SF600 Operation Manual 2009

SF-600FC Flowbench
Operators Manual
May 2004
SUPERFLOW FLOWCOM
OPERATOR MANUAL
MAN 1100A-2200 REV: 01.17.07-02
Copyright 2007 by SuperFlow Technologies Group. All rights reserved. No part of this publication may be reproduced, transcribed, or translated by any means without the prior written permission of SuperFlow Technologies Group, 3512 N. Tejon, Colorado Springs, Colorado, 80907, USA. No part of the software or firmware provided with this product may be upgraded, modified, or changed by any means without the prior written permission of SuperFlow Technologies Group, 3512 N. Tejon, Colorado Springs, Colorado, 80907, USA.
Trademark Notices
SuperFlow, WinDyn, ProFilter, SF902, XConsole, XDyno, XCart, NSCR, and Racers Pack are trademarks of SuperFlow Technologies Group. Other trademarks and trade names may be used in this document that refer to the entities claiming the marks and names or their products. SuperFlow Technologies Group does not hold any proprietary interest in trademarks or trade names other than its own.
Warranty Statements
SuperFlow Technologies Group makes no representations or warranties with respect to this manual. SuperFlow reserves the right to make changes in the specifications of the product described within this manual at any time without notice and without obligation to notify any person of such revisions or changes.
Limited Warranty
SuperFlow warrants its products to the original purchaser and to no others in the line of commerce. Any other users, purchasers or bystanders are expressly excluded from this warranty. SuperFlow hereby warrants its product for fitness for ordinary purposes for which such goods are used. SuperFlow warrants to the purchaser that each product manufactured to be delivered hereunder will be free from defects in material and workmanship. SuperFlow warrants that each product manufactured will deliver the performance described in our sales literature, provided such product is properly cared for, and operated under normal conditions with competent supervision. The warranty is valid for a period of one year from the date of shipment. If within that time the product delivered hereunder does not meet the warranty specified above, the purchaser must notify SuperFlow promptly. Thereupon, SuperFlow shall correct any defect, either by repairing any defective part or parts, or making available a repaired or replacement part. It will be the sole discretion of SuperFlow as to which manner of correction shall be employed. Said warranty extends only to the immediate purchaser and not the purchasers customers, subsequent purchasers, bystanders, or any other person who may have contact with any SuperFlow product. In the event of any defective units, the liability of SuperFlow hereunder shall be limited to replacing or repairing any defective units which are returned F.O.B. to SuperFlows plant. The option as to repairing versus replacing the part shall be solely that of SuperFlow. Equipment or parts which have been subject to abuse, misuse, accident, alterations, neglect, unauthorized repair, or improper installation are not covered by this warranty. SuperFlow shall have the right of final determination as to the existence and cause of any defects. In no case shall products be returned without first obtaining permission from SuperFlow prior to shipment. In the event of return or replacement of defective parts, the warranty period shall be pro-rated for the duration of the return or repair. The warranty shall continue for the remainder of the original period, or for 30 days, upon date of shipment by SuperFlow to the purchaser.
In no event will SuperFlow be liable for any incidental or consequential damages. If there should be any liability found, it shall be limited to the original purchase price of the product in question if said product is found to be defective. This warranty is in lieu of all other warranties, whether expressed, implied or statutory, including implied warranties of merchantability of fitness. There are no warranties that extend beyond the description on the face hereof.
Extended Warranty
SuperFlow offers an extended warranty contract. The contract grants the standard limited warranty for a additional period of one year. To take advantage of this extended warranty, the extended warranty contract must be signed and returned together with full payment to SuperFlow prior to the end of the normal warranty period. To renew the extended warranty for another year, the same procedure must be followed. Shipping charges are not included in the extended warranty.
Technical Assistance
The SuperFlow Customer Service Department is available for technical assistance or general questions regarding our products. Be specific when describing the problem or question. The problem will be solved more quickly when described in a calm, accurate manner. All technical problems should be referred to the nearest SuperFlow Customer Service Department office. Refer to section for the most convenient office and the times they are open. SuperFlow does not recognize or authorize any person who is not employed by SuperFlow to perform service on any of its products without express written permission from SuperFlow. Always contact SuperFlow Customer Service before allowing outside service work performed.
Return Material Authorization (RMA)

If it is necessary to return the system or components to SuperFlow, the Customer Service Department will issue a Return Material Authorization (RMA) number. All communications regarding the equipment should reference this RMA number.
Service Under Warranty

The system or components are to be shipped to SuperFlow at your expense. SuperFlow will repair the system at no cost and pay for shipping it back via the best way surface. Any other method, such as air express, is at your expense.
Service Out of Warranty

The system or components are to be shipped to SuperFlow at your expense. You are responsible for all parts, service charges, and shipping costs. On-site service is available. Contact the Customer Service Department for current rates. Should your company require a purchase order for standard repair service, provide the purchase order number when you call.
Contact Information
Manufacturer, Sales, Distributors, and Authorized Service Centers
SuperFlow
3512 North Tejon, Colorado Springs, CO 80907-5299 Toll Free Sales: Phone: Fax: Service Dept. Fax: (800) 471-7701 (719) 471-1746 (719) 471-1490 (719) 578-1792 E-mail: sales@superflow.com service@superflow.com
MondayFriday, 8:00 A.M.5:00 P.M. Mountain Time
SuperFlow East
Phone: (704) 957-8020 E-mail: sales@superflow.com service@superflow.com
MondayFriday, 8:00 A.M.5:00 P.M. Eastern Time
SuperFlow California
Phone: (805) 383-1186 E-mail: dmarsh@superflow.com MondayFriday, 8:00 A.M.5:00 P.M. Pacific Time
SuperFlow Europe
Grensstraat 41 A, 2243 Pulle, Belgium Phone: Sales: Service: Fax: 32 3 4846510 32 3 4846511 32 3 4844590 32 3 4846520 E-mail: sales@superflow.be info@superflow.be service@superflow.be
MondayFriday, 9:00 A.M.5:00 P.M. Central European Time
Des Moines Office

Toll Free Sales: Phone: Fax: E-mail: Heavy Duty Transmission Dynamometers: Light Duty Transmission Dynamometers and Testers: Torque Converter Rebuilding Systems: Driveshaft Rebuilding Equipment: MondayFriday, 8:00 A.M.5:00 P.M. Central Time hicklin@superflow.com axi-line@superflow.com tcrs@superflow.com dwatson@superflow.com (888) 442-5546 (515) 254-1654 (515) 254-1656
Company Internet Web Site

The Superflow Web site contains extensive test, service, and troubleshooting information and is regularly updated. Visit us at:
www.superflow.com
Our Sales and Service departments can be accessed via e-mail directly from the Web site.
Manual Conventions
The following conventions indicate items of interest or concern: WARNING: Failure to take or avoid a specific action could result in physical harm to the user or the hardware. CAUTION: Failure to take or avoid a specified action could result in loss of data or equipment. IMPORTANT: Essential operating information. NOTE: Helpful information that may provide insight to the user/operator. TIP: Additional information that may provide handy workarounds or solutions.
Cross-references refer the reader to additional information in the chapter, manual, or other sources (including Web sites).
Contents
FlowCom Operation
Introduction ..............................................................................................................................3 Feature Highlights ........................................................................................................................ 3 Test Pressure Regulation ............................................................................................................. 3 Velocity Probes and Swirl Meters .............................................................................................. 3 Flow Data Correction ................................................................................................................... 3 Flowbench Software ..................................................................................................................... 3 Power Requirements .................................................................................................................... 3 Specifications ................................................................................................................................. 4 Panel Description .....................................................................................................................4 Flow Testing with FlowCom ....................................................................................................7 Operational Check ............................................................................................................................. 7 Performing a Flow Test .........................................................................................................10 Determining Leakage ...................................................................................................................... 10 Entering Leakage into FlowCom ................................................................................................... 10 Flow Test Procedure ........................................................................................................................ 11 FlowCom Computer Connections ........................................................................................12 Configuring FlowCom to Communicate ..................................................................................... 12 RS232 Serial Connection ................................................................................................................. 13 Universal Serial Bus Connection ................................................................................................... 14 Installing the USB Driver .......................................................................................................... 15 Configuring the USB Communication .................................................................................... 16 Software Programs ................................................................................................................19 Installation and Operation ............................................................................................................. 19 Communication ............................................................................................................................... 19 Checking the COM Port Assignment ........................................................................................... 22 Changing the COM Port Assignment ........................................................................................... 23
Index
FlowCom Operation FLOWCOM OPERATION

In This Guide:
IN THIS GUIDE:
Introduction Panel Description Flow Testing with FlowCom
Operational Check Determining Leakage Entering Leakage into FlowCom Flow Test Procedure Configuring FlowCom to Communicate RS232 Serial Connection Universal Serial Bus Connection Installation and Operation Communication Checking the COM Port Assignment
Performing a Flow Test

FlowCom Computer Connections

Software Programs

Changing the COM Port Assignment
Introduction
1 Introduction
The SuperFlow FlowCom (FC) is a hand-held or panel mountable, microprocessor-based flowbench computer. It automatically gauges test pressure and temperature to show corrected flow on an easy-to-read Liquid Crystal Display (LCD). When combined with SuperFlows motor controller, FlowCom automatically controls test pressure or flow based on keypad input. When used with PortFlow Analyzer software, FlowCom graphically displays flow data (in English or metric units) in real time.
Feature Highlights
Compact, lightweight microprocessor design Rugged construction to withstand harsh shop environments Automatically calculates, corrects, and shows flow on the LCD display Automatically regulates test pressure or flow with optional motor controller External velocity-probe and swirl-meter inputs Communicates with computers equipped with optional airflow analysis software Precise calibration data for each particular flowbench can be entered into the FlowCom
Test Pressure Regulation

With the optional motor controller, FlowCom automatically regulates the test pressure based on a keypad input. The test pressure is selected at the beginning of the test, and FlowCom regulates the pressure as the valve lift is changed. The data results can be frozen at each test point with the FlowCom keypad or with a hand- or foot-operated push button (optional) while hand recording the data.
Velocity Probes and Swirl Meters

Velocity probes can be connected to the FlowCom inputs to display air speeds at any point in the test. Connect a strain gauge or frequency-based swirl meter, and FlowCom will display swirl torque or swirl per unit of flow.
Flow Data Correction

FlowCom accurately measures air temperatures and automatically corrects the flow meter readings (requires optional temperature probes).
Flowbench Software
All data can be simultaneously transmitted in real time to a computer through a serial port connection. You can add optional WinDyn or PortFlow Analyzer software to graphically display, record, and print test data.
Power Requirements
812 VDC 300mA Powered with an AC adapter or from a motor controller
SuperFlow Technologies Group
Specifications
Table 1-1. FlowCom Specifications
Item
Flow measurement accuracy Repeatability Test pressure accuracy Temperature measurement accuracy
Specification
0.5% of reading in normal operating ranges 0.25% of reading 0.05" ( 0.13 cm) of water 0.5o F ( 0.3o C)
2 Panel Description
The front panel provides the operator controls for the FlowCom. The push-button controls are encased in the membrane panel for greater reliability. View data on a 128x64 LCD. Light-Emitting Diode (LED) lights indicate power, motors, and direction status. Connections for the FlowCom are on the side panel (not applicable on SF-60 and SF-1020).
Table 1-2. FlowCom Connections
Graphic
Function
Swirl Meter
Description
RJ-45 connection for a swirl meter or other device with frequency or strain gage outputs (may require an RJ-45 adapter). 1/8-inch phone plug connection for temperature sensors. RJ-45 connection for a motor controller (requires an RJ-45 to DSUB adapter). RJ-45 connection for a valve lifter module (may require an RJ-45 adapter). 1/8-inch phone plug connection for a momentary contact record switch. Universal Serial Bus (USB) communications port. RJ-45 serial communications port (computer may require an RJ-45 to DSUB adapter) Connection for 9 VDC 300mA power supply (adapter can be either polarity).
Temperature Inputs
Motor Controller
Valve Actuator
Foot Switch
USB Port Serial Port
Power Supply
FlowCom Operator Guide
Panel Description
Table 1-3. Keypad Functions
Graphic
Key Name
RED Power
Function
Description
Turns the power on and off.
GREEN
Motor
Turns the flowbench motors on and off (requires a motor controller). Selects intake or exhaust mode. The upper button (blue LED) indicates intake; the lower button (amber LED) is exhaust.
BLUE
Direction
UP ARROW
Scroll up
Selects items on the display.
DOWN ARROW
Scroll down
F1
Conf
Accesses a menu for general setup and configuration of the FlowCom. Accesses the calibration functions.
F2
Cal
F3
Test
Accesses the test functions.
BACK ARROW
Scroll back
FORWARD ARROW BENT ARROW
Scroll forward
Enter
Activates the current selection.
Figure 1-1. FlowCom Panel FlowCom connects to the flowbench manometer through pressure ports on the side panel (not applicable on SF-60 and SF-1020). Instructions for the proper connector are in the standard FlowCom Operator manual.
See Figure 1-3, Flowbench Test Orifice Plate, on page 7. Also, refer to the Flowbench Operator Manual for proper connections.
P1: Incline manometer P2: Vertical manometer P3: Velocity probes
Figure 1-2. Pressure Ports
Flow Testing with FlowCom
3 Flow Testing with FlowCom

All test data may be recorded on the FlowCom Test Data Sheet forms (see reproducible samples in back of the manual) or automatically recorded by software installed on a connected computer.
3.1 Operational Check

Each flowbench is supplied with a test plate that verifies the bench is working properly and checks the calibration of the flowbench and FlowCom. The following procedure details how to perform an operational and accuracy check using the test orifice plate. This is also an easy way to learn how to use FlowCom because the procedure applies to normal flow testing as well. 1. Mount only the standard test orifice plate onto the top of the SuperFlow flowbench. Ensure both holes in the test orifice plate are open. NOTE: SF-60 has a different test plate. Plug all of the holes except the largest one.
Figure 1-3. Flowbench Test Orifice Plate 2. Close (clockwiseCW) the exhaust flow control knob lightly against its seat. Fully open (counter-clockwiseCCW) the intake flow control knob (not applicable to SF-60, SF-1200, and SF-1020).
3. Press the red Power button on the FlowCom panel to start it. The green LED illuminates, and the main window appears on the display. The current range setting and direction displays at the bottom of the window.
Figure 1-4. Basic Operation 4. Press the Intake Mode button to set the FlowCom in intake mode. The blue LED illuminates.
Table 1-4. Test Orifice Ranges and Pressure
Nominal Flow Reading* Model

