SuperFlow SF-1020I User manual
Pub. No.: 1058319 Rev.: 7
August 2022
Operator Manual
www.superow.com
Original Instructions
SF-1020i FLOWBENCH
SF-1020iSF-1020i
ii
Please keep this manual for future reference.
This manual is intended to assist operating personnel in becoming familiar with the product and as guidance
in ordering necessary parts inclusive of SuperFlow's warranty requirements. Maximum operating eciency
and life of any SuperFlow product will be attained through complete understanding of the instructions and
recommendations contained within this manual.
Services performed beyond preventive
maintenance by personnel other than SuperFlow
Service Technicians on any SuperFlow products
during the warranty period may void the warranty.
!WARNING
When available, please include the model
number and serial number of the product in any
correspondence.
NOTICE
Copyright 2020 by SuperFlow Dynamometers & 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 W22700 Silver Spring Drive, Sussex, WI 53089 USA.
No part of the software or rmware provided with this product may be upgraded, modied, or changed by any
means without the prior written permission of SuperFlow Dynamometers & Flowbenches.
SuperFlow, WinDyn, PowerNet, ProFilter, SF902, XConsole, XDyno, XCart, NSCR, CycleDyn, AutoDyn,
FlowCom, SuperBench, ProExport, SF-110/120/260/450/600/750, SF-1020i, SF1200, ProBench,
SuperBench, TD-1200, TDAC, Axiline, TCRS, Hicklin, Racer’s Pack, and SuperShifter are trademarks of
Power Test, Inc. Other trademarks and trade names may be used in this document that refer to the entities
claiming the marks and names or their products. Power Test, Inc. does not hold any proprietary interest in
trademarks or trade names other than its own.
Trademark Notices
iii
1.0 Introduction...................................................................................................................1
1.1 About This Manual ....................................................................................................1
1.2 Target Audience ........................................................................................................1
1.3 Product Features ......................................................................................................1
2.0 Safety Guidelines..........................................................................................................2
2.1 During Operation ......................................................................................................4
2.2 Lockout/Tagout Procedures ......................................................................................4
3.0 System Overview..........................................................................................................5
3.1 Overview...................................................................................................................5
3.1.1 Feature Highlights.........................................................................................5
3.1.2 Options..........................................................................................................5
3.1.3 Calibration.....................................................................................................5
3.1.4 Special Applications Using an SF-1020i Flowbench.....................................6
3.2 Specications............................................................................................................6
3.3 SF-1020i Description ................................................................................................7
3.3.1 Baseplate ......................................................................................................7
3.3.2 Test Orice Plate...........................................................................................7
3.3.3 Muer Assembly...........................................................................................8
3.4 Options and Accessories ..........................................................................................9
3.4.1 Optional HMI Operator Display .....................................................................9
3.4.2 Air Filter.........................................................................................................9
3.4.3 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 Operation.....................................................................................................................15
5.1 Modbus Operational Examples...............................................................................15
5.1.1 Setting the Servo Mode ..............................................................................15
5.1.2 Setting the Test Pressure............................................................................16
5.1.3 Setting the Flow Rate..................................................................................16
5.1.4 Setting the Range .......................................................................................17
5.1.5 Turning Motor ON/OFF ...............................................................................18
5.1.6 Setting Leakage ..........................................................................................18
5.1.7 Performing a Flow Test ...............................................................................19
5.1.8 Preventing Test Errors ................................................................................20
5.1.9 Analyzing the Test Data ..............................................................................20
5.2 Wago Webvisu Application .....................................................................................21
5.2.1 Connect the Wago Webvisu Application .....................................................21
5.2.2 Wago Webvisu Control Screen ...................................................................23
5.2.2.1 Controls Section.................................................................................24
5.2.2.2 Readings Section...............................................................................25
5.2.2.3 PID Settings Section ..........................................................................25
Table of Contents
iv
5.2.2.4 Orice Settings Section......................................................................26
5.2.2.5 Sensor Calibration Section ................................................................27
5.1.2 Setting the Test Pressure............................................................................16
