SF 602 Manual

SF 602 Operators
Manual
Version 2, Date 05/1998
SuperFlow
Computerized Engine and Vehicle Test Systems
1.
General Information
2.
System Overview
3.
Packaging and Handling
4.
Room Requirements
5.
Installation
6.
Operating Instructions
7.
Handheld Manual
8.
Theory of Testing
9.
Description of the Configuration File
10.
WinDyn Introduction
11.
WinDyn Tutorial
12.
WinDyn Reference Guide
13.
WinDyn Stored Data Viewer
14.
WinDyn DataLib Program
15.
Test Editor
16.
Configuration Editor
17.
WinDyn Software Architecture
18.
WinDyn How To...
19.
Advanced PC Troubleshooting
20.
Maintenance and Service
21.
Control System Set up
22.
Accessories and Options
SuperFlow
Computerized Engine and Vehicle Test Systems
1. General Information
1.1.
Introduction ................................................................................................ 3
1.1.1.
Copyright ...................................................................................................... 3
1.1.2.
Purpose of Manual ........................................................................................ 3
1.1.2.1. General Manual Explanation ..................................................................... 3
1.1.2.2. Target Audience ........................................................................................ 3
1.1.3.
Manual Conventions ..................................................................................... 3
1.1.3.1. Warning and Suggestion Labels ................................................................ 3
1.2.
Warranty, Liability, Legal Statements .......................................................... 4

1.2.1.
1.2.2.
1.2.3.
1.2.4.
1.2.5.
1.2.6.
1.2.7.
Disclaimer ..................................................................................................... 4
FCC .............................................................................................................. 4
Limited Warranty ........................................................................................... 4
Service Under Warranty ................................................................................ 5
Service Out of Warranty ................................................................................ 5
Technical Assistance .................................................................................... 6
Extended Warranty ........................................................................................ 6
1.3.
Product Identification ................................................................................. 6
1.4.
Product specifications................................................................................ 7
1.4.1.
1.4.2.
1.5.
Chassis dyno system ................................................................................... 7

Instrumentation ............................................................................................. 8
Manufacturer and distributors .................................................................... 8
2. System Overview
2.1.
Purpose ..................................................................................................... 3
2.2.
Components .............................................................................................. 4
2.3.
Control Console ........................................................................................ 4
2.4.
Sensor Box ................................................................................................ 5
2.5.
Dynamometer rollset.................................................................................. 6
2.5.1.
2.5.2.
BR-600 Rollset description ............................................................................ 6

Load Control Valve ........................................................................................ 6
2.6.
Interconnect Box ........................................................................................ 8
2.7.
Handheld Controller .................................................................................. 9
2.8.
Fuel System............................................................................................... 9
2.9.
Specifications .......................................................................................... 10
Available sensor panels ............................................................................................. 13
3. Packaging and Handling

3.1.
Weights ..................................................................................................... 3
3.2.
Lifting and Handling instructions ............................................................... 3

3.2.1.
3.2.2.
3.2.3.
3.2.4.
Rollset .......................................................................................................... 3
Console ........................................................................................................ 4
Fuel System ................................................................................................. 4
Other components ........................................................................................ 4
3.3.
Packaging of a typical SF-602 system ....................................................... 4
3.4.
Packaging of a typical WinPac system ....................................................... 5
3.5.
Order of unpacking and inspection ............................................................ 5
4. Room Requirements
4.1.
Introduction to dynamometer testing .......................................................... 3
4.2.
Accuracy of dynamometer testing .............................................................. 3
4.3.
Test room recommendations ...................................................................... 4
4.4.
Facility Recommendations ........................................................................ 8

4.4.1.
4.5.
Water System........................................................................................... 22
4.5.1.
4.5.2.
4.5.3.
4.5.4.
4.6.
Types of water systems .............................................................................. 22

Minimum flow requirements ........................................................................ 22
Water supply test ........................................................................................ 22
Fuel measurement system water requirements ........................................... 23
Electrical Requirements, Connections .................................................... 23

4.6.1.
4.6.2.
4.6.3.
4.6.4.
4.7.
Facility construction drawings ....................................................................... 8
Overall electrical requirements .................................................................... 23

Control console and sensor input box requirements .................................... 23
Fuel measurement system requirements .................................................... 24
Telephone line requirements ........................................................................ 24
Safety Precautions .................................................................................. 24

4.7.1.
4.7.2.
4.7.3.
4.7.4.
4.7.5.
General precaution ...................................................................................... 24