SF-110/120 SF-300 SF-600 SF-1020 SF-1200
Flow Range
9 5 4 6 2
Test Pressure
10 H2O (25 cm) 25 H2O (63.5 cm) 25 H2O (63.5 cm) 25 H2O (63.5 cm) 25 H2O (63.5 cm)
Intake (cfm)
150 240 240 240 240
Exhaust (cfm)
153 246 246 246 N/A
* The values shown here are nominal only. Actual values may depend upon the flowbench calibration.
5. Use the numeric keypad to set the flowbench range. Refer to Table 1-4 for the correct range and test pressure for the flowbench performing the test. NOTE: The range and flow direction appear at the bottom of the LCD display.
Figure 1-5. Range and Flow Direction
Flow Testing with FlowCom 6. Press the ENTER key to display the Test Pressure selection window. Use the numeric keypad to enter the desired test pressure. Press ENTER to set the test pressure. Then use the UP/DOWN arrows to set the units of measurement. Press ENTER to exit.
Figure 1-6. Test Pressure 7. Turn on the motor power switch and allow the flowbench to stabilize.
Flowbenches without a motor controller:
Slowly close (CW) the intake control knob until the desired test pressure is reached.
Flowbenches with a motor controller:
The green push-button switch on the FlowCom panel turns the motors on. FlowCom automatically adjusts the motor speed for the test pressure. 8. The FlowCom should now read the cubic feet per meter (cfm) flow of the test plate (see Table 1-4). If the flow is within 3% of this reading, the flowbench and FlowCom are working properly. 9. Press the LEFT ARROW key to hold the reading. Record the data, then press the RIGHT ARROW to resume active readings. 10. Open the flow control knob (CCW) and turn off the motor. Remove the test orifice plate. This completes the operational checkout test. It can be repeated in exhaust mode if desired. While this test is not time consuming, it will ensure that all test results are valid and repeatable.
4 Performing a Flow Test

Remove the test orifice plate from the flowbench and install the test head, cylinder adapter, and valve opener onto the flowbench for the actual flow tests. Set the dial indicator to read zero with the valve closed. Install either the intake manifold or an air inlet guide on the intake port.
4.1 Determining Leakage

Leakage is defined as airflow through any opening other than what is being tested. It is determined with the cylinder head valves or other opening on the test piece closed. Leakage is usually from 0.1 to 1 cfm (0.25 to 0.50 l/s). If no leakage occurs, the flow meter may read zero. The leakage does not affect the test as long as the amount is entered into the FlowCom.
4.2 Entering Leakage into FlowCom

1. Press the F3 key (Test) to access the test menu.
Figure 1-7. Test Function menu 2. Using the UP/DOWN arrow keys, scroll down and highlight Leakage. Press ENTER.
Figure 1-8. Leakage 3. Using the numeric keypad, enter zero (0). Press ENTER. 4. Using the UP/DOWN arrow keys, select the units of measurement. Press ENTER. 5. Press F3 to exit and return to the main window. 6. Ensure the test orifice is closed. 7. Set the flowbench and FlowCom range to #1 and set for the desired direction. Be certain to set the flow control knobs on applicable flowbenches to one closed (CW) and one open (CCW).
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Performing a Flow Test 8. Turn on the motor power switch and allow the flowbench to stabilize.
Flowbenches without a motor controller:
Slowly close (CW) the flow control knob until the desired test pressure is reached.
Flowbenches with a motor controller:
The green push-button switch on the FlowCom panel turns the motors on. FlowCom automatically adjusts the motor power output for the test pressure. 9. Record the flow reading. Turn off the motors. 10. Repeat steps 1 through 5 and enter the leakage value as recorded in step 9.
4.3 Flow Test Procedure

Open the valve in the test head to the first lift. Set the FlowCom and flowbench to the highest flow range and turn on the motors. The flowbench is designed with multiple ranges so the flow may be measured accurately. For greatest accuracy, use only the flow orifice ranges which give readings above 70% of the flow scale at full lift. If the reading is not high enough, switch to the next lower range. Once the proper range is determined for this test pressure and valve lift, record the flow reading. Re-adjust the valve lift to the next point and record the reading. Set the valve to each additional valve lift and repeat the above steps. Continue this procedure until you reach the maximum valve lift test point. NOTE: Always try to maintain a flow reading of greater than 50% full scale of the range used. If the range is too low or too high, FlowCom displays an out of range indication (^). Change the range and adjust the test pressure as necessary. To test the exhaust port, change the flowbench flow direction to exhaust, and change the FlowCom range to the proper exhaust range. Move the valve opener and dial indicator to the exhaust valve and repeat the above procedures. This completes the test. For intake manifold and carburetor tests, remove the radiused inlet air guide, and replace it with the intake manifold and carburetor. Repeat the intake tests and compare the results to determine the effect of the intake system.
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5 FlowCom Computer Connections

The SuperFlow FlowCom can be used as a stand-alone unit with the test pressure and flow measurements displayed on the front panel. However, application software can optimize system capabilities. The FlowCom can automatically send all data through its serial port to a computer (PC) with flowbench software. The computer can be connected with either an RS232 serial cable or a USB cable to communicate with WinDyn, PortFlow Analyzer, or other flowbench software. NOTE: USB is only applicable with the new style FlowCom. Your computer determines which type of cable will work best. Either cable requires configuring the computer for it. The RS232 cable is the easiest to configure. However, many new computers no longer have this connection as a standard option, so the USB may be the only option, which works well once the computer is configured for it.
5.1 Configuring FlowCom to Communicate

1. On the FlowCom panel, press the green button ( operation screen to appear. ) to turn on the power. Wait for the main
Figure 1-9. Main Screen 2. Press (conf) to access the configuration menu.
Figure 1-10. Configuration Menu 3. Press the DOWN ARROW button ( 4. Press the ENTER button ( ). ). ) to scroll to USB/Serial.
5. Type 3512 for the password. Press ENTER (
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FlowCom Computer Connections 6. The Select host connection screen appears. The current mode is indicated by a box around the connection typeUSB or Serial.
Figure 1-11. USB/Serial Selection 7. Press the LEFT or RIGHT ARROW button ( 8. Press ENTER ( 9. Press ). ) to select the desired connection type.
to exit and return to the main operating screen.
5.2 RS232 Serial Connection

An RS232 serial cable can be used with a direct serial port on the computer. In this procedure, a DB9 nine-pin connector is used on the computer configured as a serial port.
Ensure that the FlowCom is configured for serial communication as per Configuring FlowCom to Communicate on page 12.
SF-110, SF-120, SF-300, SF-600 and SF-1200

You will need a standard CAT-5 cable and an RJ45/DB9.
To order an adapter from SuperFlow, contact Customer Service and ask for part number 1200A-1012. Connect the CAT-5 cable with the adapter between the nine-pin serial port connection on the computer and the serial port on the FlowCom.
SF-1020
Locate the 1200A-1085 serial cable in the opening at the right-rear corner on the top of the flowbench cabinet. It may be under the small plastic cover. If you do not find a serial cable, you must order one from SuperFlow and install it in the flowbench. The cable has a nine-pin RS232 connector that will connect to the serial port on the computer and a 6-pin Molex connector that goes to the FlowCom circuit board. NOTE: Consult a computer expert if your computer does not have a nine-pin serial connection and you want one installed.
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5.3 Universal Serial Bus Connection

The FlowCom can communicate with a computer using a standard USB cable.
SF-110, SF-120, SF-300, SF-600 and SF-1200

You can use a standard printer-type USB cable available at most computer accessory supply stores.
SF-1020
The -SF1020 requires a USB cable with a right-angle square connector to clear the cabinet opening under the panel. Locate the cable in the opening at the right-rear corner on the top of the flowbench cabinet. It may be under the small plastic cover. If you do not find a serial cable, you must order one from SuperFlow and install it in the flowbench. The USB communication requires special USB/serial driver software to be installed on the computer and configured for the correct COM port to communicate with the FlowCom. CAUTION: This configuration should only be attempted by computer experts. SuperFlow does not guarantee that this is easy or that it works for all computers.
Ensure that the FlowCom is configured for USB communication as per Configuring FlowCom to Communicate on page 12.
Do not connect the cable to the computer at this time. WARNING: The USB driver must be installed on the computer before connecting the FlowCom. If the FlowCom is connected and turned on without the driver installed, Windows will detect the new hardware and unsuccessfully attempt to install a driver. To rectify this situation, the driver installed by Windows must be uninstalled and the correct driver installed per the following procedure.
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FlowCom Computer Connections
Installing the USB Driver

The driver software is provided with the FlowCom. The CD is usually placed inside the operator manual but may instead be in an accessories box. Contact SuperFlow Customer Service if you cannot locate the CD.
1. Insert the driver CD into the computer disc drive. NOTE: If the program does not automatically start, click Start and select Run. Type X:\Setup.exe (where X is the drive letter for your CD drive). Or select Start>>Run and then browse for the Setup.exe file. Double-click it to start the program. 2. When the VCP InstallShield Wizard appears, follow the subsequent instructions. 3. When the License Agreement appears, select I accept the terms of the license agreement.
4. Click Next. In Windows XP, a logo test checks for compatibility and a Software Installation dialog box appears stating the software did not pass the test. This only means the software was not submitted to Microsoft for their approval. The software will not cause any problems with your computer.
5. Click Continue Anyway. You may have to do this twice.

SuperFlow Technologies Group 15
6. The InstallShield Wizard Complete window appears stating the installation was successful.
7. Click Finish to close the program.
Configuring the USB Communication

1. Connect the USB cable to the FlowCom and to an available port on the computer. 2. Power on the FlowCom. When Windows detects the hardware, the Found New Hardware Wizard appears.
3. Do not allow the wizard to connect to the Internet. Select No, not this time and click Next.
16
FlowCom Computer Connections 4. The wizard requests an installation CD, but this is not necessary to complete the installation.
5. Select Install the software automatically (Recommended). Click Next. 6. If Windows performs a logo test to check compatibility and a Hardware Installation dialog box appears stating the software did not pass the test, this only means the software was not submitted to Microsoft for their approval. The software will not cause any problems with your computer.
7. Click Continue Anyway.
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8. The Completing the Found New Hardware Wizard window appears.
9. The installation for the first device is complete. Click Finish. 10. The Found New Hardware Wizard will open again to install a second device. Repeat steps 3 through 9.
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Software Programs
6 Software Programs
6.1 Installation and Operation
Refer to the installation and operation instructions that accompanied the software package.
6.2 Communication
The software communication must be configured for the correct COM port that FlowCom is using. For standard serial communication, this is COM1 or COM2; the serial port on most computers is COM1. For USB communication, the USB/serial driver must be assigned to a COM port that the software recognizes.
WinDyn
Start WinDyn. The FlowLink program on the taskbar indicates whether FlowCom is communicating with WinDyn. If the message on the FlowLink bar reads COMM OK, nothing else must be done. If the FlowCom is flashing NO COMM! then you must set the COM ports. 1. Click the FlowLink program to open the Communications window.
2. From the main menu, select Configure... The FlowLink Configuration dialog box appears.
19
3. Click the desired communication port (COMM1 or COMM2). If you are not certain which setting to use, refer to Checking the COM Port Assignment on page 22 to determine which COM port the FlowCom is connected to. 4. Click OK. 5. Minimize (do not close) the FlowLink window; or close the window and restart WinDyn.
PortFlow Analyzer
PortFlow Analyzer (PFA) version 3.0 or higher can use any COM port between 1 to 8. It can automatically detect the FlowCom and set the COM port accordingly. This is the default preference setting after installation. To check or change the preference setting: 1. From the PortFlow Analyzer main menu, select Preferences to open the dialog box. 2. Click the General Operation tab.
Figure 1-12. PortFlow Analyzer Preference Settings 3. In the Automatically Find Com Ports drop-down list (at the bottom), select Yes or No. Yes: The COM port will be automatically detected and set. No: The port setting can be manually set. 4. Click the OK button at the top right to keep this setting.
20
Software Programs 5. From the PortFlow Analyzer main menu, select Flow Bench. The Flow Bench Specs dialog box appears.
6. In the Com Port text box (lower left), you can now set which Com Port to use. If the FlowCom is communicating with PFA, the Load In from FlowCom Now button (in the upper right area) is active. 7. When PFA and FlowCom are communicating, the two can be used together.
Refer to the PFA operations manual for further instructions.
21
6.3 Checking the COM Port Assignment

Windows will assign a COM port to the RS232 serial communications (if one is installed) or to the USB/serial driver when installed. If the flow software is not configured for that COM port, FlowCom cannot communicate properly with the computer. To verify and assign the COM port: 1. Ensure the FlowCom is connected to the computer and is set for the desired connection (see Configuring FlowCom to Communicate on page 12). 2. Press the green button ( ) to turn on the FlowCom power.
3. Open the Windows Device Manager and determine which serial port the USB is using: Access the System Properties dialog box on the computer.
Windows XP provides several methods for opening the System Properties depending upon how the computers Start menu and desktop are configured. Refer to the Windows online Help for assistance if you do not know how to open this dialog box, or ask for assistance from someone who knows how to do this.
On the System Properties dialog box, click the System Hardware tab. Click the Device Manager button to open the dialog box. On the Device Manager dialog box, click the PLUS SIGN (+) next to Ports (COM & LPT). Note which COM port the FlowCom is connected to. the USB/serial port when a USB cable is used. the Communications (COM) port when a serial cable is used. If the COM port is compatible with the software, close all dialog boxes and use the software communication tools to set the COM port.
22 FlowCom Operator Guide
Software Programs
6.4 Changing the COM Port Assignment

