SuperFlow - DEPAC Dyno Systems

Transcription

DEPAC Dyno Systems 201 Mill St. Rome NY 13440
[email protected]
www.depac.com
MAIN INTRODUCTION:
(315) 339 –1265
Dyno Control Innovation
Auto-Dynamic Load (ADL) Control System for water brake dynos:
The ADL Control System is a significant advance in the control and operation of the
common water brake dyno. It is a Smart Load Control that works far better than the
traditional Speed Control Dynos in wide use. It is also very easy to set up and operate and
most anyone can easily run the dyno. It achieves excellent control of engine load and speed
by Improving the Stability of the Dyno/Engine connection. Unlike Speed Controls, the ADL
system does not require adjustments and provides the engine with a very smooth and
natural load, either steady state or sweeping. The ADL system controls dyno inlet water
flow to Most* dynos. This is the proper method to control the load from a water brake.
Also, designed into the hardware is the ability for future upgrades of the ADL to provide full
programmed automated testing, track, Throttle control, and inertia dyno simulations.
Dyno Applications:
The ADL Control System is upgrades existing manual dynos like Stuska®, Go- Power,
Froude, AVL, and many others. We will provide upgrade parts kits for each specific dyno.
DTS Power-Mark and SuperFlow™ dynos can be upgraded as well. But the complete
upgrade includes an ADL Control AND a precision DEPAC instrumentation package.
Special INSTALLATION Requirements for the ADL Control System:
Please MAKE the time to read and understand the included ADL instructions and MAKE the
time to do all that's required for the system installation to work at 100% performance.
The ADL system works differently than any other previous dyno control system and
requires special considerations for the water plumbing if it is to work to its full potential.
It is very important to follow the installation instructions and diagrams. We provide the
system as a kit of most all needed parts and clear, specific instructions so that it is installed
properly. The ADL system can be made to work well with most existing plumbing (that is
usually strung-out). Any new installation should try to place the dyno, pump, and water
supply in close proximity (Just because there is no need to have lines strung all over the
shop). Some existing dynos use municipal water through a long underground line. You can
continue to use this city water supply as long as it has enough pressure for the engines, you
need to test, and you will need extra Accumulators.
Most installations requires a diaphragm accumulator near the Inlet Control Valve, as
shown in the diagrams, pre-charged with air to 70% of the working water pressure. Some
installations may require more than one Accumulator to compensate for the water flow
inertia of very long water lines. A special inlet hose and nipple is supplied to connect the
accumulator to the inlet valve (see diagrams). The outlet water is required to drain freely into
a lower sump tank or open drain.
Dual rotor dynos have very special requirements in that the water flow through each half be
equal for best dyno load performance. We try to provide the parts and special manifolds to
provide a 50-50 split of the inlet and outlet water flow.
* SuperFlow™ dynos use a specially designed Outlet Valve that’s fast and precise.
1
DEPAC Dyno Systems 201 Mill St. Rome NY 13440 vv(315) 339 -1265
[email protected]
www.depac.com
To Run an ADL Controlled dyno test all you need to do:
1. Start the pre-warmed engine.
2. Pickup the throttle (the Load is automatically applied)
3. Hold the Test Switch down (to Sweep or Hold steady state).
4. Release the test switch when test is finished.
5. Pull throttle back to idle.
New Technology: The ADL Control system is Not a Speed control. This system is Superior to
any dyno speed controls we have ever seen, at any cost. The Key feature of the ADL system is
a Smart Load that's Smooth and Natural and very Stable. Picture your engine as powering a
vehicle climbing a steep hill, or grade. The ADL System affects the engine speed by changing
the Grade, or slope, of this simulated hill. It is a very natural simulation and enhances your
'feel' for when the engine is 'not right'. If the engine is running the same then it will reach the
same RPM when climbing the same Grade setting or LOAD. Sweeps are also very natural and
start by setting a LOAD or Grade to hold a start RPM at a fixed throttle setting. For a Sweep,
this Grade is slowly Reduced to sweep Up (or Increased to sweep Down). So then Imagine
that you are in this vehicle on a sustained grade and then the hill starts to slowly flatten out.
The engine picks up RPM in a smooth and natural way (as long as the engine is running
smooth). The RATE control knob sets how Quickly this Grade changes when sweeping Up or
Down, and can range from seconds to minutes. If you start at a Low RPM (hi Load) and start
an Up-Sweep, the engine smoothly accelerates Naturally as it comes up on the cam, just as
you would experience in the real world. Each sweep, or run 'up the hill', is very repeatable and
predictable. Any sweep rate change is primarily due to the engine's ability to accelerate.
Tests can be done at any throttle setting. Set a cracked throttle to simulate cruising conditions.
At startup, and at low idle speeds, there is no Grade and just a slight engine load. As you
increase the throttle, the Grade increases progressively until you reach a balanced RPM at a
set throttle position (full or partial). If the engine is repeatable it will reach the Same RPM each
time for the same throttle position. Any time you pull back the throttle to an idle the Grade
automatically flattens out to a slight road load.
Another Key Feature is that you have an enhanced sense of how well the engine is running,
much more than you had with your hand valve, and certainly better than with any speed
control. If you make a change to the engine that increases its performance it will reach a higher
RPM at the same throttle setting. If the engine has a problem it will not reach the expected
RPM and you can see immediately that there is something wrong. Note that Speed Controls,
besides being erratic and un-natural, will run an engine to destruction, while trying to hold a set
RPM. You may not detect something is wrong until too late (and expensive to fix).
The ADL Control Includes is an available RPM HOLD Mode. It is a simple speed control that is
intended for engine/injection mapping and will hold any set RPM from 1,000 to 12,000 RPM in
precise 100 RPM increments.
An added feature aids in warming up the engine. In this Warmup Mode the load is cycled to
vary the Load and RPM in a continuous loop. You should never let the engine run at a steady
speed for warm-up or break-in because of possible destructive torsional resonances.
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DEPAC ADL Load Control Panel
X
H
Explanation of ADL Controls
Z
Y
A
C
E
F
B
G
D
A - Main Power ON/OFF. Turn to activate system. PUSH to turn OFF. If engine is running the ADL will flood the water
brake and Shut-off the ignition/fuel (using the external Cut-off relay). After the engine has stopped the ADL will close the
valve and turn itself OFF. This Emergency STOP Function is a Fast and Safe way to stop a running engine.
B - The Main Set LOAD Control. In the AUTO Mode this control changes the virtual engine Load. In the MANUAL Mode
this directly turns the remote valve. The Scale or Range of this control is Set with the (SET %Full LOAD) Pot (Y).
C - The RPM Set Pot. Adjustable from 1000 to 12000 RPM in precise 100 RPM Steps, indicated by the RPM Display.
AUTO Sweep Mode: - You can set a Limit on the RPM Sweep, Hi or Lo, after which the Sweep stops.
Speed HOLD Mode: - Sets the RPM at which the ADL system will constantly hold, for engine mapping.
WARM-UP Mode: - This sets the Low Limit of the warm-up sweep (if used).
D - The Set Sweep RATE control. Turning this will change the Rate of LOAD sweeps in all Modes. Pot (Z) sets the
Scale for this control which can range from seconds to several minutes. Load Sweeps are infinitely variable.
E - Warm-Up Switch. After setting the throttle and LOAD (B) for a Start RPM and an End RPM (C) this switch will cause
the ADL to continuously sweep between Start to End RPM until shut off. RATE (D) controls how fast the sweep rate.
F - Valve MODE Switch. Most all applications this will be in the AUTO/Stable position.
MANUAL/Direct: - (as shown) Will cause LOAD (B) to directly open and close the valve. Scale set by Pot (Y).
AUTO/Stable: - Puts the ADL Control system in its Full Automatic Mode to provide a Stable engine Load.
G - Sweep Toggle. When the remote Test Switch is pushed, this toggle will determine which direction the LOAD will
Sweep. There is No Sweep in the HOLD/STOP middle position. During a Sweep you can turn this toggle to any position
to command any combination of UP, Down, or Stop Loads.
X - Push Button to Display the Settings of the (SET % Full LOAD) (Y) and (SET Max Rate) (Z) Pots. Record for future.
H - LED Indicators: LOAD (left display) Always indicates the % Open of the Valve (Actual or Virtual).
RPM - Always indicates the Setting of the RPM Control X100. Special symbols are used for 100, 110, and 120.
LED 1 - RED Indicates when an RPM Limit has been exceed and the LOAD is now Stopped.
LED 2 - Orange (Future Use)
LED T - GREEN Indicates when the Remote Test Switch in ON or Pushed (closed).
LED S - YELLOW Indicates system is in the Speed HOLD Mode (Set by turning the LOAD (B) to 0% Closed).
LED 4 - GREEN Indicates when the Engine Speed is close or Locked at the Speed HOLD RPM.
[email protected]
(315) 339 -1265
www.depac.com
READ ME FIRST: Bench Test the ADL-SF System.
Exercise 00:
Bench system function test.
There are 3 main parts to the ADL Control system, the Universal Control Console,
the SF Outlet flow control valve, and the black power-driver module. Place these
components on an open bench.