5.1.3 Setting the Flow Rate..................................................................................16
5.1.4 Setting the Range .......................................................................................17
5.1.5 Turning Motor ON/OFF ...............................................................................18
5.1.6 Setting Leakage ..........................................................................................18
5.1.7 Performing a Flow Test ...............................................................................19
5.1.8 Preventing Test Errors ................................................................................20
5.1.9 Analyzing the Test Data ..............................................................................20
5.2 Wago Webvisu Application .....................................................................................21
5.2.1 Connect the Wago Webvisu Application .....................................................21
5.2.2 Wago Webvisu Control Screen ...................................................................23
5.2.2.1 Controls Section.................................................................................24
5.2.2.2 Readings Section...............................................................................25
5.2.2.3 PID Settings Section ..........................................................................25
5.2.2.4 Orice Settings Section......................................................................26
5.2.2.5 Sensor Calibration Section ................................................................27
6.0 Maintenance................................................................................................................30
6.1 Maintenance ...........................................................................................................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 Orice Stepper Motor Assembly .................................................................39
6.4.5 Optional Air Filter Maintenance...................................................................40
6.5 Calibration...............................................................................................................44
6.5.1 Calibrating Sensors.....................................................................................44
7.0 Flowbench Theory......................................................................................................47
7.1 Flow Testing............................................................................................................47
7.1.1 Introduction .................................................................................................47
7.1.2 What Is A Flow Test?...................................................................................47
7.1.3 Flowbench History1..................................................................................................................................................... 47
7.2 Test Pressures and Comparing Flow Numbers ......................................................48
7.3 Correction for Test Pressure Variation ....................................................................50
7.4 Predicting Pressure Drop........................................................................................52
7.5 Calculating Mass Flow with the SuperFlow Flowbench..........................................53
7.6 Air Density Correction and SuperFlow Flowbenches..............................................54
8.0 Appendix .....................................................................................................................56
8.1 Default Settings For 1020i PLC ..............................................................................56
8.2 Unit Conversions ....................................................................................................57
8.3 Suggested Additional References...........................................................................61
8.4 Drawings.................................................................................................................64
8.5 Additional Documents .............................................................................................73
Table of Contents
1
1.0 Introduction
1.1 About This Manual
This manual is provided as a reference to explain the operation of the SuperFlow SF-1020i Flowbench.
An electronic PDF copy of this manual is provided on the thumb-drive sent with the SuperFlow system.
Please read the complete manual in
detail, prior to operating the machine.
Contact SuperFlow immediately if
you experience problems to avoid
any warranty issues.
NOTICE
1.2 Target Audience
This manual is intended to be used by skilled operators procient in the operation of the SuperFlow
SF-1020i Flowbench.
1.3 Product Features
• Solid metal constructed cabinet to withstand harsh shop environments
• Castors allow for easy movement
• The owbench utilizes a Modbus TCP/IP network via the internal PLC controller
• Once properly connected and congured to consumer control system the owbench will
automatically calculate and show ow on consumer automation systems display
• Once properly connected and congured to consumer control system, the owbench automatically
regulates test pressure or ow
• If properly sized, exhaust ow can be plumbed to direct air ow outside
• Once properly connected and congured, machine calibration, operation and troubleshooting can
done via a web-interface
• Can communicate with computers equipped with optional airow analysis software
• Optional Features
○HMI touch-screen display control package without data acquisition
○PowerNet Flowbench Data Acquisition and Control Software package
2
2.0 Safety Guidelines
Safety is the most important consideration when operating any machine. Operators and service personnel
should read this manual and become familiar with its content before attempting to operate this machine
or to perform service or maintenance to it. Familiarization with this manual will minimize the possibility of
accidents or injuries. Although the procedures covered in this manual have proven safe in use, SuperFlow
assumes no responsibility for personal injury or damage to equipment resulting from its applications. All
operators must be aware that there are several hazards present to anyone in the vicinity during operation.
Some of these hazards are:
• Hearing damage due to high noise levels
• Electrical shock
• Exposure to rotating parts
Always follow basic safety precautions when using this product to reduce risk of injury or damage to
equipment.
