno system 17 Launch WinDyn application 18 Use Syste...

Страница 68: ...hannel 6 Raise or lower the voltage values in either channel to perform calibration SuperFlow uses a Kestrel 3500 pocket weather station to calibrate these channels Any similar device will suffice Tem...

Страница 69: ...remain the same The offset value changes every time the system is zeroed 1 From the main WinDyn menu select Tools View Sensor Calibration 2 Using the Tutorial at the bottom of the window follow the s...

Страница 70: ...mer Service for a copy a This contains a config file cfa that changes the inlet valve control mode to always copy the outlet valve b Thus it will allow you to control both inlet and outlet control val...

Страница 71: ...trol valves in manual mode control without the engine running Normally the inlet valve will not move until engine RPM exceeds 500 c If you don t have the Diag_Pmk tgp but have the WinDyn Config editor...

Страница 72: ...tlet to see if the valve is the issue or the electronics in the sensor box are the culprit When swapping the valves if they use an extension cable be sure to use the extension cable when connecting th...

Страница 73: ...separate procedure documenting how to perform those adjustments Figure 7 4 Check Jumpers Outlet control uses shunts in A2 and the DAC1 positions Inlet control uses shunts in A1 and the DAC3 positions...

Страница 74: ...nce checks can be performed on the 902S servo valves using the cable connector and its pins If your valves use an extension cable then the values below will be correct ONLY if you are measuring with t...

Страница 75: ...he absorber impeller relatively easily If not then you may have seized a bearing or have other damage inside the absorber Another potential problem is servo valves not being securely mounted to the ab...

Страница 76: ...ing This is caused by water being unable to exhaust from the absorber properly Here are some photos showing the proper orientation of the exhaust manifold for standard rotation engines clockwise Figur...

Страница 77: ...Too high ValPos too low increase ValPos Water pressure too high or low Optimum pressure setting is between 50 80 psig Water backing up in outlet port of absorber or horn of plenty This creates backpre...

Страница 78: ...servo valve opening We recommend between 50 80 psig inlet water pressures You should monitor this pressure via one of the pressure transducer ports on the pressure panel in your sensor box If you do...

Страница 79: ...ecific to the SuperFlow SF 902S dynamometer As specifications and part numbers change these documents will be updated to reflect the equipment and requirements for your machine at the time of shipment...

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