Place the Valve on a bench or table.

Place the Power Module and the Control box nearby (do not remove the
protective strips on the Velcro). Put the long remote extension cable aside for the
moment.

Turn the large LOAD Knob to 50% and the Mode Switch to AUTO-Stable.

Plug in all the cables and attach the AC power cord and connect to AC Power.
(verify the 110 or 220 VAC setting).

The Green power LED should come on. This is the standby low power mode.

Turn the Emergency STOP button CW so it pops up and turns the system ON.

Note the Orange Power-ON LED and you will hear the sound of a small internal
cooling fan.

The two LED numeric digit displays will light and start a system ON self check.

The Valve will start to Close and then move to full Open as the system seeks its
full Open reference position, set by an imbedded magnetic sensor.

Turn the RPM Knob and see the right digit display change and show RPM x 100.

Turn the LOAD knob and see that the left digit changes from 00 to less than 99.
The valve stays closed all this time. Turn the LOAD to 50% on the Load scale
printed on the control box panel.

Turn the Mode Switch from AUTO to MANUAL-Direct and observe the valve pop
open to a % Open setting displayed on the left digit display. 00% is fully closed
and 99% is full open.

Turn the LOAD knob and now see the direct valve movement. You will not use
this mode for normal dyno testing. Its provided for whenever you need to actuate
the valve manually (like for the function demonstration right now).

Continue Next Page……
4

Turn the LOAD Knob to 100% and observe that the LOAD digit display may only
show 49%, for example. Latter we will show you how to set this LOAD Scale for
your dyno and for a wide range of engines.

Now flip the MODE switch back to AUTO-Stable. Check that the valve Opens
smoothly. In this AUTO Mode the Valve remains Open (No Load Restriction) until
your engine is running and needs more load (and the outlet flow restricted).

Switch the Mode back to MANUAL-DIRECT and see the valve jump close some,
depending on the LOAD dial. Turn the LOAD dial to 50% as see the valve move.

Use a screw driver to turn the Set % Full Load Pot (above the RPM Knob). You
will see the valve move in 1% steps to open or close. We will latter use this Set %
Full Load pot to scale the ADL system to your engine, dyno, and water system.
Set this back to near where it was to start.

Push the SET ALT button and see 2 different numbers appear on the digit
displays. These are the current settings for the Set % Full Load Pot and the Set
Max Rate Pot at the upper left. These 2 settings determine the LOAD Scale and
the Rate of LOAD change (that we will see latter). For testing you will record
these numbers so you can return to a past setup.

Turn ON the WARM-UP switch and see the Red LED come on. The Valve does
not move.

Turn the WARM-UP Switch Off. (NOTE: This mode works only when the engine is
running. See Exercise 6 latter).

Push the Emergency STOP button and see the valve fully Open and the system
turn OFF.

Unplug the small control console cable from the Power module. Add the long
extension cable to the ADL Control system. We will now test this cable extension
for proper function.

Turn the power back on and make sure the system still performs all the functions
tested above (also a good quick review).

Turn OFF the system as before by pushing in the Emergency STOP button.

Note that the Orange LED on the power box goes off while the Green LED is still
ON. The Green LED indicates the system is in low powered Standby mode.