• Only authorized personnel knowledgable of the operation of the owbench should have access 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 protection whenever operating.
• Use only the proper electrical sources. Ensure circuit breakers are easily accessible and have the
proper rating.
• Observe all warnings and instructions marked on the product.
• Provide re extinguishers that are rated for electrical and oils.
• Provide adequate lighting in the test area.
• Refer all service questions to qualied personnel.
• Do not remove any safety guards while the machine is in operation, and be sure the safety guards
are correctly mounted before operating the device.
• Disconnect the external power switch before opening the rear panel of the device.
• Replace the power cable if it is damaged.
• Do not store ammable materials in the vicinity of the owbench.
• Follow all local construction codes.
These are general guidelines for working with any machine. It is often helpful to prepare a safety checklist
that is distributed to all personnel who enter the test cell. Proper safety is achieved through reinforcement
and discipline.
3
2.0 Safety Guidelines
Refer to Manual
• Read and understand manual before operation.
• Failure to understand manual may result in personal injury and/or death.
Wear Eye and Hearing Protection
• Rotating components could cause ying debris.
• Noise levels can reach up to 85 decibels (dB) or above during machine operation.
Warning
• General warning label.
• Indicates an imminent hazard.
Entanglement Hazard
• Keep hands and arms free of rotating shaft.
• Ensure system has stopped and starting has been disabled prior to servicing.
• Do not operate without all guards and covers in place.
Electric Shock
• Exercise caution when working on or nearby. Make certain that power has been disconnected
and all residual voltage has been taken under consideration. Unqualied personnel should
never attempt electrical work.
Contact SuperFlow if you 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
description of each warning decal is provided below. In addition, these symbols will appear throughout the
manual in sections where these hazards may be encountered.
This manual places safety concerns into four categories, they are:
This is the highest level statement. Failure to
follow the listed instructions will most likely result
in severe injury or death.
!DANGER
The statements used with this level of warning deal
with a safe operating procedure. If they are ignored
the possibility of equipment damage or personal
injury may exist.
!CAUTION
This is a statement of serious hazard. Failure
to follow the listed instructions could place the
individual at risk of serious injury or death.
!WARNING
NOTICE indicates precautions relating to operation
or usage of the machine or highlights important
information on a page.
NOTICE
4
2.0 Safety Guidelines
2.1 During Operation
DO NOT remove any safety guards
while the machine is in operation,
and be sure the safety guards are
correctly mounted before operating
the device.
!DANGER
WEAR EYE and HEARING
PROTECTION. Proper eye and
hearing protection should be worn
at all times when the equipment is
operating.
!WARNING
2.2 Lockout/Tagout Procedures
The Occupational Safety and Health Administration (OSHA) requires, in addition
to posting safety warnings and barricading the work area (including, but not limited
to, control room and testing bay), that the power supply has been locked in the
OFF position or disconnected. It is mandatory that an approved lockout device
is utilized. An example of a lockout device is illustrated in "Figure 2.1: Lockout/
Tagout". The proper lockout procedure requires that the person responsible for the
repairs is the only person who has the ability to remove the lockout device.
In addition to the lockout device, it is also a requirement to tag the power control in a manner that 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 damp
locations, will not cause the tag to deteriorate or become unreadable.
Power Test does not recommend any particular lockout device, but recommends the utilization of an
OSHA approved device (refer to OSHA regulation 1910.147). Power Test also recommends the review and
implementation of an entire safety program for the Control of Hazardous Energy (Lockout/Tagout). These
regulations are available through OSHA publication 3120.
• Keep the air ducts free of dust or dirt.
• Keep loose material away from the inlet and
exhaust ducts.
!CAUTION
• Inspect the equipment monthly to ensure that
there are no broken or worn parts which could
cause injury to personnel or damage to the
equipment.
• Only qualied operators and maintenance
personnel should perform the procedures
covered in this manual.
!WARNING
When working with electrical or
electronic controls, make sure that
the power source has been locked
out and tagged out according to
OSHA regulations and approved
local electrical codes.