Interconnect box emergency stop button .................................................... 24
Protective equipment .................................................................................. 24
Press stop key on handheld to reset system .............................................. 25
The Hazards of Dynamometer Testing ........................................................ 25
5. Installation
5.1.
Placement of Dynamometer into Pit .......................................................... 3

5.1.1.
5.2.
Load Control Valve Installation .................................................................. 5

5.2.1
5.3.
Control console installation ......................................................................... 13
Handheld Connection.............................................................................. 14
5.8.1
5.9.
Interconnect box mounting .......................................................................... 12

Interconnect box connections ..................................................................... 12
Control Console Installation .................................................................... 13

5.7.1
5.8.
Boom installation .......................................................................................... 8

Cable installation .......................................................................................... 9
Sensor input box installation ....................................................................... 10
Interconnect Box Installation .................................................................... 12

5.6.1
5.6.2.
5.7.
Sump pump installation ................................................................................ 7
Sensor Input Box Installation ..................................................................... 8

5.5.1
5.5.2
5.5.3
5.6.
Sump tank installation (closed water system only) ....................................... 6

Open water system connections ................................................................... 7
Sump Pump Installation ............................................................................. 7

5.4.1
5.5.
Load control valve mounting ......................................................................... 5
Sump Tank Installation ............................................................................... 6

5.3.1
5.3.2
5.4.
Dynamometer installation ............................................................................. 3
Handheld connection .................................................................................. 14
Fuel System Installation .......................................................................... 15

5.9.1
5.9.2.
Unpack fuel system .................................................................................... 15

Fuel cooler .................................................................................................. 15
5.10. Configuration ........................................................................................... 16

5.10.1. Computer Communication ........................................................................... 16
5.10.2. Computer Setup .......................................................................................... 16
5.10.2.1.Install network card ............................................................................... 17
5.10.2.2.Install network cable .............................................................................. 17
5.10.2.3.Configure PC for NetBEUI communications ........................................... 17
5.10.2.4.Install WinDyn ........................................................................................ 18
5.10.2.5.Run WinDyn ........................................................................................... 18
5.10.2.6.How to configure your system for US units or Metric units ..................... 19
5.11. Description of sensor connections ........................................................... 20

5.11.1.
5.11.2.
5.11.3.
5.11.4.
Thermocouple Connections ......................................................................... 20

Pressure Connections ................................................................................. 21
Engine speed sensor .................................................................................. 21
Blowby sensor ............................................................................................ 22
5.11.5.
5.11.6.
5.12
Opacity sensor ........................................................................................... 22

Rack point sensor ....................................................................................... 23
Basic System Tests .................................................................................. 23

5.12.1
5.12.2
5.12.3
5.12.4
5.12.5
5.12.6
5.12.7
Turn system on ........................................................................................... 23

Basic roll lock test ...................................................................................... 24
Brake system bleeding ............................................................................... 24
Roll lock over-ride test (due to presence of vehicle speed) ......................... 24
Load control valve test ............................................................................... 25
Full flow water test (closed water system only) ........................................... 25
Absorber packing adjustment ...................................................................... 26
5.13. Calibration ............................................................................................... 27
6. Operating Instructions
6.1.
Quick Start ................................................................................................. 3
6.2.
General precaution .................................................................................... 5

6.2.1.
6.2.2.
6.2.3.
6.2.4.
6.2.5.
6.3.
Turn System On ......................................................................................... 7

6.3.1.
6.3.2.
6.3.3.
6.4.
Check installation ....................................................................................... 18
Zero Sensor Readings ............................................................................ 19

6.7.1.
6.8.

Pressure connections ................................................................................. 14
Temperature sensors .................................................................................. 15
Diesel Fuel measurement system ............................................................... 16
Verify Proper Installation of Vehicle ......................................................... 18

6.6.1.
6.7.
Vehicle installation procedure ........................................................................ 9

Tie-down strap installation procedure .......................................................... 11
Truck rear axle tie-down methods ................................................................ 12
Connect Sensors ..................................................................................... 13

6.5.1.
6.5 .2.
6.5.3.
6.5.4.
6.6.
Control console ............................................................................................. 7

Sensor input box ........................................................................................... 7
Fuel system .................................................................................................. 8
Install Vehicle............................................................................................. 9
6.4.1
6.4.2.
6.4.3.
6.5.
Emergency stop button ................................................................................. 5