Bench test is done. Remove the Power cord first and then both cables.
5
ADL Control System Installation:
Before Any installation:
SuperFlow®
See Exercise 00 to bench test system.
Note: you do Not Need any special fine suction filter, as was required for the old SF valve.
The ADL Precision outlet valve does not jamb and you can just use a coarse screen filter.
Existing Dyno Installation: The ADL Control system uses the existing SF suction (boost)
pump, sump tank, and your existing plumbing to supply and drain water. Also you can get
rid of that restrictive inlet filter. Simply remove the existing SF Outlet valve and install the
SF-ADL valve. It will work with both two and four bolt patterns. We supply stainless
threaded rod and hardware to complete the change over. The SF ADL valve is longer and
has a more straight-through flow design and is much finer and precise. Add your existing
outlet flange to hose adapter and a short section of hose to minimize water splashing in
the drain tank.
Avoid recalculating the hot outlet water back to the supply tank if it will significantly raise
the temperature of the inlet water (which should always be as cool as possible). Possibly
return the hot drain water to a holding tank where it can be cooled before returning to the
main water supply tank
Mount the Power/Driver Module: The Valve actuator cable (8') plugs into the PowerDriver module. The Power Module needs to be located far from any radiant heat sources,
like the exhaust and cooling system. It needs to be in the open where cool moving room
air will flow over it. Mount it on a wall or other vibration free support. Do NOT mount on the
Dyno frame because of the destructive vibration and proximity of heat. Use 8-32 or the
screws provided. Plug in the power cord securely to the Power Module.
Mount the Operator Control Console: There are two recommended ways to mount the
operator panel. Use the Velcro strips or sink into a panel cutout. Use the Velcro strips for a
possible initial location, which should be easily accessible while running the tests. When
you have selected a good location you can carefully make a 5 ½" by 8" cutout so that the
panel will drop in snuggly up to its top flange. The Box is slightly tapered and the aim is to
have a snug fit but still be able to pull up and out for service and re-programming. Drilling
holes and using silly-cone is verboten
Optional Ignition Cut-Off Relay: The ADL Control panel has a pair of wires for an
external relay that you can use as an ignition cutoff for either magneto (close circuit) or
conventional ignitions (open circuit). It is connected to the panel's Emergency STOP
button. Hitting this Button, when the engine is running, also commands the Load Valve to
flood the dyno. When the engine is stopped it closes the valve and shuts itself off.
Flooding the dyno alone is not enough to stall an engine, but the combination of quick
dyno flooding and ignition cutoff stops the engine the quickest, when you really need to.
Connect the relay to 12 Volt battery power and the relay contacts as needed for your
ignition. Avoid mounting on the vibrating dyno frame. The relay is Energized when the ADL
system is turned ON. This then enables the Ignition (and fuel pump). Using this Cut-Off
relay the ADL System needs to be turned on Before you can start the engine.
6
DEPAC Dyno Systems 201 Mill St. Rome NY 13440 (315) 339-1265
[email protected]
www.depac.com
ADL - SF Outlet Valve Assembly:
Installation
The DEPAC ADL Valve for the SuperFlow dyno is a specially designed butterfly
valve that has a straight through flow design and not affected by dirt (although
its never good to have any abrasives wearing out the insides of your dyno). The
valve attaches the same way as the original valve although it is longer. We
supply (2) 6” long ¼” x 20 cap bolts and spacers. Note that the holes tapped into
the SF brake are blind and bolts can bottom out. Note that SuperFlow made
their new dyno with a 4 bolt pattern using ¼” x 28 threads. Our valve works with
either old or new brakes.
You can use the existing outlet hose adapter although you may need to countersink the flange to allow the cap screws to grip the housing at 3/8” to ½”. The
outlet water streams out straight down at high velocity and may cause water to
splash over the sump. You may need a cover to contain this splash.
The SuperFlow suction filter does not need to be used because the new valve is
much less sensitive to dirt. If you have a water supply that may have abrasive
dirt then use an appropriate water filter in your pressure supply to the holding
tank. Always a good idea to use clean water and no dirt.
8
DEPAC Dyno Systems 201 Mill St. Rome NY 13440 (315) 339 -1265
[email protected]
www.depac.com
Installing the Universal ADL Operator Control Panel:
This Same Panel is used for all different dynos to provide a consistent
universal operator interface. This provides a consistent, universal, interface so
that you can easily operate different ADL equipped dynos, once you have
learned to use on another dyno.
The control panel has Velcro strips attached to the bottom. Use this first to place
the box onto your control panel where you can easily get at the manual controls.
Move the box around your console until you locate a sweet spot and then remove
the protective strips and push down hard on the flat surface. Latter, if you like,
you can carefully cut out a 5 ½" by 8" opening so that the panel can sink up to its
top cover flange for a near Flush mount. The sides of the box are slightly tapered
and if you get the opening just right it will lock in snuggly but still can be lifted out
easily if needed, like to return to DEPAC for updated programming. (PLEASE, do
not use any screws or silly-cone). Let gravity, and a snug fit, do the work.
There are several cables that exit the box. All have connectors for easy removal
of the box.
The 1st cable goes out to the Power Module, mounted near the valve. We
include a 45 foot extension cable. Route this cable out of harm's way.
A 2nd cable has connections for the Tach signal input and the Test Switch. If you
have a DEPAC system, we supply the ends so that you can Tap into the existing
Tach input and Remote test Switch plug. This cable will be bare wires if you do
not have a DEPAC instrumentation system. (2 pair for Tach input & Test Switch).
A 3rd cable (2 wire with connector) can be used with a remote ignition cut-out
relay. This works in conjunction with the Red Emergency STOP switch.
Emergency Stop will flood the dyno and kill the ignition. This relay can also be
used to cutoff any electric fuel pumps. When the engine has stopped turning, the
ADL system will close the valve and automatically power down.
9
[email protected]
(315) 339 -1265
www.depac.com
Power Connections, and Inputs to the ADL Control System:
AC Power Input: The Main AC power can be either 90-130 V AC or 190-264 VAC at 50-60
Hz. We set this at the factory and mark the product label.
The AC Power is connected at all times in Standby and consumes less than a watt. The
Green LED indicates standby power is ON. The operator control panel commands the main
power-up/down as needed. When the ADL System is active the Orange LED will be ON.
Connections to the ADL Control System: There are three main Inputs and one Output
1.
Operator Test Switch is a Push to Close switch, when closed, will command the ADL to
Sweep UP/DWN if the sweep mode switch is set. It's only active in the AUTO/Stable Mode.
If you have a DEPAC System we provide a cable tap into the existing remote test switch
used by this Physics based instrumentation. Otherwise we provide a loose pair of wires to
an isolated switch. These wires are polarized and refer to the wiring diagram.
2.
Dyno RPM: The ADL uses the existing SuperFlow 60 pulse per revolution magnetic
sensor signal. We provide an interface cable that taps into the existing TACH Input on the
back of the Blue Box of the DEPAC system. Note: The ADL is not compatible with existing
SuperFlow controls and instrumentation but works exceptional well with a complete DEPAC
Package.
3.
Output to an Ignition Cut-Off relay: We provide a 12Volt DPDT relay for you to mount
in your console. Pair of wires from the Control box is used to activate this relay using your
12V battery voltage. You can also use this hookup to turn-off you fuel pumps for a complete
emergency shutdown capability.
Connecting Cables: The Outlet Control Valve has a heavy 8 foot cable that plugs into the
Main Power Module. The Control Console has a smaller cable that also plugs into this
Remote Module and we provide a 45 foot cable extension if needed.
Mounting the ADL Control box: The control box comes with 2 strips of Velcro on the
bottom along with 2 adhesive protective strips. First position the box as received in an easy to
operate location. When you have a good operating position remove the protective strips and
push the unit onto your panel solidly. Now its fixed but still can be easily removed by peeling it
off the Velcro. Latter you can make a 5 ½" by 8" cutout in your panel so that the console can
drop-in snuggly up to its top flange. The unit is nearly flush and uses gravity to hold in place.
Done carefully it is snug but still can be pulled out (for re-programming by DEPAC). Please do
Not drill holes, use screws, or silly-cone on this box (This will reduce the value of the unit).
10
DEPAC Dyno Systems
201 Mill St. Rome NY 13440
[email protected] www.depac.com
(315) 339 -1265
START #1: AFTER INSTALLATION – – – SuperFlow Dyno