CAUTION: SuperFlow is not responsible for any damage that may occur to your computer settings if this procedure is not followed correctly. 1. On the Device Manager dialog box, select USB Serial Port and double-click or press ENTER. The dialog box for the communication port appears.
2. Click the Port Settings tab, then click the Advanced button. 3. The COM Port Number displays in the dialog box at the bottom left. Click the drop-down arrow to change the COM port. 4. Click OK and close all dialog boxes. 5. Restart the computer for the changes to take effect. CAUTION: If no compatible COM ports are available, one must be made available. This may require changes to the BIOS settings on the computer and should only be attempted by a computer expert. An option would be to add a serial input/output (I/O) device to the computer and use the serial connection setting on the FlowCom.
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24
Index
A
Assigning COM ports, 1-22
F
Features FlowCom, 1-3 Flow test determining leakage, 1-10 performing with FlowCom, 1-10 procedure, 1-11 using FlowCom, 1-7 Flowbench manometer connecting to FlowCom, 1-6 operational check, 1-7 software, 1-3 test orifice plate, 1-7 ranges and pressure, 1-8 FlowCom communication, 1-12 connecting to flowbench manometer, 1-6 defined, 1-3 entering leakage, 1-10 flow data correction, 1-3 testing, 1-7 flow test procedure, 1-11 keypad functions, 1-5 panel description, 1-4 performing flow test, 1-10 power requirements, 1-3 RS232 serial connection, 1-13 specifications, 1-3 test pressure regulation, 1-3 USB connection, 1-14 velocity probes and swirl meters, 1-3
C
Cables RS232, 1-13 Changing COM port assignment, 1-23 Checking flowbench operation and accuracy, 1-7 COM ports changing assignment, 1-23 checking assignment, 1-22 communicating, 1-19 Communication configuring FlowCom, 1-12 USB, 1-16 RS232 serial connection, 1-13 software, 1-19 USB connection, 1-14 Configuring FlowCom to communicate, 1-12 USB communication, 1-16 Connections FlowCom, 1-4 RS232 serial, 1-13 Correcting flow data, 1-3
D
Description FlowCom panel, 1-4 Determining leakage, 1-10 Drivers USB, 1-15
I
Installing software programs, 1-19 USB driver, 1-15
E
Entering leakage into FlowCom, 1-10
K
Keypad functions FlowCom, 1-5
L
Leakage determining, 1-10 entering into FlowCom, 1-10
U
USB configuring communication, 1-16 connection, 1-14 USB driver installing, 1-15
O
Operating software programs, 1-19
V
Velocity probes connecting to FlowCom, 1-3
P
Panel description FlowCom, 1-4 Performing flow test, 1-10 PortFlow Analyzer configuring COM ports, 1-20 software, 1-3 Ports COM assignment, 1-22 Power requirements FlowCom, 1-3 Programs software, 1-19
W
WinDyn configuring COM ports, 1-19
R
Regulating test pressure, 1-3 Requirements FlowCom, 1-3
S
Serial connection RS232 cable, 1-13 Software COM ports, 1-19 flowbench, 1-3 PortFlow Analyzer COM ports, 1-20 WinDyn COM ports, 1-19 Software programs installing and operating, 1-19 Specifications FlowCom, 1-3 Swirl meters connecting, 1-3
T
Test orifice plate flowbench, 1-7 Testing flow, 1-11
Index I-2
SF-300/600FC Flowbench Operators Manual

Page # SF-300/600 Flowbench Check-Out Instructions 1.0 Flow-Testing 1.1 1.2 1.3 SuperFlow SF 300/600 Description What Is A Flow Test? Adapting Heads for Testing 1.31 Installation of SF-300/600 Retrofit Kit 1.32 The Flow Computer Flow Test Preliminaries Performing a Flow Test Sample Test Data Sheets Analyzing the Test Data Avoiding Test Errors 1 3 3 4 4 5 7 8 9 11 15 15 16 18 24 27 27 28 33 34 35 37 39 41 42 44
1.4 1.5 1.6 1.7 1.8 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0
Air Flow Through Engines Power, Speed & Flow Relationships Intake Port Area and Shape The Valve Seat Valve Sizes Valve Lift & Flow Combustion Chamber Dynamic Flow Effects Inertia-Supercharge Effect Flowbench Test Pressure Adapting the SuperFlow Flowbench to Two-Stroke Engines Trouble Shooting Your SF300/600 Flowbench Suggested Additional References Unit Conversion, Schematics, Data Forms and Graphs

Appendix: The Flow Computer Advanced Mode Advanced Calibration Default Values Appendix: page 1 Appendix: page 2 Appendix: page 4

Check-Out Instructions for the SF-300/600 Flowbench
240VAC
120VAC
120VAC
1.
Power Requirements.
The power requirement for the SF-300 Flowbench is Single Phase, 240 VAC, 28 amps. The power requirement for the SF-600 Flowbench is 37 amps. In order to plug in your SF300/600 Flowbench, a 50 amp, 240 volt AC, 60 Hz receptacle is required. Do not assume your receptacle is correctly wired. Use a voltmeter to be certain there is no more than 120 volts between the center prong of the receptacle and each outside prong, and 220 to 240 volts across the outside two plug prongs only. This is standard, single phase wiring. If you plug the SF-300/600 into an improperly wired receptacle, the motors will burn out! If the receptacle checks out properly, turn the motor off-on switch to OFF and plug in the SuperFlow SF-300/600 Flowbench. A flowbench electrical schematic is included in the rear of the manual. 2.
Machine Placement.
After you remove the SuperFlow SF-300/600 from its crate, place it in its final location. Shim between the base and floor until the main base plate is level. Install the fluorescent tubes into the light fixture, and turn the Light Off-On switch to on. 3.
Instrument Connections and Set-up
To keep the fluid inside the test pressure meter and the flow meter during shipping, the clear plastic tubes were disconnected and the valves closed. Read the instructions on the small red and white tag attached to the meters. Open the plastic fluid valves on both meters (four valves on SF-300, six valves on SF-600.). Check the valves to make sure they are open by blowing gently into each valve, using the extra length of plastic tubing provided. If the fluid column moves and returns freely, the valve is open. Connect the flexible plastic tubes onto the meter inlets. A bubble level is built into the flow meter. Level the flow meter by turning the knob near the right end of this meter Counter-clockwise to loosen it. Raise or lower the right side of the flow meter until the level bubble is centered between the two marks, then retighten the screw. To zero the flow-percent scale, loosen the thumbscrews at the bottom of the flow meter and slide the scale to zero. Zero the scale on the vertical test pressure meter by rotating the scale adjuster near the bottom.
-1-

Note: The extra gage oil provided is usually not required unless the meters have leaked. Note: The extra gage oil provided is usually not required unless the meters have leaked. 4.
Operation Check for SF-300/600FC flowbenches with FlowCom attached.
If you purchased a cylinder head adapter, it is mounted to the flowbench base plate on top of a flat test orifice plate. Remove the adapter and mount only the six-inch square test orifice plate to the flowbench. Leave both the 1.875 (47.6 mm) and 0.312 (7.92 mm) holes in the test orifice open. Install the four 1/4-20 bolts and flat washers in the test orifice plate. Lift the flow range locking knob and set the flow range to #5 for the SF-300 or #4 for the SF-600. Set the flow direction levers to Intake and Intake above 150 cfm (71 l/s). Close the Exhaust flow control knob lightly against its seat. Fully open the Intake flow control knob. Turn on the SF-300/600 flowbench motor switch and the FlowCom power switch. Use the Cycle and Arrow keys to set the test pressure to 25.0 (63.5 cm) of water, followed by the Enter key. Use the Cycle and Arrow keys to set the computer flow range to #5 for SF-300 or #4 for SF-600, followed by the Enter key. Turn on the FlowCom motor control switch and record the reading on the upper flow meter Percent of flow scale. It should be approximately 80% on the scale. Record the cfm reading from FlowCom. Turn off the FlowComs motor control switch. Switch flow direction levers to Exhaust and Exhaust above 150 cfm. Close the Intake flow control knob lightly against its seat. Fully open the Exhaust flow control knob. Use the Cycle and Arrow keys to set the computer flow range to Exhaust , followed by the Enter key. Turn on the FlowCom motor control switch and record the reading on the Percent of flow scale. It should read approximately 77%. Record the cfm reading from the FlowCom unit. Turn off the FlowCom motor control switch. Multiply the Percent of flowscale readings by the data from the calibration card on the flowbench. Check to make sure the FlowCom readings match these numbers. This completes the check-out test. If the SF-300/600 meets the above figures with +3%, it is ready for flow tests. Remove the test orifice plate and install the cylinder head adapter. If the SF-300/600 fails to meet the above standards, the unit may have been damaged in shipment. Please call SuperFlow at 719-471-1746 and ask for Flowbench Customer Service, or fax SuperFlow at 719-471-1490. Notice: The output of the SuperFlow SF-300/600 flowbench is proportional to the line voltage at your location. At voltages below 240 VAC, the SuperFlow flowbench capacity will be less than normal. This does not have any effect on the accuracy.
-2-

1.0 1.1 Flow-Testing SuperFlow SF-300/600 Description
The SuperFlow SF-300/600 Flowbench is designed to measure the air-flow resistance of engine cylinder heads, intake manifolds, velocity stacks, and restrictor plates. For intake testing, air is drawn in through the cylinder head into the SF-300/600 flowbench, through the air measuring orifice, through the blower, and exits through the rear of the SF-300/600 flowbench. For exhaust testing, the path of the air-flow is reversed by a switch on the front control panel.
Test pressure Meter Dial Indicator and bolt to open the valve Flow Control Knob Test Head Cylinder Adapter Flow Meter Orifice Plate Air Pump
Flowbench Cross-section
The test pressure meter (manometer) measures the pressure or vacuum at the base of the test cylinder. The test pressure is adjusted to a standard value, for instance 25.0(60 cm) of water, by turning the flow control knob on the lower front panel. Separate knobs control either the intake or exhaust flow. The amount of flow is read from the inclined flow meter (manometer). The flow meter reads percent flow for the six flow range orifices in the SuperFlow SF-300/600 flowbench.
NOTE:
The SuperFlow SF-300/600 is equipped with an automatic temperature protector, set for 190oF (88oC), which will shut off the machine if it becomes too warm. When this occurs, wait a few moments. The switch will reset itself automatically after a few minutes. The SuperFlow SF-300/600 flowbench can then be cooled by running it 60 seconds with the right flow direction mode selector set half-way between INTAKE and EXHAUST.
-3-

1.2 What Is A Flow Test?
In its simplest form, flow testing consists of blowing or sucking air through a cylinder head at a constant pressure. Then the flow rate is measured at various valve lifts. A change can be made and then the head can be re-tested. Greater air flow indicates a flow improvement. If the tests are made under the same conditions, no corrections for atmospheric conditions or machine variations are required. The results may be compared directly. At the other extreme, it is possible to adjust and correct for all variations so test results may be compared to those of any other head, tested under any conditions on any other SuperFlow SF300/600 flowbench. Further calculations can be made to determine valve efficiency and various recommended port lengths and cam timing. The calculations are very cumbersome without a small electronic calculator, preferably with a square root key. The calculations are not essential to simple flow testing. 1.3 Adapting Heads for Testing
Cylinder heads are mounted onto the SuperFlow SF-300/600 Flowbench by a cylinder adapter. The adapter consists of a tube 4 (100 cm) long with the same bore as the engine and a flange on each end. The lower flange is bolted to the flow tester and the upper flange is bolted or clamped to the test cylinder head. The flanges must be flat or gasketed to make an airtight seal. The adapter tube may be 0.06 (1.5 mm) larger or smaller than the actual engine cylinder. In some cases, it is convenient to make the upper flange of the adapter about 20% wider than the test cylinder head so the head will be supported when it is offset for testing the end cylinders. A device must be attached to the cylinder head to open the valves to the various test positions. The usual method is to attach a threaded mount to a rocker arm stud so the end of a bolt contacts the end of the valve stem. As the bolt is rotated, it pushes open the valve. A 0 to 1 x 0.001 (20 mm x 0.1) dial indicator may be mounted to the same fixture with its tip contacting the valve spring retainer to measure the amount of valve opening. The standard valve springs should be replaced with light springs for testing. See the photos in the SuperFlow Flowbench brochure for various types of valve openers. On the intake side of the cylinder head, it is strongly recommended a radiused inlet entrance guide be installed to lead the air straight into the head. The guide should be about one port width in thickness and be generously radiused on the inside all the way to the head. The intake manifold can also be used. The exhaust flow may exit directly from the head.
-4-

1.31 Installation of SF-300/600 FlowCom Retrofit Kit
Front
Drill 1.5" (38 mm) dia. access hole through panel behind flow meter Flowscale %
Super Flo w
Back (with panel removed)

12", (30.5 cm) 12", (30.5 cm) Add four new Tees to the existing pressure lines and connect to the Flowcom inputs. Control cable connected to Jack Ground Tab New Ground Wire Green To Fuse Flow Control Module To P2+
To P2-
To P1To P1+
Flow Meter
SUP ERFL O C O PO RATI O , CO LO AD O SPR N G CO M ADE I N USA . W R N R I S, .
To J1
FlowCom flowbench computer
To J2
To Swirl Meter To T1
Velocity Probe
Super Flo w
Black
To Motors
Fuse
P1: Flow Pressure. P1+, P1P2: Test Pressure, P2+, P2P3: Velocity Pressure, P3+, P3T1: Lower Temperature T2: Upper Temperature (not used on SF-300/600) S1: Remote Record Switch J1: Swirl Meter J2: Motor Controller J3: Computer Serial port P: Power (If no motor controller) : Display
1. 2. 3. 4. 5.
Turn off power to flowbench and remove the power cord from its outlet. CAUTION: Lethal voltages are present if power cord is not removed. Cover any openings on the baseplate of the flowbench to prevent entry of debris. Carefully disconnect the plastic tubes from the inclined manometer and close the ports. Remove the inclined manometer from the front of the flowbench (four screws). Store the manometer in a safe place temporarily. Mark the location of the 1.5" (38 mm) diameter hole as indicated on the illustration. CAUTION: Drill only 1/4" deep from the front side of the flowbench. Any deeper will cause a wood blowout on the far side of the panel.
6. Using the 1.5" (38 mm) diameter spade drill supplied, carefully drill a hole 1/4" (6 mm) deep in the location indicated.
-5-
White
Temperature Probe
k ac Bl e hit W