!WARNING
Figure 2.1:
Lockout/Tagout
XXXXXXXXXXXX
XXXXXXXXXXX
OPERATE
DO NOT
5
3.0 System Overview
3.1 Overview
The SuperFlow SF-1020i owbench is designed to measure the intake airow resistance of engine cylinder
heads, manifolds, lters, or other devices. For testing, the owbench draws air into the machine through the
air pump and exits out the vent on back side of the owbench.
The SF-1020i owbench includes an industrial grade programmable logic controller (PLC) with the ability to
network with various consumer automation systems for automated control to ensure repeatable end-of-line
testing.
3.1.1 Feature Highlights
• Solid metal constructed cabinet to withstand harsh shop environments
• Castors allow for easy movement
• The owbench utilizes a Modbus TCP/IP network via the internal PLC controller.
• Once properly connected and congured to consumer control system the owbench will
automatically calculate and show ow on consumer automation systems display.
• Once properly connected and congured to consumer control system the owbench automatically
regulate test pressure or ow.
• If properly sized, units exhaust can be plumbed to direct air ow outside.
• Once properly connected and congured, machine calibration, operation and troubleshooting can
done via a web-interface
• Can communicate with computers equipped with optional airow analysis software
3.1.2 Options
• Flowbench Control and Software systems: SuperFlow oers an optional HMI touch-screen
display control package or a computer system with data acquisition and control software. With a
properly congured computer system, all data is simultaneously transmitted in real time and then
PowerNet Flowbench Data Acquisition and Control software graphically displays ow data (in
English or metric units) in real time and records data for later analysis.
Contact SuperFlow Sales or Customer Service for more information on operator control systems.
• Air Filter: Designed for high-contamination environments, this lter can help protect the motors and
other internal components in the SF-1020i. The washable lters are designed with low restriction to
ensure minimal eect on capacity.
3.1.3 Calibration
Sensors are calibrated at the factory for each particular owbench. A dynamic ow calibration is performed
yielding unique ow range values for each of the ten ranges of operation. This precise calibration data is
entered into internal memory.
Calibration Kit (P/N # SF1200A-2517) required for system ow calibration.
6
3.0 System Overview
3.1.4 Special Applications Using an SF-1020i Flowbench
Many SuperFlow owbenches are used daily to measure airow through cylinder heads, manifolds, throttle
bodies, carburetors and other components.
What can you measure on a SuperFlow SF-1020i owbench? The answer is just about anything you can
mount on the bench. Some manufacturers use the bench as a Quality Control (QC) process to quantify
catalyst materials. Other applications include muers and air lters. The aerospace industry also uses the
benches to maintain QC on parts for various gas turbine components. Using PowerNet Flowbench Data
Acquisition and Control software provides an easy way to compare parts by Eective Flow Area (EFA). The
software can also be used to quantify cylinder heads and manifolds with a relatively new 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 power generator.
Odd applications? How about natural gas control valves that control the fuel for gigantic shipboard
engines? How large? A 10,000-hp valve is considered small.
Small applications? The smallest known application is used to set the idle opening in throttle bodies where
the target is 3.5 cfm at 25"H20.
3.2 Specications
Capacity
• 1000 cfm ± 5% @ 25” test pressure
(472 l/s ± 5% @ 64 cm)
Instrumentation
• Not included by default
Accuracy
• Flow Measurement: ± 1% of full scale
reading (in normal operating ranges)
• Test Pressure: ±0.20” H2O (±0.13 cm)
Repeatability
• ± 0.5% of full scale reading
Temperature Measurements
• Thermocouple probe(s): –328 to +
2192°F ±33°F (–200 to +1200°C ±1°C)
Weight
• 2,100 lbs. (953 Kg)
Dimensions
• 50" L x 34" W x 44" H
(127 x 86 x 111 cm)
Machine Power Requirements
• 480 VAC 3-phase, 60 Hz, 30 amps
• 380 VAC 3-phase, 50 Hz, 36 amps
Table of contents
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