Check all cables and connections. Check that Valve is sealed and the ¼” draw
bolts are torqued and free from obstructions.

Apply main AC power to the Power module. See the green LED come on.

Turn on the ADL power from the control Panel. See the Orange LED come on and
note the sound of an internal cooling fan turn running inside the power module.

Switch to MANUAL Mode. Turn the LOAD knob to see the valve follow your
moves. Manual Mode is a direct connection to the valve (no auto features).

Turn the LOAD Knob to Closed or 0%. The Yellow LED should be ON.
(Note: The SF outlet Valve is really now Full Open).

Switch to the AUTO Mode. The valve should now be full OPEN for any LOAD.

Turn the LOAD knob open to about 20% (make sure the Yellow LED is Off).

Start your engine.

Pick up the throttle a little and you will notice the outlet valve start to CLOSE
some. (On a cold motor only apply part throttle and keep the RPMs low).

At part throttle start to increase the LOAD control and see the ADL control pull
down the RPM. Turn the LOAD knob to change the RPM and see that it is steady.
Add more throttle to pick up the RPM a bit.

You can add more part throttle and LOAD to hold any RPM for warm-up. RPM
should be steady and the engine will not tend to ‘take off’ or be pulled down and
stall.

By now you will see how easy it is to Control your Engine with the ADL Control’s
Smart AUTO load Mode.

If the engine oil is warm you can now add more Load and more throttle and see
that you can set the RPM anywhere you want with good control.

OPTION: Jump to Exercise #6 to learn how to use the WARM-UP Mode.

Proceed with Exercise #1 to SET the LOAD Range for your engine.
12
DEPAC Dyno Systems
START #2:

(315) 339 -1265
Getting more familiar with the SF-ADL Control system.
Check again that the T-Handle Valve is set for the power and speed range of
your engine.
The T-Handle restricts flow from the internal booster pump into the dyno
vortex cups. It sets the flow to carry heat energy absorbed from the engine.
Try to keep the dyno outlet water temperature between 110 and 125 Deg F.

Turn the ADL system back ON and observe the normal startup sequence.

Switch to the AUTO Mode. The valve should now be Open for any LOAD.

Turn the LOAD knob open to about 20% (make sure the Yellow LED is Off).

Start your engine and warm up.

Pick up the throttle a little and you will notice the outlet valve start to Close
some. (On a cold motor only apply part throttle and keep the speeds down).

At part throttle start to increase the LOAD knob and see the ADL apply some
Load and pull down the RPM some. Turn the LOAD knob to change the RPM
and see that it is steady. Add more throttle to pick up the RPM a bit and get a
feel for the engine load by turning the LOAD knob a little.

You can add more part throttle and LOAD to hold any RPM for warm-up.
RPM should be steady and the engine will not tend to ‘take off’ or be pulled
down and stall.

By now you will see how easy it is to Control your Engine with the ADL
Control’s Smart AUTO load Mode. (Trying the Direct Mode will not be as
stable as in the AUTO-Stable Mode).

If the engine is warm you can now add more LOAD and more throttle and see
that you can set the RPM anywhere you want with good smooth control.

OPTION: Jump to Exercise #6 to learn how to use the WARM-UP Mode.