7. Turn the flowbench around so you are facing the rear. Remove the Phillips-head screws holding the back to the flowbench. Remove the back. Locate the spot where the tip of the 1.5" (38 mm) drill has penetrated the panel of the flowbench. Using the 1.5" (38 mm) drill from the backside, finish boring the hole that was started from the front. Drill four each 0.094 (3/32)" (2.5 mm) diameter x 3/8" (9 mm) deep holes for mounting the Motor Control Module as indicated by the illustration. CAUTION: The wood panel is 1/2"(12 mm) thick. Do not drill through the panel! you push them through the panel to ensure proper connection to the FlowCom unit. 19. Install the 1.5" (38 mm) plastic grommet into the hole drilled in Steps #6#8. 20. Attach the control cable (9-pin connector) (1200a-13) to the jack in the top of the Flowbench Control Module. Pass the free end of this cable through the 1.5" (38 mm) hole. Tighten the jackscrews. 21. Attach 1/8" (3 mm) I.D. plastic tubes to each of the tees installed in Step #18. Pass the free ends of these tubes through the 1.5" (38 mm) hole. 22. Refit the plywood back to the flowbench. 23. Carefully refit and level the inclined manometer to the front of the flowbench, making sure not to kink or pinch the plastic tubes or electric cable. Route the plastic tubes and electric cable out the lower left corner of the inclined manometer mounting plate next to the vertical manometer. 24. The FlowCom unit has Velcro strips attached to the back panel. Remove the protective covering from the Velcro and press the whole unit into place in the lower left hand corner of the inclined manometer mounting plate as shown in the illustrations.
8.
9.
10. Vacuum or blow out any wood chips or debris from the rear of the flowbench. 11. Attach the Flowbench Control Module to the rear of the flowbench using four each #6 x 1/2" (12 mm) long screws supplied. The white and black terminals should be on the bottom. 12. Remove the white and black #10 ga. wires from the right side of the large fuse block located on the dividing shelf in the rear of the flowbench. 13. Carefully disengage these two wires from their cable bundle by carefully cutting the appropriate bundles tie wraps. Do not damage or nick any wires during this process. 14. Attach these two wires to the motor terminals on the lower right on the Flowbench Control Module. White to white, black to black. 15. A white and a black #10 ga. wire are already attached to the left lower terminals of the Flowbench Control Module. Route these two wires to the fuse block terminals previously disconnected. Attach the wires to the fuse block. White to white, black to black. 16. A "U" shaped 1/4" (6 mm) terminal lug is included in the retrofit kit. Locate the lower flowbench power switch mounting screw. Attached to the back of the flowbench and to this screw are a number of green grounding wires. Remove the screw and add the "U" shaped terminal to the one that is already there. Reinstall the screw and nut. 17. Locate the green wire attached to the center bottom of the Flowbench Control Module. Route this wire along the path of the bundled wires in back of the flowbench and attach its spade terminal end to the "U" shaped terminal installed in step #16. 18. Insert the supplied plastic tees into the tubes as shown in the accompanying illustrations. Label tubes before
P1+
P2+
P3+
P1P2P3-
25. Attach the hoses and electric control cable to the FlowCom unit as shown in the illustrations. 26. Attach the temperature probe to the jack in the center of the front of the SF-600 just below the baseplate. Use the included adhesive-backed plastic wire locators to route the temperature probes wire along the front of the SF-600 to the left, around the corner, across the left side and up to the FlowCom unit. Attach the wire to the T1 jack. 27. Attach the flowbench power cord to its outlet and turn the power back on.
-6-

1.32 The Flow Computer
SuperFlow
FlowCom
00.00 In.H20 00.00 cfm 00.0 % Vel.
1 0
P1
P2
P3
+ -
J1
T1
T2
J2
J3
SUPERFLOW CORPORATION, COLORADO SPRINGS, CO. MADE IN USA.
Simple Mode For The Flow Computer

The SuperFlow flow computer is very easy to use for normal flow testing. When you first turn on the Power switch, the computer display will show: SuperFlow Corporation, FlowCom, SF-600 (or 300). This message will be quickly followed by the words, Simple Mode, and then Data screen #1 for normal test readouts as shown above. Notice the blinking cursor under the In H20 label. This is the test pressure reading in inches of water. The middle reading is the corrected test flow in cfm. The reading on the right is the % of maximum velocity when the velocity probe is used. Most testing requires only this screen. With the cursor positioned under any of the three displayed measurements, push the Enter key. A new menu will appear showing the units of measurement. Use the Up/Down keys to select other units. Push Enter when you have made a selection and you will return to the first screen. To freeze the readings during a test, push the Up key. Solid bars will appear between the readings. The reading will be freeze until the Down key is pushed. Push the Cycle key to change to Data display #2 , and then to the Data entry
15.00 In.H2O
00.00 89.30 leakage
screen. Use this screen to enter the test pressure, leakage, and Flow Range at the beginning of a test. Push the Enter key when the cursor is under each function, followed by the arrow Up/Down keys to change each value. Push Enter when you are done, and then the Cycle key to return to screen #1 for the tests. Your entries will NOT be saved if the unit is turned off. To Save these entries permanently, push Left and Right key at the same time. The Flow computer will prompt you, Save Config Info? Position the cursor under the Yes and push Enter.
-7-

1.4 Flow Test Preliminaries
All test data may be recorded on the SuperFlow FC Test Data Sheets forms (see reproducible samples in back of the manual). Before beginning a test, record the head description, and measure the valve stem and valve diameters. The net valve area is the valve area minus the stem area.
net valve area = 0.785 (valve Diameter2 - stem Diameter2)
Cycle Arrow
Enter Arrow
Left Arrow Right Arrow Up Arrow
Down Arrow
Before installing the cylinder adapter, install only the standard test orifice plate onto the top of the SuperFlow SF-300/600 flowbench. Lift the flow range locking knob and rotate the flow range selector to #1. Close the exhaust flow control knob lightly against its seat. Fully open the intake flow control knob. With only the small diameter test orifice open, turn on the flowbench motor and turn on the Power Switch on the FlowCom unit Use the Cycle and Arrow keys to set the test pressure to 25.0, (63.5 cm), of water, followed by the Enter key. Use the Cycle and Arrow keys to set the computer flow range to 1 Intake, followed by the Enter key. (Set the flowbench range to #1.) Turn on the motor power switch and the flow meter should now read approximately 7.0 cfm (3.31 lps) on the #1 range. If flow is within 1.0 cfm (0.50 lps) of this reading, the flowbench is working properly. Remove the test orifice plate. All engine valve tests should be performed at the same ratio of valve lift to valve diameter, or L/D ratio. Then the flow efficiencies of any valves can be compared, regardless of size. Multiply the valve diameter by each of the seven L/D ratios, (0.05, 0.10, 0.15, 0.20, 0.25, 0.30, 0.35), to obtain the valve lift test points. Fill these in on the data sheet. See Samples on the following page. Many additional data sheets and graph forms are in Section 15.0 of this manual. Make multiple copies of the appropriate forms for your tests. This completes all the preliminary test preparations. While this preparation is very time consuming, it will insure the test results are valid and repeatable. Most of the preliminaries will not be required for subsequent tests of the same head.
-8-
1.5
Performing a Flow Test
Remove the test orifice plate from the flowbench and install the test head, cylinder adapter, and valve opener onto the flow bench for the actual flow tests. Set the dial indicator to read zero with the valve closed. Install either the intake manifold or an air inlet guide on the intake port. Turn on the flowbench motor and observe if the test pressure reads the test pressure you intend to use. We will assume the test pressure is 25.0, (63.5 cm), for this example. Determine the leakage flow with the valves closed. On the flowbench range #1, leakage will usually be from 1.0 to 10.0 cfm (0.50 to 5.0 l/s). If there is no leakage, the flow meter may read zero. The leakage will not affect the test as long as you enter the leakage on screen 3. Turn off the flowbench. Enter the leakage on Screen 3 from the flowbench computer panel. Open the valve in the test head to a lift of 0.30 x valve diameter, (l/d = 0. 30). Set the flowbench flow orifices to the highest flow range and turn on the SuperFlow flowbench. The flow bench is designed with multiple ranges so the flow may be measured very accurately. For greatest accuracy, use only the flow orifice ranges which give readings above 70% of the flow scale at full lift. If the reading is not high enough, switch to the next lower range. Now you have determined the proper range for this test pressure, valve, and valve lift. Always use the same combination for future tests at this point. Record the corresponding flow range on Line 4. Readjust the valve lift to the first point and record the reading of the flow onto the test data sheet. Set the valve to each additional valve lift and repeat the above steps. Continue this procedure until you have reached the maximum valve lift test point. To test the exhaust port, change the flowbench flow direction to exhaust, and change the flow computer range to the proper exhaust range. Move the valve opener and dial indicator to the exhaust valve and repeat the above procedures. This completes the test. For intake manifold and carburetor tests, remove the radiused inlet air guide and replace it with the intake manifold and carburetor. Repeat the intake tests and compare the results to determine the effect of the intake system (counter-clockwise) before turning the machine back on. The thermal overload switch shuts off the SF-300/600 at 190oF (88oC) and will reset automatically.
To test the exhaust port, turn the flow direction levers to exhaust and close the intake flow control valve. Move the valve opener and dial indicator to the exhaust valve and repeat the above procedures. This completes the test. For intake manifold tests, remove the radiused inlet air guide and replace it with the intake manifold. Repeat the intake tests and compare the results to determine the effect of the intake manifold.
-9-

Important Note: The SF-300/600 flow ranges are based on a test pressure of 25(63.5cm) of water. If other test pressures are used, the flow scale calibration ranges should be corrected by the following amounts. Test Pressure Correction Factors
Test Pressure Intake Flow Exhaust Flow
48 (120cm) 36 (91.4 cm) 28 (71.1 cm) 25 (63.5 cm) 20 (50.8 cm) 15 (38.1 cm) 10 (25.4 cm) 5 (12.7 cm)
0.978 0.989 0.997 1.000 1.005 1.010 1.014 1.019
1.019 1.009 1.003 1.000 0.996 0.992 0.988 0.984
Example:
The calibration for range #4 is 300cfm at 25 of water test pressure. You wish to test at 36 test pressure. The corrected flow scale range is . 300 x 0.989 = 296.7cfm. for intake and 300 x 100.9 = 302.7 for exhaust
- 10 -

1.7 Analyzing the Test Data
For simple analysis of the test results, it is only necessary to measure the Corrected Test Flow, Line 5. This flow can be compared to other tests of the same head with the same setup without further calculations. No atmospheric corrections are required. Atmospheric differences cancel out automatically. To obtain the valve efficiency, it is necessary to calculate the flow in cfm/square inch, (lps/sq.cm), of valve area, and then to compare that flow to the best yet achieved. Divide Line 5 by the effective valve area to obtain Line 6, Test Flow Then fill in Line 7, Potential Flow from the chart in Section 7 (Valve Flow Potential per Unit Area) at the test pressure for your test. Divide Line 6 by Line 7 and multiply by 100% to obtain the % potential flow, Line 8. The % potential flow can be used as an indicator of the remaining improvement possible. To determine the valve Cd (coefficient of discharge), divide line 6, Test Flow/ unit area, by the Maximum Potential Flow/ Unit Area for that test pressure from Section 11. For example, the Maximum Potential Flow/ Unit Area at 25 H20 is 138.0 cfm/sq.in. If test flow is measured as 71.7 cfm/sq.in., the Cd is: Cd = Test Flow (line 6) @ 25 H20 Cd = 71.7/138.0 = .520 Potential Flow @ 25 H20 The flow results can also be plotted on graphs. Copy the forms in Section 15.0 of this manual. Circles are used to indicate the intake test points. Triangles are used to indicate the exhaust test points. Many additional factors and relationships are discussed in Sections 2.0 through 10.0.
1.8
Avoiding Test Errors
Each test you can make involves considerable effort on your part. This effort can all be wasted if you allow undetected errors to creep into your test programs. Always check the following points to reduce the chances of mistakes. 1. 2. 3. 4. 5. 6. Always use the same orifice range at the same test point. Keep the leakage flow to a minimum by making a good seal on all surfaces, including the valves in the head. If light valve springs are used, make sure the exhaust valves are not sucked open by the vacuum of the intake tests. Always level and zero the meters before each test. Always use a flow inlet guide on the intake side of the head and always use the same guide and cylinder adapter. Try to conduct your tests when there are no frequent changes in line voltage. Voltage changes will not affect the accuracy of the SuperFlow flowbench, but they will cause it to surge and be unstable.
- 15 -

7. As nearly as possible, conduct all tests with the same equpiment, used in the same way, at the same temperature.
8. 2.0
When in doubt, repeat the tests. If you don't get the same results, start over. Air Flow Through Engines
The power of an engine is directly proportional to the amount of air drawn into the cylinder and retained until ignition occurs. By reducing the air flow resistance of the intake and exhaust tract, cylinder filling is improved and engine power is increased directly. The average air flow through each engine cylinder can be estimated as follows:
(1) (2) Average air flow (cfm) = 1.67 x HP per cylinder Average air flow (l/s) = 1.06 x kW per cylinder
The maximum intake air flow rate for a single cylinder will be about 2.5 times the average airflow for the cylinder because the intake occurs during only 40% of the total cycle. For example, if a Chevrolet V-8 engine produces 440 HP, the power per cylinder is 55 HP.
Average Air Flow Avg. Intake Rate Peak Intake Rate = = = 1.67 x HP 2.5 x 92 CFM 2.5 x 230 CFM = 92 CFM (43.4 l/s) = 230 CFM (108 l/s) = 575 CFM (271 l/s)
When an engine is operating, the pressure drop across the cylinder head ranges from 0 up to about 200 (500 cm) of water at the 575 cfm (271 l/s) flow rate. (This is equivalent to the test pressure reading on the SuperFlow Flowbench). The average pressure drop is about 25 of water, 2" of mercury, or 63 cm of water, at the 230 cfm (108 l/s) flow rate. When testing with the SuperFlow SF-300/600 Flowbench, it is not important whether a test pressure of 15, 25, or 70 is used, provided the same pressure is used for each subsequent test that will be compared to the original test. A head that measures 10% better at 15 will also measure 10% better at 25 or 28 or 200. The exception to this rule is at lower valve lifts or through small, long passes. Then the test pressure must be kept above a certain minimum to insure the flow remains turbulent and does not slow down and become laminar. The minimum recommended pressures are as follows:
- 16 -