Handheld stop key ........................................................................................ 6
Protective equipment .................................................................................... 6
Consider hazards .......................................................................................... 6
Static Electricity ........................................................................................... 6
Zero (AutoZero) channels ........................................................................... 19
Activate Facility Systems ......................................................................... 20

6.8.1.
Water supply system pump (closed water system) ..................................... 20
6.8.2.
6.9.
Ventilation system (enclosed test room) ..................................................... 20
Select Automated Test ............................................................................. 20

6.9.1.
6.9.2.
Description of standard automated tests ..................................................... 20

Select test .................................................................................................. 20
6.10. Start Engine. ............................................................................................ 21

6.10.1.
6.10.2.
Engine starting ........................................................................................... 21

Alignment check ......................................................................................... 21
6.11. Perform Automated Test ........................................................................... 22

6.11.1.
View handheld data screen ......................................................................... 22
6.12. Analyze Test Results ............................................................................... 23

6.12.1.
6.12.2.
6.12.3.
Test data description ................................................................................... 23

View current test from handheld .................................................................. 23
Storing and analyzing the test results ......................................................... 24
6.13. Remove Vehicle ...................................................................................... 25

6.13.1.
6.13.2.
6.13.3.
Disconnect fuel system .............................................................................. 25

Disconnect sensors .................................................................................... 26
Remove vehicle from dynamometer ............................................................ 26
6.14. Test Tips .................................................................................................. 26

6.14.1.
6.14.2.
6.14.3.
Running a Manual Test ................................................................................ 26

Running an Auto Test .................................................................................. 28
Cylinder Cutout test for the new SF602 testing systems ............................. 30
7. Handheld Manual
7.1.
System power-up choices ......................................................................... 3
7.2.
Start menu choices .................................................................................... 5

7.2.1.
Autozero functions ........................................................................................ 6
7.2.2.
Test functions ............................................................................................... 7
7.2.3.
Stored Data display choices ....................................................................... 11
7.2.4.
Configuration choices ................................................................................. 12
7.2.4.1. Configuration of Specifications ............................................................... 13
7.2.4.2. Configuration of Calibration ..................................................................... 15
7.2.4.3. Configuration of Limits ............................................................................ 20
7.2.4.4. Configuration of system .......................................................................... 20
7.2.5.
Help choices ............................................................................................... 23
7.2.6.
Dynamometer controls ................................................................................ 23
7.2.6.1. Roll lock controls .................................................................................... 23
7.2.6.2. Counts / revolution control ...................................................................... 24
7.2.6.3. Fuel System controls ............................................................................. 25
7.3.
Other handheld controller keys ................................................................ 26
8. Theory of Testing
8.1.
Chassis Dynamometer testing ................................................................... 3

8.1.1.
8.1.2.
Engine dynamometer .................................................................................... 3

Chassis dynamometer .................................................................................. 3
8.2.
Loaded testing ........................................................................................... 4
8.3.
SF-602 absorber theory of operation ......................................................... 5
8.4.
Load control ............................................................................................... 7
8.5.
Torque measurement ................................................................................. 7
8.6.
Typical applications of the SF-602 Test System ......................................... 8

8.6.1.
8.6.2.
8.6.3.
8.6.4.
8.6.5.
8.6.6.
8.6.7.
8.6.8.
8.6.9.
8.6.10.
Performance Testing ...................................................................................... 8

Diagnostic Testing ......................................................................................... 8
Used Truck Certification ................................................................................ 9
Durability Testing ........................................................................................... 9
Fleet Testing ................................................................................................. 9
Emissions Testing ......................................................................................... 9
Research and Development ........................................................................ 10
Engine or Vehicle Break-in .......................................................................... 10
End-of-production-line Testing ..................................................................... 10
Education ................................................................................................... 10
8.7.
Tire-roll interface ...................................................................................... 10
8.8.
Interpreting power measurements ........................................................... 11

8.8.1.
8.8.2.
8.8.3.
8.9.
Vehicle Torque ............................................................................................. 11

Vehicle Power ............................................................................................. 12
Corrected Vehicle Power ............................................................................. 12
Power correction factors .......................................................................... 12
8.10. SF-602 Test Modes .................................................................................. 14

8.10.1.
8.10.2.
8.10.3.
8.10.4.
8.10.5.
Manual control mode (position control) ........................................................ 14

Engine speed control mode ......................................................................... 15
ECM engine speed control mode ................................................................ 16
Vehicle speed control mode ........................................................................ 16
Vehicle power control mode ........................................................................ 16
9. Description of the Configuration File