Proceed with Exercise #1 to SET the LOAD Range for your engine.
13
Exercise 1: Setting the LOAD RANGE of the ADL-SF Control System.
Purpose: Adjust the ADL Control to work with your Engine on the SuperFlow Brake.
This will result in a good range of control using the LOAD % Knob. Changing the ‘T’
Handle adjustment has the same affect as changing the Set % Full LOAD Scale.
Summary: The ADL-SF System can work with a very wide range of engines up to the
TP limit of the SF Brake. The FIRST Step is to SET the SuperFlow ‘T’ Handle Valve
to the BHP range of your test engine. This sets the Water flow rate to match the
power absorbed and so keeps the internal water temperature in range and Not Too Hot.
More power requires more water flow. 2nd Step is to adjust the Load range control (Set
% Full Load) for the engine being tested so that the LOAD Knob is near 50% to provide
a good adjustment range Up/Down. Once a setting is found then you can record the Set
% LOAD number for future reference and always return to the exact same setting.
Always record the setting of the ‘T’ handle (fraction + turns from closed). It's easy to
estimate an initial Load RPM just by turning the LOAD knob. Remember, the Engine
determines the RPM it climbs at the set Load and therefore very easy to see if the
engine is OK. Engine also sets it’s own Acceleration Rate as the ADL sweeps the load.
Set the Mode switch to AUTO-Stable. Turn ON the ADL system and see that the selfON-test is completed. The valve should move a little to Close and then it seeks its full
Open position and stay open (minimal load). If you have the Manual Mode set then the
valve will jump to whatever the setting of the LOAD % Knob.
Turn ON the water pump/supply to fill the SF sump tank. Suction Filter is Not Needed.
Start with a fully warmed up engine. You should know approximately the Torque
Peak RPM You will need a flat blade screw driver to adjust ‘SET % Full Load’ pot.
1. The ‘T’ handle Valve MUST be SET (and may require trial & error)
2. Turn the LOAD knob to 50%, pointer straight UP.
3. Make sure the suction sump is primed and sump-fill pump is ON.
4. Slowly pick up the throttle and as the RPM climbs to about Torque Peak,
5. Adjust the SET % Full Load pot with screwdriver so at full throttle you have
about Peak Torque RPM.
Screwdriver is no longer needed.
Note: Changing the T-Handle setting has a similar effect.
6. Return throttle to idle and then pickup full throttle again and see if the engine
Holds smoothly at the same RPM. It should if the engine is running right.
You have just scaled the ADL system to your engine and ‘T’ valve setting. Push the
SET ALT button and record the Number in the left LED window. When you were doing
Step 5 you noticed that the engine speed stepped as you slowly turned the ‘Set % Full
Load’ pot. The adjustment jumps in 1% steps, like going from 34% to 35%, so you can
always return to the exact same setting in the future. Also record the ‘T’ valve setting.
This setting will work with all engines with similar RPM/Torque. If you want to test a
much larger or smaller engine then you may need to re-set the % Scale and ‘T’ valve.
Now the LOAD knob position is very similar to an analog RPM Tach indicator. The
advantage to setting the Set % Full LOAD Scale this way is that you have a Similar
range/setting of LOAD Knob adjustment for your smallest to largest engines.
14
DEPAC Dyno Systems
[email protected]
www.depac.com
(315) 339 -1265
Exercise 2: Use the MANUAL (or DIRECT) SF Valve Mode:
Purpose: To show that while in the MANUAL, or Direct Valve Mode, the LOAD
knob is a Direct connection to the Outlet valve. It has NO Auto-Stability but It is
sometimes useful to test the valve movement or operate SF-dyno pure manually.
Note: When the LOAD Knob is turned to CLOSE (0%) the Outlet valve is Fully OPEN
to allow water out and provide minimum brake Load. Turning the LOAD knob CCW
will move the outlet valve to close and restrict water flow.
The marking on the panel CLOSE (0%) Actually means No-Load for SF dyno.
Note: The Actual Valve closing depends on the Load Range set in lesson 1. The
Actual Valve Closing will usually be much less than the LOAD Knob % Setting. This
Ratio or Course Scale is adjusted by the SET % Full Open Pot.
Turning the LOAD Knob to Full Open (100%) will normally CLOSE the actual valve to
less than 50% Closed or about 45 degrees open for this special butterfly valve.
Exercise: The Engine and Water pump is OFF, The ADL System is ON.
1.
2.
3.
4.
Flip the Mode Switch to MANUAL
The Valve will jump to a position set by the current LOAD Knob %.
Turn the LOAD knob to lower % and check that the valve is Opening.
Turn the LOAD Knob to 100% and see the Valve move more to close, which
will generally be less than half closed, set by Lesson 1 range setup.
5. Turn the LOAD Knob quickly and see how fast the valve can follow your
movements. The valve will respond very directly to your inputs.
6. Switch back to AUTO Mode and see the valve immediately Open and remain
open no matter the setting of the LOAD Knob (leave in AUTO Mode for tests).
You can Run your dyno in the Fully MANUAL Mode but it would offer no real
advantage over the much better Stable operation in the AUTO position. Also
Load Sweeps are only made in the Auto/Stable mode.
Note that the ADL does not control RPM or RPM/Sec like ordinary dyno controls
based on Speed control loops. The ADL is a stabilizing Load Control and works
much better than any speed control (more smooth and natural, like it should be).
NOW the engine determines its own speed and RPM/sec rate with the ADL
controlling the Load and Load sweep. If the engine wants to run better it will
naturally stabilize at a higher speed and sweep faster, since the ADL Control
allows the engine to run the way it wants, better or worst. (as it should be done).
15
DEPAC Dyno Systems
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201 Mill St. Rome NY 13440 (315) 339 -1265
www.depac.com
Exercise 3: Sweep Tests by Turning the LOAD Control knob
SuperFlow Dyno
The ADL Control System should be Ranged to LOAD your engine in Lesson 1.
Purpose: To demonstrate that the LOAD Knob can smoothly control Engine
RPM over a very wide range. This also demonstrates the Stability and easy use
of the ADL system in the AUTO/Stable mode doing an ADL 'manual sweep'. Also
use the LOAD knob to ‘feel’ the engine's torque curve.
Start warmed-up engine and have SF brake/pumps ready to Load engine
1. Set the LOAD knob to an approximate Starting % or estimated Load RPM.
2. Set the UP-Stop-DWN switch to the Stop-HOLD position. (No sweep).
3. Smoothly add throttle to full and see where the RPM holds.
4. Make any LOAD adjustments to set your desired RPM. (Note LOAD dial %).