Minimum Recommended Test Pressures at Low Valve Lift
Minimum Valve Lift Minimum Test Pressure
.050" (1.2 mm) .100" (2.5 mm) .200" (5.0 mm) .300" (7.5 mm)
15" 8" 5" 3"
(38 cm) water (20 cm) water (13 cm) water ( 8 cm) water
Conveniently, the bigger the opening, the lower the required minimum test pressure. Beginners in flow testing are frequently confused by carburetor flow ratings. In the United States, most carburetors are rated in flow capacity at a test pressure of 20.4 of water, (1.5 of mercury, 51.8 cm of water). An 850 cfm (400 l/s) carburetor is one that passes 850 cfm of air at a test pressure of 20.4 (51.8 cm) of water. However, if you observe a manifold vacuum gauge on a racing engine at full throttle, you will see that it only reads about 0.5 of mercury (6.8 of or 17 cm water). At a test pressure of 6.8 of water, the same carburetor would only pass 490 cfm (230 l/s) of air. This is why carburetor ratings appear to be all out of proportion to engine requirements. Large carburetors may be tested and compared on the SF-300/600 Flowbench, but only at a reduced test pressure. At a test pressure of 1" (2.54 cm) of water, the carburetor will flow 22% of its rated capacity at 1.5 of mercury. For example, at 1" (2.54 cm) test pressure, a 660 cfm carb will flow 0.22 x 660 = 145 cfm. The amount of power gained by improved air flow depends on the engine's volumetric efficiency (the percent the cylinder is full). An engine with 60% volumetric efficiency can be improved more than an engine with 90% volumetric efficiency.
- 17 -

Estimated Volumetric Efficiency For Gasoline Burning Engines (3) (4) Volumetric Efficiency = 5,600 x HP x 100% / (RPM x CID) Volumetric Efficiency = 123 X kW x 100% / (RPM x Liters)
CID is the cubic inch displacement of the engine. Be sure you use accurate power figures. If the volumetric efficiency on an un-supercharged engine exceeds 130%, the power or RPM figures are probably in error. For alcohol burning engines, the formula for estimating volumetric efficiency is:
Estimated Volumetric Efficiency For Alcohol Burning Engines (5) (6) Volumetric Efficiency = 4750 x HP x 100% / (RPM x CID) Volumetric Efficiency = 104 x kW x 100% / (RPM x Liters)
3.0
Flow, Power, and Speed Relationships
Power, RPM, displacement and engine air flow capacity are all related in a definite fashion. With the wide spread use of accurate engine dynamometers and flowbenches, it has become possible to measure the air flow potential of an engine, predict its maximum potential power, and the RPM at which the power will peak. The effect of porting and manifold changes can be anticipated in advance and proper camming changes made to take full advantage of the differences. The total air flow through a gasoline engine determines its maximum power. At peak power, a racing engine will use 1.67 cubic feet of air per minute (cfm) for each horsepower it develops. For example, a 100 horsepower engine will use 167 cfm. This is true for any four-cycle gasoline burning racing engine. Alcohol burning engines will use 1.47 cfm per horsepower developed.
Estimated Engine Airflow (7) (8) (9) 10) Gasoline, naturally aspirated Gasoline, naturally aspirated Alcohol, naturally aspirated Alcohol, naturally aspirated cfm = 1.67 x HP l/s = 1.06 x kW cfm = 1.47 x HP l/s = 0.93 x kW
To increase the engine power output, either the air flow capacity of the engine must be increased, or the air-fuel charge must be burned more effectively. Racers have tended to concentrate primarily on increasing the air-flow.
- 18 -

To put more air through an engine, the flow resistance of the carburetor, injector, intake manifold and cylinder head must be reduced. This need has led to hundreds of after-market carburetors, manifolds, and ported cylinder heads -- all designed to get more air through the engine. The flowbench is a measurement device designed to measure the airflow capacity of various engine components. Air is blown or sucked through the intake system at a standard pressure, and then the air flow capacity is measured. In this manner, different parts can be compared and the effect of changes can be quickly evaluated. These flow tests are conducted at a constant peak air velocity at the valve, usually between 100 and 400 feet per second (30 to 120 m/s). While the flowbench air velocity is not varying as it does in an operating engine, experiments have shown that flowbench tests actually simulate engine operation closely enough. This is why flowbenches have become a major development tool for engine manufacturers and racers alike. What is the relationship between the capacity on the flowbench and the power of the engine? Tests have shown that if the complete intake system air flow is measured at maximum valve lift at a test pressure of 25" (60 cm) of water, a well developed racing engine will produce the following power per cylinder:
Calculated Engine Power From Flowbench Test Flow (11) (12) HP = 0.27 x ( Corr. Test Flow cfm ) x ( 25 / Test Pressure inches ) kW = 0.44 x ( Corr. Test Flow l/s ) x ( 60 / Test Pressure cm )
0.5 0.5
To reach this level, the engine must also have the maximum compression, the right cam, and a tuned exhaust system. In short, it must be a well-tuned racing engine. With this formula, a head-porter can see that if he improves the maximum flow through the intake system by 1 cfm at 25 of water the engine will gain 0.27 horsepower per cylinder. (The formula is only for gasoline, 4-stroke engines without super-chargers). The intake system flow also determines the RPM at which the engine will develop peak power:
Calculated Engine Speed For Peak Power From Flowbench Test Flow (13) (14) RPM = 1265 x ( Corr. Test Flow cfm ) x ( 25 / Test Pressure inches ) / CID per cylinder RPM = 45,200 x ( Corr. Test Flow l/s ) x ( 60 / Test Pressure cm) / cc per cylinder
0.5 0.5
The engine displacement is per cylinder. For super-stock and engines which are not all-out racing engines, peak power will occur at 10% higher RPM than the above formula indicates.
- 19 -

If you have a "220 horsepower" small block 292 Chevy which runs in super-stock, determine what the maximum power will be, and at what RPM. Tests show that at a test pressure of 25" 60 cm) of water, this intake system will flow 166 cfm (75.8 l/s) of air. The CID per cylinder is one-eighth of 292 or 36.5 CID (600 cc).
HP = 0.27 x 166 cfm x (25/25) = .27 x 166 x 1 = 44.8 HP kW = 0.44 x 75.8 l/s x (60/60) = 0.44 x 75.8 x 1 = 33.3 kW
or for all 8 cylinders
0.5 0.5
HP = 8 x 44.8 = 358.4 HP kW = 8 x 33.3 = 266.4 kW
The RPM for maximum power will be (multiply by 1.1 for super-stock engines): RPM = 1265 x 1.1 x 166 cfm x (25/25)0.5 / 36.5 in3= 6290 RPM RPM = 45,200 x 1.1 x 75.8 l/s x (60/60)0.5 / 600cc = 6280 RPM The engine has a maximum potential of 359 horsepower (266 kW) at 6290 RPM. Remember, this is the maximum potential power. The engine will only approach this if everything else is optimized. For a small block Chevy 302 with a displacement of 37.75 CID per cylinder, the table below shows how changes in the intake system will effect the engine's performance.
Head Intake System Flow @ 25 or (60cm)
190 cfm (89.7 l/s) 226 cfm (106.7 l/s) 253 cfm (119.4 l/s) 288 cfm (135.9 l/s)
Power Produced
Stock, 2.02" valve Normal ported, 2.02" valve Best ported, 2.02" valve Westlake, 2 x 1.5" valve
413 HP(308kW) @ 6360 RPM 492 HP(367kW) @ 7570 RPM 550 HP(410kW) @ 8470 RPM 602 HP(449 kW) @ 9270 RPM
The normal ported head is about the best that can normally be achieved, even with careful flowbench testing. However, it is possible to improve the head up to the best ported level, though welding might be required. For the last two heads, the engine must be wound up to 8500 and 9300 rpm to take full advantage of the additional flow. This brings us to the need for another guideline. If the engine must hold together for more than a couple runs down the drag strip, the peak power should not be developed at an average piston speed in excess of 3700 feet per minute (18.8 m/s). If a few runs down the strip are all you want, this limit may be raised to 4600 feet per minute (23.4 m/s), but the engine will need superior internal parts to last even one run.
- 20 -

These rules can be reduced to a simple formula for the RPM for peak power (remember, your shift points may be 10% or more above the speed for peak power):
Maximum Safe Engine Speeds (15) (16) (17) (18) Safe peak power RPM = 22,000/inch stroke Safe peak power RPM = 558,800/mm stroke Maximum peak power RPM = 27,600/inch stroke Maximum peak power RPM = 701,040/mm stroke
Returning now to the example of the 302 engine, a well ported head would be adequate for most road race applications for the 302 because the peak power is already being developed at slightly more than the 3,800 fpm (19.3 m/s) piston speed. If the power peak was pushed to an even higher RPM, the engine would frequently fail to finish the race. To take full advantage of the extra breathing of the Westlake 4-valve head, the power peak would have to be at 9,270 RPM (4630 fpm) and engine life would be short. Without super internal parts, it would probably not survive even one run down the drag strip the shift point would be up around 10,500 RPM. A lot for any Chevy! Now, if we pull all the formulas together, it is possible to construct a graph for determining the maximum intake system flow required for a particular engine and application. From this graph on the following pages, you can easily select the required flow for any engine and RPM. Remember that the flow, displacement, and power figures are for each cylinder, not the entire engine. To use the graph, determine the displacement per cylinder of your engine and then you can read the RPM required for any particular power and the flow capacity that will be required on the flowbench at a 25 (60 cm) test pressure. For example, suppose you have a 427 CID V-8 engine which will hold together at up to 7500 RPM. From the graph on the following page, look up 53.4 CID (1/8 of 427). The maximum power per cylinder would be 85 HP (63.4 kW), if you can improve your intake system to 310 cfm (146 l/s) on the flowbench at 25" (60 cm) of water test pressure. For all eight cylinders, the engine could produce 680 HP (507 kW) at 7500 RPM
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600
160
550
Engine Airflow Required At 25" H20 Test Pressure
150
140
500 130 Required Flow Bench Intake Flow (cfm at 25" H20) For Each Cylinder 450
120
400 10000 RPM 350 9000 RPM 300 8000 RPM 7000 RPM 250 6000 RPM 200
110
100 90
80
70
60 50
5000 RPM 4000 RPM
150
40 3000 RPM
100 2000 RPM
30
20 50 1000 RPM 10 0 CID/Cyl. 10 20 30 40 50 60 70 0
Engine Cylinder Displacement (cubic inches)
- 22 -
Horsepower / Cylinder

440
190
420 400 380 360 340 Required Flow Bench Intake Flow (lps at 60 cm H20) For Each Cylinder 320 300 280
13000RP M 120 11 100
E n g in e A irflo w R e q u ire d A t 6 0 c m H 2 0 T e s t P re s s u re
180
170
160
150 140 14000R P M
130
260
12000R P M
240
11000R P M
220 200 180

8000 R P M 10000 R P M 9000 R P M
90 80
160 140 120

5000 R P M 7000 R P M 6000 R P M
70 60
50 40 30
100
4000 R P M
80 60 40
1000 R P M 3000 R PM 2000 R PM
20
20 0 0 200 400 600 800 1000 E n g in e C y lin d e r D is p la c e m e n t (c c ) 1200
10 0
1400
- 23 -
Kilowatts / Cylinder

Of course, it is not enough to simply calculate the flow capacity required. The engine must achieve it. In section, 4.0, we will discuss how to improve the engine air flow, and how to judge the flow potential of any engine. 4.0 Intake Port Area and Shape
For maximum flow, the ideal intake system would have a single carburetor or injector per cylinder with a slide-plate throttle and a venturi equal to 0.85 times the intake valve diameter. Below the venturi, the carburetor bore should gradually open up to the size of the intake valve at the intake manifold entrance, and gradually taper down to about 0.85 times the intake valve diameter at a point about 1/2" (12 mm) above the valve seat. The optimum length for the port will be discussed in Section 9.0.
In practice, this ideal is never achieved, but it does provide a guide-line for what an efficient port would be like. When porting a cylinder head for maximum flow, keep the following points in mind. 1. Flow losses arise from changes in direction and decreases in velocity (bends and expansions in the port).
- 24 -

2. 3. 4. 5. Port area should be between 65% and 100% of valve area. Remove material primarily from the outside of port bends, not the inside. This will improve the air flow by increasing the radius of the bend. Port length and surface finish are not important to flow. The greatest flow loss in the intake port is due to the expansion of the air out of the valve. This makes the area from 1/2" (12 mm) below the valve to 1/2" above the valve the most critical part of the port. The valve seat shape has a substantial effect on the flow.
6.
If flow losses are caused by port expansions, not contractions, you may wonder why the port should be necked down above the valve seat. The reason is the air must both turn 90 degrees and expand as it flows out the valve into the engine cylinder. "Humping" the port inward just above the seat allows the air to make the turn outward toward the valve edge more gradually, reducing the total flow loss. Unfortunately, many stock ports are too large in this area already.
- 25 -

The chart below shows approximately where the flow losses occur in a stock Chevy head with a 1.94" (49.3 mm) diameter intake valve. Note that the flow losses are negligible in the straight part of the port where it is easy to grind.
Source of Flow Loss
% of Loss
1. 2. 3. 4. 5. 6. 7. 8.
Wall Friction Contraction at Push-Rod Bend at Valve Guide Expansion Behind Valve Guide Expansion, 25 Degrees Expansion, 30 Degrees Bend to Exit Valve Expansion Exiting Valve
4%* 2% 11% 4% 12% 19% 17% 31% 100%
*(for sand cast surface; 3% for polished surface)
As manufactured, this head flows about 83% of its potential for a wedge combustion chamber head. The best head porters are able to increase the flow to about 95% of its potential with the aid of careful flow testing. Further improvements are difficult without major surgery and welding. Grinding and enlarging the first 2.5 of the Chevy port, where it is easy to reach, has very little effect.
- 26 -