9.
Channel Functions .................................................................................... 3

9.1.
9.2.
9.3.
9.4.
9.5.
Sensor Channels .......................................................................................... 3

Specifications ............................................................................................... 8
Calculations .................................................................................................. 8
Interpolation Tables ..................................................................................... 10
System Channels ....................................................................................... 10
10. WInDyn Introduction

10.1
SuperFlows Software License Agreement ................................................ 3

10.1.1.
10.1.2.
10.1.3.
10.1.4.
Grant of License ........................................................................................... 3

Copyright ...................................................................................................... 3
Other Restrictions ......................................................................................... 3
Dual Media Software ..................................................................................... 4
10.2. Limited Warranty ........................................................................................ 4

10.2.1.
10.2.2.
10.2.3.
Customer Remedies ..................................................................................... 4

No other Warranties ....................................................................................... 5
No Liability for Consequential Damages. ....................................................... 5
10.3. WindynTM minimum Computer and Printer Requirements .......................... 6

10.3.1.
10.3.2.
WinDyn Minimum Computer Requirements ............................................... 6

WinDyn Suggested Printer Requirements .................................................. 6
10.4. WinDynTM Release Notes ......................................................................... 7

10.4.1. Introduction ................................................................................................... 7
10.4.2. How to install WinDyn ................................................................................... 7
10.4.3. Some New features for WinDyn Release 1.10 ............................................... 7
Other features for WinDyn Release 1.10 ...................................................................... 8
10.4.4. How to run WinDyn ....................................................................................... 9
10.4.5. How to remove (uninstall) WinDyn ................................................................. 9
10.4.6. How to run WinDyn in DEMO mode ............................................................ 10
10.5. WindynTM How To Notes for Windows95 users ....................................... 10

10.5.1.
10.5.2.
10.5.3.
10.5.4.
10.5.5.
10.5.6.
10.5.7.
10.5.8.
How to place a program into the startup group ............................................ 10

How to create a new folder .......................................................................... 10
How to place a folder or program on Win95 desktop .................................... 10
How to start a program in Win95 ................................................................. 11
How to explicitly run a program ................................................................... 11
How to add a program icon to a folder ......................................................... 11
How to use the print screen program ........................................................... 11
How to change the printer spool settings .................................................... 12
10.6. All New Features for WinDynTM Release 1.10 .......................................... 12

10.6.1. New Features ............................................................................................. 12
10.6.2. Current data display enhancements ............................................................ 13
10.6.3. Test data display & plotting enhancements ................................................. 13
10.6.3.1. New Plotting Features ........................................................................... 13
10.6.3.2. Other .................................................................................................... 13
10.6.4. General Windyn enhancements .............................................................. 13
11. WinDyn Tutorial

11.1. Using the Current Data Screens ................................................................ 3
11.2. The WinDynTM Menu .................................................................................. 3
11.3. Designing Test Screens ............................................................................. 4
11.4. Screen Editing Mode Preferences ............................................................. 5
11.5. Resizing Objects ....................................................................................... 5
11.6. Selecting Objects for a Screen Design ...................................................... 6
11.7. Designing Panel Meters ............................................................................ 7
11.8. Designing Bar Graphs ............................................................................... 8
11.9. Designing X-T Graphs ............................................................................... 9
11.10. Designing Configurations ........................................................................ 11
11.11. Modifying a Configuration File ................................................................. 11
11.12. Types of Channels ................................................................................... 12
11.13. Measured Sensors Channels .................................................................. 12
11.14. Specifications Channels .......................................................................... 13
11.15. Calculated Channels ............................................................................... 14
11.16. Interpolation Tables .................................................................................. 15
11.17. Setting File Paths .................................................................................... 16
11.18. Determining the Channel Order ............................................................... 16
11.19. Running Tests .......................................................................................... 17
11.20. Selecting Other Test Features .................................................................. 18
12. WinDyn Reference Guide

12.1. WinDyn Terms ........................................................................................ 5
12.2. Design Test Group ..................................................................................... 5
12.2.1.
Dialog Box Options ....................................................................................... 6
12.3. Channel Order ........................................................................................... 7

12.3.1.
12.3.2.
Overview ...................................................................................................... 7
Using ............................................................................................................ 7
12.4. Autoload Test Group .................................................................................. 8