5. If you are recording this test, Hold the test Switch ON. (No Load Sweep).
6. Now Slowly and Smoothly turn the LOAD Knob to raise, or lower, the RPM.
7. When test sweep is done release the test Switch and bring throttle to idle.
8. Repeat the above with different Start and End LOAD points, Up or Down.
This is not the recommended method of sweep testing because the operator can
never turn the LOAD Knob the same each time. The ADL Controlled AUTO
Sweep is Very consistent and repeatable, with an enhanced ‘feel’ for the engine.
See Next Exercise 4 for the Recommended Sweep Mode:
Use the UP - Stop - DWN Switch to have the internal process control change the
LOAD at a very smooth and repeatable Rate. (Set by the RATE knob).
The UP - Stop - DWN Switch works with an external push to close TEST switch
to Command the sweep. This uses the same Push-to-Test switch for by the
DEPAC instrumentation system.
16
DEPAC Dyno Systems
201 Mill St. Rome NY 13440 (315) 339 -1265
Exercise 4: Automatic LOAD Sweeps with a Remote Test Switch.
ADL System should be ranged to your engine in Exercise 1.
Purpose: To demonstrate the Auto Sweep Mode using the UP-Stop-DOWN
toggle. A remote test switch commands a Load Sweep at a Rate set by the
RATE Control. If the Auto Sweep is in the HOLD position the LOAD will not
change when you push the Remote Test Switch (use for a Static Pull).
Start and warm-up the engine. You can use the LOAD knob and Throttle to put a
partial load on the engine. Use either the LOAD Knob or throttle to change RPM.
(Also see WARM-UP Mode exercise #6).
1. Push your remote test switch to Check if the Green (T) LED comes on.
2. Set the LOAD Knob to an approximate Starting % dial or estimated RPM.
3. Set the Load Sweep toggle to either the UP or DWN position.
4. Set the RPM knob to its lowest point 1000 RPM. (See Note below)
5. Smoothly add Full throttle and the engine will come up and Hold an RPM.
6. Make any LOAD adjustments to set your desired RPM. (Note LOAD dial %).
7. Close the TEST Switch and the Load starts to sweep either UP or DOWN.
8. During the Sweep you can change the UP-Stop-DOWN Switch at any time.
9. Release the Test Switch anytime to end sweep. Load returns back to Start.
10. Now You can pull back the throttle to idle.
NOTE: Setting the RPM Control Knob. You can use the RPM Knob to Set an
End Point. The sweep will automatically stop after Exceeding the Set RPM Limit.
Example: Start an UP Sweep at 4000 RPM and set the RPM control to 7000
RPM (70 displayed). As the engine sweeps past 7000 RPM the LOAD Sweep
Stops and holds the LOAD just above 7000 (#1 Red LED comes ON). It will hold
here as long as you want. Release the Test Switch and the LOAD returns back to
the start point of 4000 RPM.
If you do not want to use the RPM Limit feature, just set the RPM outside the
expected speed range and you then control the end of sweep point with the Test
Switch. Also if you set the RPM Control to a low value, the limit is also ignored.
NOTE: Changing Sweep Direction during a TEST Sweep. During a test
sweep the UP-Stop-DWN Toggle can be changed anytime for any combination
of sweeps or Steady states, while the Remote test switch is closed. Releasing
the Test Switch will always return the Load to the Start point.
17
Exercise 5:
Setting the Range of the Load Sweep RATE Control.
Purpose: To range the ADL RATE Control to Sweep the LOAD to the testing
needs of your engine. Set a mid-position of the RATE control Knob so you can
latter adjust up or down as needed. You can change the RATE during a sweep.
Summary: The ADL System can work with a very wide range Sweeps ranging form
seconds to several minutes. You need to adjust the Set MAX Rate Trim Pot to match
your sweep requirements. The ADL System sweeps the LOAD with stability and you
will see a natural and smooth RPM sweep of the engine. You cannot set an RPM/Sec
rate as you can with conventional dynos but the ADL Load RATE control is infinitely
variable and can be changed during the sweep. Sweeps can be closely fine-tuned.
The Sweep UP-STOP-DWN Toggle is used in conjunction with a Remote Test
Switch. If you have the Toggle in the STOP/Hold position and you push the Test
Switch the ADL system will Hold the engine at the same steady RPM. If you have the
Toggle in either UP or DWN, and you push the Test Switch, the ADL will start to
sweep at a smooth LOAD change Set by the RATE Knob.
Complete Exercise 1 to Scale the LOAD range to your engine and dyno.
Have your engine warmed-up and ready for a test sweep. The ADL system and
pumps should be ON. Have a flat blade screw driver ready for adjustment. You
should have a remote Sweep Test pushbutton, preferably on your throttle. The Test
Switch will Command the LOAD to sweep UP, DWN, or Hold Steady LOAD
1. Set the RATE Knob to 5 on the scale. (A mid-point for latter fine adjustments)
2. Set a Starting LOAD, for an approximate starting RPM. (see exercise #1)
3. Make sure that the RPM control is set either below your start RPM or above your
expected end RPM point. (RPM is on the Right LED display).
4. Switch the Sweep Mode Toggle to UP.
5. Pick-up the throttle to full and adjusting the LOAD knob as needed to Start RPM.
6. Hold the Sweep Test button down and the LOAD will start to Sweep smoothly UP
(set in #4). Observe the Rate of change of the Engine RPM.
7. Use the screwdriver to adjust the Set MAX Rate Pot to increase or decrease the
sweep rate you want. This will set a Middle point for the RATE Knob.
8. Release the Test Button to end the sweep. This will cause the Engine RPM to
jump quickly back to the Start LOAD point. Pull back the throttle to idle.
You have just scaled the Load Change RATE Knob to your testing needs either a fast
sweep for a drag race engine or a slower sweep for a circle track race engine.
Set MAX Rate even slower for Marine and Diesel engines. Rate can range can be
from 10 minutes down to seconds (non-linear adjustment).
The LOAD sweeps are natural and will Smoothly speed up when coming up on the
cam. If you want, you can turn the RATE Knob down to slow the rate when coming up
on the cam and increase the sweep rate at the top end. If everything is working right
with your whole test the sweep rate should be smooth and natural.
18
DEPAC Dyno Systems
201 Mill St. Rome NY 13440 (315) 339 -1265
Exercise 6:
Warming up the Engine:
WARM-UP Mode. Break-In Mode.
NOTE: Engine dynos always have torsional resonances at Unkown RPMs.
Every engine dyno will have different dyno resonant Speeds, with can be
destructive. Holding the engine at a resonant RPM could cause very high +/torque stress and can eventually lead to catastrophic failure over time (fatigue
damage). Broken driveshafts are a very common result of this fatigue stress.