5.0 The Valve Seat
The valve seat has three purposes: 1) To seal the port 2) To cool the valve, and 3) To guide the air through the valve Sealing and cooling are promoted by a fairly wide seat between 0.060" (1.5 mm) and 0.100" (2.5 mm). Maximum flow is frequently achieved with a narrower seat, usually around 0.030" (.75 mm) wide. Multiple angle to fully radiused seats are essential for good air flow. A typical competition intake valve seat will consist of a 30 degree top cut 0.100" (2.5 mm) wide, a 45 degree seat .040" (1 mm) wide, and a 70 degree inside cut 0.180" (4.5 mm) wide. An exhaust valve will work well with a 15 degree top cut .060" (1.5 mm) wide, followed by a 45 degree seat 0.060" (1.5 mm) wide, and a 75 degree inside cut 0.100" 2.5 mm) wide. The O.D. of the valve should coincide with the outside of the 45 degree seat. Flowbench experimentation will frequently uncover a superior shape for any particular head. A three angle seat will out-flow a simple 45 degree seat by up to 25% at a lower valve lifts. 6.0 Valve Sizes
The total flow through the engine is ultimately determined by the valve diameters. While welldesigned smaller valves will out-perform larger valves on occasion, a good, big valve will always out-flow a good, smaller valve. Valve size is limited by the diameter of the engine bore. For wedge-shaped combustion chambers, the practical maximum intake valve diameter is 0.52 times the bore diameter. Hemiheads permit intake valves up to 0.57 times the bore diameter due to the extra space available in the combustion chamber. Four-valve heads are best, but the engine must operate at very high speed to take advantage of the extra valve area. The present trend in racing engines is to keep the exhaust system flow to 80% or 90% of the intake system flow. This may be more than is necessary. Tests indicate that there is generally no power improvement as long as the exhaust flow is greater than 60% of the intake flow. This would dictate an exhaust valve diameter 0.77 to 0.80 times as large as the intake valve.
- 27 -

7.0 Valve Lift & Flow
The air flow through the engine is directly controlled by the valve lift. The farther the valve opens, the greater the flow, at least up to a point. In order to discuss a wide variety of valve sizes, it is helpful to speak in terms of the ratio of valve lift to valve diameter, or L/D ratio. Stock engines usually have a peak lift of 1/4 of the valve diameter, or 0.25 d. Racing engines open the valves to 0.30 d, or even 0.35 d. The graph below shows how flow varies with lift for a well-designed valve and port. Up to 0.15 d, the flow is controlled mostly by the valve and seat area. At higher lifts the flow peaks over and finally is controlled by the maximum capacity of the port. Wedge-chamber intakes have lower flow at full lift due to masking and bends, and are port-limited at a 15% lower level. These Valve Flow Potential graphs can be used as a guide for judging the performance of any valve. To determine the flow rate for a particular valve, simply multiply the flow/area from the graph by the valve area minus the valve stem area. The flow rate you get is not the "expected" flow rate, but rather the maximum potential flow rate for a particular head at the test pressure.
- 28 -

150
140
130
Valve Flow Potential In cfm/sq.in Of Valve Area
48 Inches
Test pressure
120
110 36 100 28 90
Intake Flow (cfm/sq.in.)
25
80
70
15
60 10 50 7 40 5 3
30
20
10
0 0.00
0.05
0.10
0.15
0.20
- 29 -
0.25
0.30
0.35
0.40
Valve Lift To Diameter Ratio

12
11
V a lv e F lo w P o te n tia l In lp s /s q .c m . O f V a lv e
T e s t p re s s u re
10
9 120 cm
8 90
Intake Flow (lps/sq.cm.)
70 60
40 5
25 4 20
12 8
0 0 .0 0
0 .0 5
0 .1 0
0 .1 5 0 .2 0 0 .2 5 V a lv e L ift T o D ia m e te r R a tio
0 .3 0
0 .3 5
0 .4 0
- 30 -

The maximum potential flow at 25 of water test pressure for some of the popular heads is shown in the comparison chart below. Maximum Potential Air Flow
Intake Valves VW 1200, 1.24" D 24.2 Norton 850, 1.50" D Yamaha TX 650, 1.62" D Chevy Sm Blk, 1.72"D Chevy Sm Blk, 2.02"D Chevy Westlake, 2x1.5"D Ford 302, 2.25"D Chrysler Hemi, 2.25"D .05d 48.7 40.2 42.5 47.9 66.9 80.2 83.5 83.5 Valve Lift/Valve Diameter .10d .15d .20d .25d cfm @ 25" Test Pressure 73.0 83.8 89.5 93.1 80.5 20.9 161.9 172.6 85.5 128.4 171.9 183.1 96.3 144.7 165.7 177.1 134.2 201.7 146.3 231.3 160.9 241.9 323.8 345.3 167.6 251.7 288.7 308.3 167.6 251.7 337.1 359.2 .30d
177.9 188.1 184.5 257.2 355.7 321.1 369.0
If the flow reaches a maximum value at a lift of about 0.30 d, you may wonder why some cams are designed to open the valve farther, even as high as 0.37 d. The answer is in order to open the valve more quickly and longer at lower lifts, it is necessary to "over-shoot" the maximum head-flow point. The extra flow is gained on the flanks of the lift pattern, not at the peak. The head-flow figures are for the cylinder head alone with just a radiused inlet guide on the inlet port. When the intake manifold is installed, the total flow will drop of from 5% to 30%, depending on the flow efficiency of the manifold. By measuring the flow at each valve lift with and without the intake manifold, it is possible to accurately measure the flow efficiency. Frequently, the intake manifold will have even more room for improvement than does the cylinder head. It is the total flow with the intake manifold installed which must be used in total
power calculations.
Valve Flow Potential at Various Test Pressures
For Hemi-Intake and All Exhaust Valves (English)

.05 Test Pressure 3" 5" 7" 10" 15" 20" 25" 28" 36" 48 8.8 11.3 13.4 16.0 19.6 19.2 25.3 26.7 30.3 35.0 .10 16.4 21.2 25.0 29.9 36.7 38.6 47.3 50.1 56.8 65.6 Valve Lift/Diameter .15 .20 .25 .30 cfm per square inch of valve area 22.7 27.8 31.5 34.0 29.4 35.9 40.7 43.9 34.7 42.5 48.2 51.9 41.5 50.7 57.6 62.1 50.9 62.2 70.6 76.0 58.0 77.6 82.7 85.0 65.7 80.2 91.1 98.2 69.6 84.9 96.4 103.9 78.8 96.3 109.3 117.8 91.0 112.2 126.2 136.0 .35 35.2 45.4 53.7 64.2 78.6 88.0 101.5 107.4 121.8 140.6 .40 35.0 45.2 53.5 63.9 78.3 87.3 101.1 107.0 121.3 140.1
Valve area = .785 (D2Valve - D2Stem)
- 31 -

For Wedge Intake Valves (English)
.05 Test Pressure 3" 5" 7" 10" 15" 20" 25" 28" 36" 48 8.8 11.3 13.4 16.0 19.6 22.6 25.3 26.7 30.3 35.0 Valve Lift/Diameter Ratio .15 .20 .25 .30 cfm per square inch of valve area 16.4 22.7 25.7 27.5 28.6 21.2 29.4 33.2 35.5 37.0 25.0 34.7 39.3 42.1 42.8 29.9 41.5 47.0 50.2 52.3 36.7 50.9 57.5 61.5 64.0 42.3 58.7 66.4 71.1 74.0 47.3 65.7 74.2 79.5 82.6 50.1 69.6 78.5 84.0 87.4 55.8 78.8 89.0 95.3 99.2 65.6 91.0 102.7 110.0 114.5 .10 .35 .40
28.6 28.6 37.0 37.0 42.8 428. 52.3 52.3 64.0 64.0 74.0 74.0 82.6 82.6 87.4 87.4 99.2 99.2 114.5 114.5
For Wedge Intake Valves (Metric Measurements)

.05 Test Pressure 8cm 12 20 25 40 60 70 90 120 0.66 0.80 1.04 1.16 1.47 1.80 1.94 2.20 2.54 Valve Lift/Diameter Ratio .15 .20 .25 lps/sq.cm of valve area 1.23 1.70 1.93 2.06 1.51 2.09 2.36 2.53 1.94 2.70 3.05 3.26 2.17 3.01 3.41 3.65 2.75 3.81 4.31 4.62 3.37 4.67 5.28 5.65 3.64 5.04 5.70 6.11 4.12 5.72 6.46 6.92 4.76 6.60 7.46 8.00 .10 .30 2.14 2.63 3.39 3.79 4.79 5.87 6.34 7.19 8.30 .35 2.14 2.63 3.39 3.79 4.79 5.87 6.34 7.19 8.30 .40 2.14 2.63 3.39 3.79 4.79 5.87 6.34 7.19 8.30
For Hemi-Intake and All Exhaust Valves (Metric Measurements)

Test Pressure 8cm 12 20 25 40 60 70 90 120 .05 0.66 0.80 1.04 1.16 1.47 1.80 1.94 2.20 2.54 .10 1.23 1.51 1.94 2.17 2.75 3.37 3.64 4.12 4.76 Valve Lift/Diameter Ratio .15 .20 .25 .30 lps/sq.cm of valve area 1.70 2.08 2.36 2.55 2.09 2.55 2.90 3.12 2.70 3.29 3.74 4.03 3.01 3.68 4.18 4.51 3.81 4.66 5.29 5.70 4.67 5.71 6.48 6.98 5.04 6.16 6.99 7.54 5.72 6.00 7.93 8.55 6.60 8.07 9.16 9.87 .35 2.64 3.23 4.17 4.66 5.89 7.22 7.80 8.84 10.21 .40 2.62 3.21 4.15 4.64 5.87 7.19 7.76 8.80 10.17
From a flow standpoint, a hemi-shaped combustion chamber has a clear advantage over the wedge. Until the valve lift reaches 0.15 valve diameter, there is little difference. At higher lifts, the hemi-valve is usually less shrouded. In most designs, the hemi-port is also straighter due to the valve angle. These two advantages add up to an average flow advantage of 16% at higher lifts, even with equal valve diameters. When you consider that a hemi-combustion chamber also generally permits the intake valve to be 10% greater diameter than a wedge, it is easy to understand the success of the hemi-head racing engine.
- 32 -

8.0 Combustion Chamber
In most engines, it appears the combustion chamber design was dictated by the choice of the valve geometry. Perhaps it should be the other way around. Most combustion chambers just don't combust as well as they should. Hemi and pent-roof combustion chambers are generally the best with wedge chambers being 5% to 10% worse. Most gasoline burning racing engines use a compression ratio of between 12 and 14.5 to 1. If the cylinder is completely filled, you would expect the torque per cubic inch (N-m/Liter) of engine displacement would be the same, regardless of engine design. It isn't, and the differences are mostly due to combustion chamber effectiveness. One way to judge a combustion chamber's performance is to measure the torque output per unit of engine displacement. At the RPM of peak torque, a good combustion chamber will develop 1.25 to 1.30 pound-feet of torque per CID (100 to 108 N-m/liter). It may be possible to raise this as high as 1.5 pound-feet per CID (124 N-m/Liter), though not without an outstanding combustion chamber design and ram-tuning. Most racing Detroit V-8's only reach 1.15 pound-feet per CID (95 N-m/Liter). There is plenty of room for improvement. A second guide line for judging efficient burning is the required spark advance for maximum power. The more efficient combustion chambers have a higher turbulence and require less spark advance. A turbulent combustion chamber substantially reduces the "ignition delay" time between when the spark fires and the charge begins to burn rapidly. For example, a small-block Chevy with a normal combustion chamber shape might require 42 degrees BTDC (Before Top Dead Center) maximum spark advance (35 degrees ignition delay), while a highly turbulent combustion chamber might only require 33 degrees BTDC advance (27 degrees ignition delay). The more turbulent chamber will also burn more rapidly and produce up to 10% greater power from the same initial charge Combustion chamber improvement is more of an art than a science, so trial and error methods are frequently the only choice. In general, strive for high turbulence and minimize the distance from the spark plug to the farthest part of the combustion chamber. At times, combustion chamber burning complexities can make it very confusing when trying to compare cylinder heads on an engine. For instance, it is difficult to compare a cylinder head on a Chevy 302 and then on a Chevy 330. While the same head will bolt onto both engines, the compression ratio, combustion chamber effectiveness, and RPM range will all change. Even the degree of turbulence will change. These factors can mask differences due to the flow capacity of the heads and confound even the experienced engine builder.
- 33 -

9.0 Dynamic Flow Effects
Engine volumetric efficiency and power can be increased considerably by taking advantage of the natural dynamic effects which occur during the intake cycle. Both the kinetic energy and the resonant pulses can be harnessed to fill the engine cylinder at volumetric efficiencies up to 130%. Without these dynamic effects, volumetric efficiency is limited to 100% without supercharging. When the inlet valve closes, a pressure pulse bounces back out the intake tract, and then in again toward the valve. By making the intake tract the proper length, the returning pulse can be timed to arrive just after bottom dead center of the next intake cycle, shoving extra air in and keeping exhaust gases out of the intake port. To visualize what occurs, imagine that one end of a steel bar is placed against a hard surface. If the other end is struck with a hammer, a strong pulse (the hammer blow) will travel down the bar to the other end, and then back to the hammer end. The pulse will actually cause the bar to jump back towards the hammer! While the bar (or the air in the port) moves very little, a strong pulse has been transmitted through it. To use this pulse, the intake port must be the correct length. The pulse will help only through a narrow range of RPM. Above or below a certain range the pulse will actually decrease power so proper synchronization is essential. There are actually several pulses which can be used, corresponding to the 2nd, 3rd and 4th time the pulse arrives at the valve. The 2nd pulse is best, the others being weaker and shorter. Inlet Pulsation Chart
Harmonic Length (inches) (cm) Lower RPM Upper RPM Pulse Strength*
2nd 3rd 4th
132,000/ RPM 97,000/ RPM 74,000/ RPM
335,000/RPM 246,000/RPM 188,000/RPM
89% 91% 93%
108% 104% 104%
+ 10% + 7% + 4%
*Pulse Strength Varies with Inlet Flow and Inlet Valve Opening
This chart shows the pulses which can be used. To obtain the inlet system length, divide the number shown by the RPM for peak power as determined by the flow measurements (See Section 3.0). For example, at 8000 RPM for the 2nd harmonic, the formula would be: Length = 132,000/8,000 = 16.5 Length = 335,000/8,000 = 41.9 cm
- 34 -