12.4.1.
12.4.2.
Overview ...................................................................................................... 8
Using ............................................................................................................ 9
12.5. Edit Stored Data Headings ........................................................................ 9

12.6. Auto-Incrementing Data Filenames ......................................................... 10
12.6.1.
12.6.2.
12.6.3.
Name Format .............................................................................................. 10

Manual Increment Filename ........................................................................ 10
Auto-Increment Filename ............................................................................ 11
12.7. Playback Data ......................................................................................... 11

12.7.1.
12.7.2.
12.7.3.
12.7.4.
12.7.5.
12.7.6.
Overview .................................................................................................... 11
Playback Data Menu .................................................................................. 11
Playback Data Menu - Load Saved Test ...................................................... 12
Playback Data Menu - Playback Functions ................................................ 12
Playback Data Menu - Repeat Play ............................................................ 14
Playback Data Menu - Exit Playback Mode ................................................ 14
12.8. Selecting Channels ................................................................................. 14

12.8.1.
Dialog box options ...................................................................................... 15
12.9. Editing Specifications Channels .............................................................. 15

12.9.1.
12.9.2.
Overview .................................................................................................... 15
Editing Specifications ................................................................................. 16
12.10. Channel Calibration and Autozero .......................................................... 18

12.10.1. To calibrate a channel, follow these steps ................................................... 18
12.10.2. To zero a channel, follow these steps ......................................................... 18
12.11. Password Protected WinDyn Features ................................................ 19

12.11.1. Overview .................................................................................................... 19
12.11.2. File Menu - Login ........................................................................................ 19
12.11.3. File Menu - Logoff ....................................................................................... 19
12.11.4. File Menu - Change Password..................................................................... 19
12.11.5. File Menu - Configure Password System .................................................... 20
12.11.5.1. Disabling the Password Protection system ......................................... 20
12.11.5.2. Selecting the WinDyn default access ............................................... 20
12.11.5.3. Adding a user ...................................................................................... 21

12.11.5.4. Update an existing user ...................................................................... 21
12.11.5.5. Deleting a user .................................................................................... 21
12.11.6. WinDyn User Configuration ...................................................................... 21
12.11.7. Individual WinDyn Access Features ........................................................ 22
12.12.
Custom Tools .................................................................................... 23

12.12.1. Overview .................................................................................................... 23
12.12.2. Dialog box options ...................................................................................... 24
12.13.
Bargraph Display Configuration .......................................................... 24

12.13.1.
12.13.2.
12.13.3.
12.13.4.
12.13.5.
12.13.6.
12.14.
Tabular Display Configuration ............................................................. 28

12.14.1.
12.14.2.
12.14.3.
12.14.4.
12.14.5.
12.15.
Meter Display ............................................................................................. 32

Meter Display Dialog Box ........................................................................... 32
Meter Dialog Box - Channel Select ............................................................. 33
Meter Dialog Box - Meter Style ................................................................... 34
Meter Dialog Box - Color Ranges ................................................................ 34
Meter Dialog Box - Annotation .................................................................... 35
Stripchart Display Configuration ......................................................... 36

12.16.1.
12.16.2.
12.16.3.
12.16.4.
12.16.5.
12.16.6.
12.16.7.
12.17.
Tabular Display ........................................................................................... 28

Tabular Display Dialog Box ......................................................................... 29
Tabular Dialog Box - Channel Select ........................................................... 30
Tabular Dialog Box - Style ........................................................................... 30
Tabular Dialog Box - Color Ranges .............................................................. 31
Meter Display Configuration ................................................................ 32

12.15.1.
12.15.2.
12.15.3.
12.15.4.
12.15.5.
12.15.6.
12.16.
Bargraph Display ........................................................................................ 24

Bargraph Display Dialog Box ...................................................................... 24
Bargraph Dialog Box - Channels ................................................................. 25
Bargraph Dialog Box - Ranges .................................................................... 26
Bargraph Dialog Box - Style ........................................................................ 26
Bargraph Dialog Box - Title ......................................................................... 28
StripChart Display ...................................................................................... 36

StripChart Display Dialog Box..................................................................... 36
Stripchart Dialog Box - Y Channels ............................................................. 37
Stripchart Dialog Box - Timebase ............................................................... 37
Stripchart Dialog Box - Start Trigger ............................................................ 38
Stripchart Dialog Box - Stop Trigger ............................................................ 38
Stripchart Dialog Box - Title ........................................................................ 38
XY Display Configuration .................................................................... 38