These destructive oscillations have nothing to do with dyno load, and can occur
with No Brake Load applied. With heavy flywheels you can have engine damage.
The Only defense from damage with torsional resonance is to constantly change the
RPM, so as to avoid long exposures at these destructive resonant RPMs.
Purpose: To use the ADL to help warm the engine up to operating temperature
without the dangers of damage from torsional resonant stresses. To apply a Load
to the engine, at part throttle, at a low warm-up or break-in RPM. The constant
changing of engine Speed will greatly reduce any long-term fatigue damage from
any destructive torsional resonance’s on driveshafts and engine internals.
Auto Warm-up (or Break-in) Mode
1. Add part throttle and set LOAD knob to a Warm-up (break-in) Start RPM.
2. Turn the RPM Knob to a lower speed you want as a lower End RPM.
3. Turn ON the Warm-Up Switch and the ADL will start quickly sweeping down to
the RPM End point, and then back up to the Start point, continuously. Turn the
RATE Knob to change how quickly the engine sweeps up and down.
4. Switch OFF when done and the RPM will return to the start point set in #1.
5. You can either pull the throttle back to idle or proceed to do a test sweep.
Note: You can hold down the DEPAC test switch to have a test average record of
the warm-up (break-in) process. Also you can watch the record pattern of Machine
Gun dots on the DEPAC LINK3 grafplot screen.
After you Start the WARM-UP Mode the Upper Start RPM is Locked in, but you
can re-adjust the LOAD setting and the Lower RPM setting. Also you can change
warm-up sweep rate using the RATE Knob.
NOTE: When you first turn on the WARM-UP Mode the ADL will Ignore any RPM
knob setting that happens to be set Above your Start RPM point (Step #1). It will
then automatically Set a lower Default RPM sweep limit that's ½ the Start RPM.
19
Exercise 7:
Using the Speed HOLD (Mapping) Mode
Purpose: The Speed HOLD Mode is intended for mapping an electronic
engine management system. It is a very simple speed control that constantly
adjusts the LOAD to Hold a set RPM. When you change the throttle, mixture, or
ignition, the system will slowly adjust the Load to return any changed RPM back
to the precise set-point. You can set a Speed Hold Speed in precise 100 RPM
increments from 1,000 RPM to 12,000 RPM. Use ONLY for Mapping.
Operation: The Speed HOLD Mode must be locked, or initialized, before it can
function in the Speed Hold mode. The right LED display shows the current
setting (x100 RPM) and is controlled by the RPM Knob. Best to set a low RPM
set-point to initialize this Mode. The valve starts closed and will remain closed as
long as the engine speed is less than the set-point. You need to add enough
throttle so the RPM is above the set-point to initialize. Then the system will detect
a speed error and start to open the valve to compensate. It may take several
seconds for the system to take control of the engine and bring the RPM down
and hold it at the Initial set-point RPM. Watch the LOAD Number in the left LED
display change as the ADL Control changes in response to the speed error.
Caution: The ADL Speed Hold mode MUST be First slowly INITIALIZED.
Note: Open the throttle slowly when initializing the Hold Mode .
The Valve is Closed Until the engine speed exceeds the Set RPM.
1. Set the LOAD Knob to Zero. The yellow #3 LED indicates the Hold Mode ON.
2. Set the RPM Knob to a Low to Mid Start Speed.
3. Slowly add throttle to about 500 RPM above your Set Start RPM and wait.
4. You will see the left Load Digit display start to increase as the valve opens.
5. After a few seconds the ADL pulls the Speed Down to your Selected Start
RPM point. The #4 Green LED will flicker on/off when the Engine Speed is
within 10 RPM of the Start/Set-point. The Load number digit is now steady.
6. The Speed HOLD Mode is Now Initialized and the ADL will hold RPM.
7. Now make small step Changes like bump the throttle, or change the mixture
or timing. After a few seconds the ADL system should lock back to set RPM.
8. You can now change the RPM Knob to set other Speeds in 100 RPM steps.
9. Make changes in steps and then wait till the ADL is back on Lock. -- Repeat.
10. You can also begin a Standard Load Sweep test at any time (UP-Stop-DWN).
11. When done just slowly pull back the throttle. The valve will close.
12. You can also cancel the Speed HOLD-Mode by turning the LOAD knob
Open until it over-rides the control of the Valve and pulls the motor down. The
Yellow LED turns Off and you now have complete control with the LOAD Dial.
Any Flicker of the #4 Green LED indicates how smooth the engine is running.
After the system is Locked onto the Hold-point speed you can then make any
reasonable changes you want and the Speed Hold Mode will automatically
change the LOAD to hold the set RPM. Make any changes in steps and then wait
a few seconds for the system to respond. You can make a Torque Sweep, or a
Static test, at any time and the system will respond to the UP-STOP-DWN
switch. Each sweep will be a Smart Load Control Mode sweep and when
completed the system will revert back to the Start RPM in Speed Hold Mode.
20
DEPAC Dyno Systems 201 Mill St. Rome NY 13440 (315) 339 –1265
[email protected]
www.depac.com
Exercise 8: DEPAC Inertia Correction Factor -- Making Torque Loops.
Purpose: Use the LOAD Knob to rapidly cycle the Torque Load to create Loops of DEPAC
Machine Gun (MGun) Dots used to set the Inertia correction. This uses a unique Advanced
feature of DEPAC LINK version 3 system to set the inertia correction after the tests.
DEPAC Version 3 system can record and playback Torque vs. RPM MGun Dots used to test
and set the DEPAC Inertia Correction Factor. The engine is loaded at full throttle at the RPM
you want to test the inertia. (Note: On some dynos like the Stuska® the Internal brake inertia
can change with the amount of water inside the brake). The Load is then quickly changed up
and down to create a high +/- RPM/second sweep around the Steady Load point. With No
inertia correction the Torque MGun dots will plot in a counter-clockwise loop. The goal is to
have a large vertical loop pattern of dots so that when entering an Inertia correction number
the sweep Up & Down dot Loops will be on the same curve, thus canceling the inertia error.
1.
2.
3.
4.
5.
6.
7.
8.
1.
2.
3.
4.
5.
6.
Make the Loop Test: We assume you have a DEPAC version3 system.
The engine is warmed and ready to test.
Go to the GrafPlot screen to view the Machine Gun (MGun) Torque dots.
Set the UP/DWN switch to HOLD/Stop.
Start with the DEPAC Inertia Setting of Zero to enhance the Torque Looping action.
Set a LOAD so the engine throttles up a Speed between peak torque and peak power.