This is the desired length from the intake valve to the air inlet entrance. For engines with a plenum chamber type intake, the length is from the valve to the plenum chamber. The pulse in the example will benefit from 89% up to 108% of 8,000 RPM, or from 7,120 RPM up to 8,640 RPM. The greatest benefit will occur at about 3% below 8,000 RPM. Below 7,120 RPM or above 8,640 RPM, the pulse will actually work to decrease engine power. To obtain benefits from the pulsation, it is also necessary that the intake valve be open to a lift of at least 0.02 times the valve diameter by 15 degrees BTDC (Before Top Dead Center). Openings of 20 degrees to 40 degrees BTDC are usually preferable. The intake flow rating, Cv, must also be 0.3 or greater for significant benefits. 10.0 Inertia-Supercharge Effect
When the intake valve starts to close, the fast moving air column tries to keep ramming itself into the cylinder. If the inlet valve is closed at just the right instant, the extra charge will be trapped in the cylinder (called inertia-supercharging). Volumetric efficiencies up to 130% can be obtained. To determine the proper valve timing for maximum inertia-supercharge, it is necessary to determine the inertia supercharge index, Z, and then the valve closing timing can be determined from the Intake Valve Closing Angle Graph. Z, the inertia-supercharge index, depends on the average inlet valve area, so this must be measured. First determine the inlet flow versus the valve lift for the complete intake system. Next, determine the cam lift profile at the valve versus the degrees of engine rotation. From these two pieces of information, construct a graph, as shown below, of engine flow units per unit of valve area in versus degrees of engine rotation. This is a plot of the total engine flow considering both the intake system and the cam.
- 35 -

Count the number of squares under the flow curve and divide this by the total number of squares beneath the maximum valve flow potential line for the test pressure used for the flowtest. The number obtained is the intake system flow rating Cv.
(19) Cv = Area under flow curve Total area under potential flow line
The Cv will generally be between 0.35 and 0.45 for good engines. This is a total rating of the intake system flow for any engine. The higher the Cv, the better the engine. The average inlet valve area is the Cv times the intake valve area.
(20) Average Inlet Area = Cv x Valve Area (in or cm )
2 2
This data can be used to determine the inertia-supercharge index, Z, from the formula below:
(21) Z = __RPM__ x 126,000 Z = __RPM__ x 320,000 Cyl. Disp. (in ) x Inlet Length (in) 2 Average Inlet Area (in ) Cyl. Disp. (cm ) x Inlet Length (cm) 2 Average Inlet Area (cm )
3 3
0.5
(22)
0.5
Z will usually be between 0.9 and 1.2, and is also a measure of the strength of the inertiasupercharge which will be obtained. When Z has been determined, use the graph to obtain the correct intake valve closing angle where the valve should be closed down to a lift of .01 x valve diameter.
- 36 -

11.0
Want Flow At:
3 5 7 10 12 15 20 25 28 30 35 40 45
Flowbench Test Pressure Conversion Chart
Have Flow At:

3 5 7 10 12 15 20 25 28 30 35 40 45
1.000 0.774 0.655 0.548 0.500 0.447 0.387 0.346 0.327 0.316 0.293 0.274 0.258 1.290 1.000 0.845 0.707 0.645 0.577 0.500 0.447 0.422 0.408 0.378 0.354 0.333 1.530 1.180 1.000 0.387 0.764 0.683 0.592 0.529 0.500 0.483 0.447 0.418 0.394 1.820 1.410 1.120 1.000 0.913 0.816 0.707 0.632 0.598 0.577 0.535 0.500 0.471 2.000 1.550 1.310 1.090 1.000 0.894 0.774 0.693 0.654 0.632 0.586 0.548 0.516 2.240 1.730 1.460 1.220 1.120 1.000 0.866 0.775 0.721 0.707 0.655 0.612 0.577 2.580 2.000 1.690 1.410 1.290 1.150 1.000 0.894 0.845 0.816 0.756 0.707 0.667 2.890 2.240 1.890 1.580 1.440 1.290 1.120 1.000 0.945 0.913 0.845 0.791 0.745 3.050 2.370 2.000 1.670 1.530 1.370 1.180 1.060 1.000 0.966 0.894 0.837 0.489 3.160 2.450 2.070 1.730 1.580 1.410 1.220 1.100 1.040 1.000 0.926 0.866 0.816 3.420 2.650 2.240 1.870 1.710 1.530 1.320 1.180 1.120 1.080 1.000 0.935 0.882 3.650 2.830 2.390 2.000 1.830 1.630 1.410 1.260 1.200 1.150 1.070 1.000 0.943 3.870 3.000 2.540 2.120 1.940 1.730 1.500 1.340 1.270 1.220 1.130 1.060 1.000
Example: If flow is 65 cfm at a test pressure of 5, what would flow be at 15?

CFM = 65 cfm x 1.73 = 112.5 cfm
Example: If flow is 42 l/s at a test pressure of 12 cm, what would flow be at 40 cm?
l/s = 42 l/s x 1.83 = 76.9 l/s
Flow at any test pressure will vary as the square root of the ratios of the two test pressures. An example is shown below:
Flow at first test pressure x ( second test pressure/ first test pressure) Flow at second test pressure
0.5
Example: if flow is 122 at a test pressure of 7, what will the flow be at a test pressure of 28?
Flow at 28 = Flow at 7 x ( 28/7) = 2.0 x 122 = 244
0.5
- 37 -

Maximum Potential Orifice Flow Rate Vs Test Pressure (English)
Test Pressure 1 H2O 3 5 7 10 12 15 20 25 28 30 35 40 45 65 Peak Velocity 66.2 ft/sec 114.7 148.0 175.1 209.3 229.3 256.4 296.0 331.0 350.3 362.6 391.6 418.7 444.1 533.7 *Flow/Unit Area 27.6 cfm/sq in 47.8 61.7 72.9 87.1 95.6 106.9 123.4 138.0 146.0 151.1 163.3 174.6 185.1 222.5
*Through a perfectly streamlined orifice (coefficient of velocity equals 1)
Maximum Potential Orifice Flow Rate Vs Test Pressure (Metric)

Test Pressure 2 cm H2O 8 12 20 25 40 60 70 90 120 165 Peak Velocity 17.9 m/s 35.8 43.9 56.7 63.3 80.1 98.1 106.0 120.2 138.8 162.7 *Flow/Unit Area 1.79 lps/sq cm 3.58 4.39 5.67 6.33 8.01 9.81 10.60 12.02 13.88 16.27
*Through a perfectly streamlined orifice (coefficient of velocity equals 1)
- 38 -

12.0 Adapting the SuperFlow Flowbench to Two-Stroke Engines
The SuperFlow SF-110, SF-300, and SF-600 flowbenches have been successfully adapted to twostroke engine cylinder development. For two-stroke engine cylinder testing, both the flow quantity and the flow direction must be measured. To perform a flow test, it is first necessary to mount the two- stroke cylinder onto the flowbench. A picture of a typical two-stroke cylinder mounting system is shown on page five of the SuperFlow flowbench brochure. The photo in the upper right corner shows a Yamaha cylinder mounted onto an SF-110 Flowbench. The cylinder is mounted with a standard piston in place inside the cylinder. The piston should have only one very light piston ring, or no piston rings. A lever mechanism is attached to the piston to allow the piston to be positioned up and down in the cylinder during testing. The piston should be adjustable at all positions from fully open port to fully closed port. The mechanism must be strong enough to resist the air pressure of the flowbench without movement. On the top of the cylinder, a plexiglass cover should be fitted to allow viewing into the cylinder from the top side. It is also recommended that a light be installed in the plexiglass cover to illuminate the interior of the cylinder. A small flashlight bulb works well. To perform a test, flow is measured in increments of piston opening. It may be desirable to mount a dial indicator on the cylinder head plexiglass cover to measure the exact position of the piston. This series of tests allows you to evaluate the quantity of the flow which can pass through the cylinder. The most important test is to determine the direction of the flow. To help in visualization of the air flow, it is necessary to build an air flow tell-tale probe. A tell-tale probe consists of a small diameter rod, such as a brazing or welding rod, with a groove ground near the tip. In the groove, tie a piece of light weight string with a loose knot so that it may rotate on the groove, but will not slide out of the groove. A small drop of glue may be added to the knot to prevent it from becoming untied during use. Trim the tail of the string to approximately 0.25 inches (6 millimeters) in length. A correctly constructed tell-tale should now rotate in the direction of the air flow and move freely on the probe. It should not be tied securely to the probe, but should rotate in the groove. You may test the probe by setting the tell tale at right angles to the direction of your breath and then blowing on it. It should immediately align to the direction of flow. Once you have successfully constructed a tell-tale probe, you may insert this in through the exhaust port of the engine, or if desired, in through a port in the plastic cylinder head cover, and sample the direction of the air flow at all points in the cylinder. It is generally agreed that for a good cylinder configuration, the air should flow up the side of the cylinder opposite the exhaust port, across the top of the head, and down the exhaust port side to exit from the exhaust port. There should be no short-circuiting from the intake port across the head of the
- 39 -

piston to the exhaust port. There should also be no dead spots of air flow in the cylinder. It should be your goal to achieve this at all port opening positions. The initial testing program should consist of testing cylinders that are known to be good and known to be bad. By observing the differences between these, you can ascertain the features which make one set of cylinders perform better than another. No cylinder is likely to achieve all of the goals. Two-stroke cylinder development is still largely in the area of a black art, and many different techniques have been used to achieve similar final results. There is no single correct way or best theory. We wish you good luck in your test program, and hope that you will develop the finest cylinders that you have ever built. While SuperFlow builds engine testing equipment, we do not normally do engine cylinder testing. We will be happy to assist you in questions involving the use of the flowbench, but we do not have a wide range of knowledge about the exact techniques which give good results on a given cylinder.
- 40 -

13.0 Trouble Shooting your SF-300/600 Flowbench
When there seems to be a problem with the flowbench measuring system, do the following: 1. 2. 3. Unplug the brass/plastic tubing from the flow meter elbows, (4 places). Unscrew the elbows from the 3/4" nylon hex until they are flush with the top of the hex. Then unscrew the 3/4" hex assembly until the elbows point toward the tubing. Using spare plastic tubing, puff or suck into each flow meter elbow, making sure fluid responds and settles back to zero smoothly. Reconnect the tubing to the elbows. Turn flowbench back on.
If the problem still exists, please run the next three tests. The data you collect will be helpful in evaluating your problem.
No Flow Test
With the SuperFlow Flowbench test orifice plate bolted on and the rubber stopper in the test orifice hole, switch to intake mode and flow range 1. Turn the flowbench motor on and place your finger over the small hole in the test orifice plate. Slowly, with both holes in test orifice plate plugged, adjust intake control valve until you reach 25" (63.5 cm) of test pressure on the vertical test pressure meter. The horizontal flow scale should rise slightly, then settle back to zero with the flow bench running. If not, record the horizontal flow scale reading. Repeat this test on exhaust.
Low Flow Test
Perform the same test as above except remove your finger from the small hole in the test orifice and slowly open intake control valve until you reach 25" (63.5 cm) on the test pressure meter. Record the reading of the horizontal flowscale. Shut the Intake Control Valve. Repeat test in exhaust mode.
High Flow Test
You should still be in the exhaust mode from the last test. Select Flow Range 5 on the SF300 and Range 4 on the SF600. Turn the machine on and open the Exhaust Control valve to obtain 25" (63.5 cm) on the test pressure meter. Record the flow scale reading.
After recording the collected data, please call SuperFlow Customer Service at 719-471-1746 or fax 719-471-1490.
- 41 -

14.0 Suggested Additional References
Gas Flow in the Internal Combustion Engine, Annand and Roe, 1974 (out of print). Haessner Publishing Co. (Search Engineering Library). The Internal Combustion Engine in Theory and Practice, Charles Fayette Taylor, 2nd edition, John Wiley & Sons, N.Y., N.Y. (Search Engineering Library). Internal Combustion Engines, Edward F. Obert, 2nd edition, International Textbook Co., Scranton, PA (Search Engineering Library). Internal Combustion Engine Fundamentals, J. B. Heywood, McGraw Hill, New York, NY, 1988. Scientific Design of Exhaust and Intake Systems, P. H. Smith and J. C. Morrison., Robert Bently Incorporated, 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, Osceola, WI, call (800) 826-6600 to order. Tuning BL's A-Series Engine, David Vizard, 1985. Haynes Publishing Co., 861 Lawrence Drive, Newbury Park, CA 91320, (805) 498-6703, F414-$19.95
S.A.E. Technical Papers
S.A.E. Technical Papers may be obtained by contacting the Society of Automotive Engineers, Inc., 400 Commonwealth Drive, Warrendale, PA 15096, (412) 776-4841. Request a Current Year Catalog or order by Number, Author, and Paper Title listed below. 650448* A Study of Engine Breathing Characteristics, 1965, C. H. Wolgemuth and D. R. Olson. Research and Development of High-Speed, High-Performance, Small Displacement Honda Engines, 1970 by S. Yagi, A. Ishizuya, and I. Fujii. Design Refinement of Induction and Exhaust Systems Using Steady-State Flowbench Techniques, 1972 by G.F. Leydorf, Jr., R. G. Minty, and M. Fingeroot. Analysis of the Volumetric Efficiency Characteristics of 4-Stroke Cycle Engines Using the Mean Inlet Mach Number. February-March 1979 by Itaru Fakutani & Eiichi Watanabe.
- 42 -
700122*
720214*
790484*

820154* AirFlow through Poppet Inlet Valves - Analysis of Static & Dynamic Flow Coefficients, February 1982 by Itaru Fakutani & Eiichi Watanabe.
820410*
A Study of Gas Exchange Process Simulation of an Automotive Multi-Cylinder Internal Combustion Engine, February 1982 by Masaaki Takizawa, Tatsuo Uno, Toshiaki Oue, Tadayoshi Yura. Valve Events and Engine Operation, 1982, by T. W. Asmus. Exhaust Valve Geometry And Its Effect on Gas Velocity and Turbulence in an Exhaust Port, 1983, by S. G. Oldfield and N. Watson. Characterization of Flow Produced by a High-Swirl Intake Port, 1983, by T. Uzkan, C Borgnakke, and T. Morel. 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. Tindal, and M. Yianneskis.
820749* 830151*
830226* 900058*
Bosch Automotive Handbook, from SAE Publications.