Push the DEPAC Test Switch to record the MGun Dot loops.
Roll the LOAD Knob Up and Down to make these torque loops. Only sweep 1000 RPM
(or less) and try to get a Large change in +/- RPM/Sec to get large vertical torque loops.
Release the Test Switch and throttle back and stop the engine.
Set the Inertia Correction: Use Vers3 to playback the test on the GRAF-Plot screen.
Use the Insert Key to Playback the MGun dots on the Graph Screen.
Use the Letter (I) key to pop-up the Inertia Set menu.
Enter an estimated Inertia Correction Number (Like 0.10).
Replay the MGun dots and observe any reduced size of the inertia error loops.
Hit the F8 key (twice) to clear the old MGun dots and redraw the GrafPlot screen.
Find a number that eliminates any looping (with the Red and white Dots are mixed evenly).
Note: An Over correction will cause the Dot loops to rotate clock-wise with the Red Dots Below
the White Dots. An Under Correction will loop the Red Dots ABOVE the white dots.
Note: The remaining pattern of MGun dots represent the engine's torque scatter.
Note: To Re-Draw the Screen and erase the MGun dots by hit the F8 key twice.
Note: Use the Space-Bar to turn ON-OFF test run Data Curves and MGun dots.
21
DEPAC Dyno Systems
201 Mill St. Rome NY 13440 (315) 339 -1265
Exercise 9:
The Emergency Shut-Down Feature:
Also for a Clean Cut for a plug check:
The RED turn Power ON and OFF button will function as an Emergency Stop, if
you use the external ignition (and/or Fuel Pump) relay. If you use this relay the
ADL system needs to be ON before you can turn On the Ignition (or fuel pumps).
When you turn OFF the ADL system by pushing the Emergency Stop button,
and the engine is not running, the system just turns itself Off. If the Engine is
Running and you hit this Button the Valve opens and floods the dyno and the
external relay kills the ignition (and fuel pump). The engine should stop very
quickly. When the system sees that the engine is stopped it will then close the
valve and then turn itself Off.
You should have the External Relay wired to cut the ignition and/or fuel pumps.
1. Start the engine.
2. Pickup the throttle a little and apply a little load.
3. Now Hit the Emergency STOP button
4. The engine should stop very quickly.
5. The valve should close and the ADL system shuts itself Off.
Its good practice to occasionally test this feature, under controlled conditions, so
that you don't have to think about what to do if a real Emergency occurs.
The normal Emergency STOP Action is to pull back on the throttle while hitting
the Emergency stop button.
If you do not use the External Ignition Cut-off relay then the engine may continue
to run at low RPM with the brake full of water. The brake itself will Not stall the
engine. The ADL system will remain ON (and at full valve open) as long as the
engine is still running. When you do stop the engine the valve will automatically
close and turn the system off.
22
DEPAC Dyno Systems 201 Mill St. Rome NY 13440 (315) 339 -1265
Exercise 10:
RESET the Control Valve.
NOTE: Every time you Turn ON the ADL system it will automatically cycle the
valve to find its Reference Position (Closed or Open, depending on Dyno).
Purpose: To demonstrate how to Reset the ADL System if the Valve losses its
Reference Position while the engine is running or stopped.
Summary: On Power-up the ADL Control system moves the valve to find its
Reference Position. There is a magnetic sensor imbedded in the plate for this
purpose. All movement after this is relative to this Closed Reference point.
Some times the valve may lose track of its absolute position and therefore be at the
wrong opening. So, if the Engine does not come up to the expected RPM for a LOAD
setting then maybe the valve has lost its reference. It's easy to check and RESET the
Valve. This should not happen very often, if at all.
Whenever the engine is Off the System will check itself Automatically for its reference
position and, if not, will Reset the Valve automatically.
So by turning off the engine will cause the ADL Control to self-check its reference.
Reseting the Valve while The Engine is Running and ADL is ON:
Exercise Situation: Say We suspect that the system has lost its Valve Reference
Point and we want to check and Reset the Valve, if needed.
Method 1: Pull the throttle back to Idle and then turn the LOAD Knob to Zero for a
moment (see the Yellow 'S' LED come on) and then turn it back to your normal
setting. This commands a Valve Reset. You can then pick up the throttle again and
see if that made any difference in the operating load point.
Method 2: Stop the engine. The system will self-test and Reset the Valve
automatically, if needed, without you touching the ADL panel. Restart the engine and
continue your testing.
Both Methods will cause the ADL System to check and reset the valve to its
Reference position, if needed, while the system is still powered ON.
Note: When the engine is not running, you can always push the system OFF, then
back ON, to re-initialize the system and reset the inlet valve to the closed position.
23
DEPAC Dyno Systems 201 Mill St., Rome, NY 13440 (315) 339-1265 www.depac.com
To Cable Connector from
ADL Control Panel
Mount the 12Volt DPDT Relay inside your console so that you can easily work on it. Crimp some Faston 18 gauge wire
connectors for the relay tabs and hookup as shown (and/or use as an optional fuel pump Cut-off).
Connect the Relay to your +12 Volt battery power and to the 2 wires from the ADL system as shown using Faston crimps.
The Relay is Energized/ON when the ADL system is ON. You can not start your engine until the ADL system is turned ON,
which will Energize the Relay to the condition shown above. (you can always put in a bypass switch to defeat this if needed).
When you HIT the Emergency STOP Button the Brake is flooded with water AND this Relay is turned OFF to kill your Ignition (and fuel pumps). Then when the ADL system detects that the engine is Stopped it will turn itself OFF.
(FULL Load)
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(ALT)
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50 %
201 Mill St.
Rome, NY 13440
(315) 339-1265
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(Max RATE)
Auto-Dynamic
Load Control
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MAX OPEN
LOAD
0%
Speed-Hold
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RATE
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www.depac.com
Valve MODE
AUTO
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STOP
HOLD
Load
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Not Stable
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Manual
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