American Society of Mechanical Engineers Publication United Engineering Center, 345 East 47th St., New York, NY.
76-WA/DGP-4 Short Pipe Manifold Design for Four-Stroke Engines, December 1976, P. C. Vorum.
*All papers belonging to S.A.E. are covered by U. S. Copyright laws and cannot be reproduced without paying a fee or obtaining permission to reproduce from S.A.E. Publishing Division.
SuperFlow Technologies Group reserves all rights for these instructions worldwide. Reproduction or translation of this work beyond that permitted by Sections 107 and 108 of the 1976 U. S. Copyright Act without permission of copyright owner is unlawful. Request for permission or further information should be addressed to SuperFlow Technologies Group. - 43 -

15.0 Units Conversions
Pressure Conversions Have Multiply By To Get
inches of water (in.H2O) inches of water (in.H2O) inches of water (in.H2O) inches of water (in.H2O) centimeters of water (cm.H2O) centimeters of water (cm.H2O) centimeters of water (cm.H2O) centimeters of water (cm.H2O) pounds per square inch (psi) inches of mercury (in.Hg) inches of mercury (in.Hg) Kilopascals per square cm (kPa) Bar Bar
Flow Conversions Have
3
0.03610 0.0736 2.54 0.2488 0.3937 0.0142 0.0978 0.000978 27.70 0.4897 13.57 4.019 1022 14.50
pounds per square inch (psi) inches of Mercury (in.Hg) centimeter of water (cm.H2O) kilopascals per square cm (kPa) inches of water (in.H2O) pounds per square inch (psi) Kilopascals per square cm (kPa) Bar inches of water (in.H2O) pounds per square inch (psi) inches of water (in.H2O) inches of water (in.H2O) centimeters of water (cm.H2O) pounds per square inch (psi)
Multiply By
To Get
cubic feet per second (ft /sec) 0.0283 3 cubic feet per second (ft /sec) 28.32 3 cubic feet per minute (ft /min) 0.472 3 cubic feet per minute (ft /min) 0.0283 3 cubic feet per minute (ft /min) 1.700 3 cubic meters per second (m /sec) 2120 3 cubic meters per minute (m /min) 35.3 3 cubic meters per hour (m /hr) 0.589 liters per second (l/s) 2.12 liters per second (l/s) 3.60
Length Conversions Have Multiply By
cubic meter per second (m /sec) liters per second (l/s) liters per second (l/s) 3 cubic meters per minute (m /min) 3 cubic meters per hour (m /hr) 3 cubic feet per minute (ft /min) 3 cubic feet per minute (ft /min) 3 cubic feet per minute (ft /min) 3 cubic feet per minute (ft /min) 3 cubic meters per hour (m /hr)
To Get
inches (in) inches (in) centimeters (cm) millimeters (mm) millimeters (mm)
25.4 2.54 0.3937 0.3937 0.10
millimeters (mm) centimeters (cm) inches (in) inches (in) centimeters (cm)
- 44 -
Speed Conversions Have Multiply By To Get
feet per second (ft/sec) feet per minute (ft/min) meters per second (m/s) meters per second (m/s)
Power Conversions Have
0.3049 0.00508 3.28 0.0547
meters per second (m/s) meters per second (m/s) feet per second (ft/sec) feet per minute (ft/min)
Multiply By
To Get
horsepower (hp) kilowatts (kW)

Area Conversions Have
0.746 1.34
kilowatts (kW) horsepower (hp)
Multiply By
To Get
square inches (sq.in.) square inches (sq.in.) square centimeters (sq.cm.) square millimeters (sq.mm.) square millimeters (sq.mm.)
6.4516 645.2 0.155 0.00155 100
square centimeters (sq.cm.) square millimeters (sq.cm.) square inches (sq.in.) square inches (sq.in.) square centimeters (sq.cm.)
- 45 -
- 46 -

Advanced Mode For The Flow Computer
Select menu: 5I The Flow computer can also be operated in an Advanced mode for additional displays and calibration. To enter the advanced mode, push the Cycle and Enter key at the same time. This will switch the computer to the Advanced mode. First you will see the title: Advanced mode, followed by a data screen. Only one current data screen is available in the Advanced mode, but the displayed data can be selected from 15 choices for each display position.
Appendix
15.00 In.H20
00.00 leakge
89.30
Config
Calibrate
From the data screen, push the Cycle key and the Select menu will appear, with the cursor positioned under: Config. Push Enter to select the configuration options.
Select config item:
TstP [ 00.00 In H20]

Now use the Up/Down arrow keys to step through the choices. Then use Enter to select an item to change.
TestP Save Configuration Auto Zero Channels Default Calibration Set Swirl Source Frq. Pulses/Rev Exhaust Full Scale (1-9E) Intake Full Scale (1-9I) Set Filter Rates Intake/Exhaust Leakage Range Setting
00.00 | 00.0. In.H20 | degF
| 00.00 | CFM
To change the display item, use the Left/Right arrows to move the cursor to the data position and then push Enter to select. Now use the Up/Down arrow keys to step through the choices. Then use Enter to select an item to change. Both the units for display and the degree of data filtering (or smoothing), for measured channels, can also be changed from these menus.
Measured channels Chan #1 - Flow Press Chan #2 - Test Press Chan #3 - Velcty Pres Chan #4 - Baro Press Chan #5 - Temp. #2 Chan #6 - Temp. #1 Chan #7 - Frequency Chan #8 - Torque Calculated channels Chan #9 - Flow Rate Chan #10 - Velocity Chan #11 - Delta Temp Chan #12 - % of Flow Chan #13 - Rel Swirl Chan #14 - Host Data Chan #15 - Range/Dir
If you make a selection incorrectly, you may reset all selections by turning off the computer power before selecting: Save Configuration. The previous values will be restored. Push Enter to select a feature to change. The most common choices are Auto Zero Channels, setting new values for Intake or Exhaust full scale, and Save Configuration.
TestP selects the Test pressure to be used by the
flowbench motor controller. It can also be entered from the Simple menu, but value entered here is the default value on power-up.
Appendix: page 1

Save Configuration will save all the settings to memory so they will all be installed on powerup. Auto Zero Channels sets all of the measured sensor channels except temperature and barometric pressure to zero. Do not make thisselection if there is any pressure, frequency, or torque applied to the sensors. On models with automatic motor control of test pressure, the pressures are automatically auto zeroed every 10 seconds when the motor is off. On units without motor control, the test pressure must be zeroed manually with this command. Default Calibration installs default values for the
Appendix
Intake Full Scale provides individual data entry for each of the available intake flow ranges. You must Save Configuration as well if you wish these values to be used in future sessions. Do not change these values unless you have accurate calibration data. Set Filter Rates selects the filtration rates for averaging the displayed data. The rates can be selected individually for each sensor input. The default rate is 1.24 seconds. No change is usually required for these values. Only measured channels can be filtered. Intake/Exhaust setting must match flowbench settings. Flow direction can also be changed by selecting I or E flow ranges from the Simple menu. Leakage sets the leakage which will be used on start-up. Leakage can also be set from the Simple menu. Range Setting selects the flow range which will be used for flow calculations. Range can also be set from the Simple menu.
pressure and temperature sensors. These values will generally be within 1% of the correct values. This selection over-writes the calibrations for flow pressure, test pressure, and velocity pressure.
Set Swirl Source selects whether a frequency or torque type swirl meter is used. This selection has no effect if you do not have a swirl meter and is not possible an SF-60 models. Frq. Pulses/Rev sets the counts per revolution for frequency type swirl meters. Exhaust Full Scale provides individual data entry for each of the available exhaust flow ranges. You must Save Configuration as well if you wish these values to be used in future sessions. Do not change these values unless you have accurate calibration data.
Use the Cycle key to return to the Current data display for the Advanced Menu. Push the Cycle key again for the Select menu, and then push the Right arrow key to select Calibrate, and then push Enter for the Calibration menus.
Advanced Calibration
Warning! Do not try to recalibrate the sensors unless you have an accurate pressure source, frequency reference, or barometric pressure data as required. To enter the Calibration menu after power-up, push the Cycle and Enter keys at the same time. This will switch the computer to the Advanced mode. First you will see the title: Advanced
mode, followed by a data screen. Only one
current data screen is available in the Advanced mode, but the displayed data can be selected from 15 choices for each display position. Push the Cycle key.
Select menu:
Config
Calibrate
Appendix: page 2

The Select menu will appear, with the cursor positioned under: Config. Push the right arrow key and then Enter to select the Calibrate options.
Appendix
Chan #1 00.00 In H20
Apply ZERO-hit ENTER

Make sure that the pressure, torque or frequency applied to the sensor is zero, and push the Enter key.
Enter Password:
0000
A special password is required to change the calibration of your system. The password for your system is available from SuperFlow customer service. Enter the password, followed by the Enter key. Now use the Up/Down arrow keys to step through the choices. Then use Enter to select an item to change.
Chan #1 00.00 In H20
Apply NFS-hit ENTER

The next menu asks you to apply NFS ( Near Full Scale) value to the sensor. For flow, test, or velocity pressure, use an accurate manometer with a tee in the pressure line connected to the transducer.
Calibrate: Sel. Chan
Chan #1 - Flow Press

There are nine channels available for calibration:
Chan. #1 Flow Press Chan. #2 Test Press Chan. #3 Velcty Chan. #4 Baro Press Chan. #5 Temp. #2 Chan. #6 Temp. #1 Chan. #7 Frequency Chan. #8 Torque Chan. #9 Flow Rate
Enter NFS and units
000.000
In H20
When you select a channel to calibrate, a menu will appear to ask if you are sure to prevent accidental choices. If you select yes, the first calibration screen will appear. If you find that you do not have enough information to proceed with the calibration, push the Cycle key to exit. If you have already performed the auto zero step, but have not Saved the configuration, you can erase your changes by turning the computer power off and on again.
Apply a value near the full scale range of the transducer and push the Enter key. Then enter the value, and then the units used for calibration. The transducer will now be calibrated to the zero value and the Near Full Scale value you applied. Push the Enter key to accept these values, and then the Cycle key to select the Save Configuration choice. If you wish to save this calibration permanently, push the Enter key and save it. If you wish to only use this calibration temporarily till the next power down, Push the Cycle key to return to the data screen. These calibration values will be valid until the FlowCom unit is turned off. Values will be permanent if you have followed the Save Configuration procedure mentioned earlier. To return to the Simple mode of operation, Push both the Enter and the Cycle keys at the same time.
Appendix: page 3
Appendix
Suggested default values for FlowCom attached to: SF-300FC:

C.F.M. Intake Exhaust L.P.S. Intake Exhaust 1 23.7 26.7 1 11.2 12.6 2 3 4 5 6 47.4 100.0 200.0 300.0 400.0 52.7 106.0 213.0 321.0 428.0 2 22.4 24.9 3 4 5 6 47.2 94.4 141.6 188.8 50.0 100.5 151.5 202.0
SF-600FC:
C.F.M. Intake Exhaust L.P.S. Intake Exhaust 1 35.5 40.0 1 16.8 18.9 2 3 4 5 6 71.0 150.0 297.0 447.0 600.0 79.0 159.0 319.0 481.0 642.0 2 33.5 37.3 3 4 5 6 70.8 140.2 211.0 283.2 75.0 150.6 227.0 303.0
Appendix: page 4

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SF-600FC Flowbench

MAN 1100A-2200 REV: 01.17.07-02

Return Material Authorization (RMA)

Service Under Warranty

Service Out of Warranty

MondayFriday, 8:00 A.M.5:00 P.M. Mountain Time

MondayFriday, 8:00 A.M.5:00 P.M. Eastern Time

MondayFriday, 9:00 A.M.5:00 P.M. Central European Time

Des Moines Office

Company Internet Web Site

FlowCom Operation FLOWCOM OPERATION

Performing a Flow Test

FlowCom Computer Connections

Changing the COM Port Assignment

Test Pressure Regulation

Velocity Probes and Swirl Meters

Flow Data Correction

SuperFlow Technologies Group

USB Port Serial Port

FlowCom Operator Guide

Table 1-3. Keypad Functions

Selects items on the display.

Selects items on the display.

Accesses the test functions.

Selects items on the display.

FORWARD ARROW BENT ARROW

Selects items on the display.

Activates the current selection.

SuperFlow Technologies Group

P1: Incline manometer P2: Vertical manometer P3: Velocity probes

Figure 1-2. Pressure Ports

FlowCom Operator Guide

Flow Testing with FlowCom

3 Flow Testing with FlowCom

3.1 Operational Check

SuperFlow Technologies Group

Nominal Flow Reading* Model

Figure 1-5. Range and Flow Direction

FlowCom Operator Guide

SuperFlow Technologies Group

4 Performing a Flow Test

4.1 Determining Leakage

4.2 Entering Leakage into FlowCom

FlowCom Operator Guide

4.3 Flow Test Procedure

SuperFlow Technologies Group

5 FlowCom Computer Connections

5.1 Configuring FlowCom to Communicate

5. Type 3512 for the password. Press ENTER (

FlowCom Operator Guide

to exit and return to the main operating screen.

5.2 RS232 Serial Connection

SF-110, SF-120, SF-300, SF-600 and SF-1200

SuperFlow Technologies Group

5.3 Universal Serial Bus Connection

SF-110, SF-120, SF-300, SF-600 and SF-1200

FlowCom Operator Guide

FlowCom Computer Connections

Installing the USB Driver

5. Click Continue Anyway. You may have to do this twice.

7. Click Finish to close the program.

Configuring the USB Communication

FlowCom Operator Guide