12.17.1.
12.17.2.
12.17.3.
12.17.4.
12.17.5.
12.17.6.
XY Display ................................................................................................. 38
XY Display - Options .................................................................................. 39
XY Display - Stop (Start) ............................................................................ 39
XY Display Dialog Box ............................................................................... 39
XY Dialog Box - Y Channels ....................................................................... 40
XY Dialog Box - X Channel ......................................................................... 41
12.17.7. XY Dialog Box - Start Trigger ...................................................................... 42

12.17.8. XY Dialog Box - Stop Trigger ....................................................................... 44
12.17.9. XY Dialog Box - Title .................................................................................. 44
12.18.
Panel Indicator Configuration ............................................................. 45

12.18.1. Panel Indicator Display ............................................................................... 45
12.18.2. Panel Indicator Display Dialog Box ............................................................. 45
12.19.
Push Switch Configuration ................................................................. 46

12.19.1. Push Switch Display ................................................................................... 46
12.19.2. Push Switch Display Dialog Box ................................................................. 46
12.20.
Push Switch with Indicator Configuration ........................................... 48

12.20.1.
12.20.2.
12.20.3.
12.20.4.
12.21.
Push Switch with Indicator Display ............................................................. 48

Push Switch with Indicator Display Dialog Box ........................................... 48
Panel Indicators with Push Switches - Panel Indicator ................................ 49
Panel Indicators with Push Switches - Push Switch .................................... 49
Video Display Configuration ............................................................... 50

12.21.1. Video Display ............................................................................................. 50
12.21.2. Video Display Dialog Box ........................................................................... 51
12.21.3. Video Dialog Box - Video Setup .................................................................. 51
12.22.
Remote Status Display Configuration ................................................ 52

12.22.1. Remote Status Display ............................................................................... 52
12.22.2. Remote Status Display Dialog Box ............................................................. 52
12.23.
Background Bitmap Configuration ..................................................... 53

12.23.1. Background Bitmap Display ........................................................................ 53
12.23.2. Background Bitmap Display Dialog Box ...................................................... 54
12.23.3. Background Bitmap - Style ......................................................................... 54
12.24.
XY-Reference Plots ............................................................................ 55

12.24.1. Adding Reference Plots .............................................................................. 56
12.24.2. Removing Reference Plots ......................................................................... 56
12.24.3. Reference File Info ..................................................................................... 56
13. WinDyn Stored Data Viewer

13.1.
What is the Stored Data Viewer? .......................................................... 3
13.2.
View Test Data (File Commands) .......................................................... 4
13.3.
Printing Test Data .................................................................................. 4
13.4.
Plotting Test Data .................................................................................. 5

13.4.1.
13.4.2.
13.4.3.
Overview ...................................................................................................... 5
Plot Window Main Menu... ............................................................................ 5
Using the Data Cursor ................................................................................... 6
13.5. View Data as Recorded (Auto-Refresh) .................................................... 8

13.5.1.
13.5.2.
Auto data refresh .......................................................................................... 8

Refresh Current Data .................................................................................... 8
13.6. Export Data (*.CSV) .................................................................................. 8

13.7. Exporting OLE Plots .................................................................................. 9
13.7.1.
13.7.2.
Overview ...................................................................................................... 9
Example ....................................................................................................... 9
13.8.
Convert (*.DDF) file to (*.SFD) ............................................................ 10
13.9.
Viewing WinDyn Current Data ........................................................ 10

13.9.1.
13.9.2.
13.10.
Leave data viewer running .......................................................................... 10

Terminate Stored Data Viewer ..................................................................... 10
Column Averages, Minimums, Maximums ......................................... 11
13.11. Averaging Test Data ................................................................................. 11

13.11.1. Overview .................................................................................................... 11
13.11.2. Sequence ................................................................................................... 12
13.11.2.1.Selecting Data Files To Average ........................................................... 12
13.11.2.2.Selecting the Average Reference Channel (Non-NGE systems only) ... 12
13.11.2.3.Saving the Averaged Data ................................................................... 13
13.11.2.4.Deleting the Source Files ..................................................................... 14
13.11.2.5.Displaying the Averaged Data .............................................................. 14
13.11.2.6.Adding the Averaged Data to the Database .......................................... 15
13.11.3. Test Description ......................................................................................... 15
13.11.3.1.
Average Engineering Details ....................................................... 16
13.12. Post Processing Data .............................................................................. 17

13.12.1. Overview .................................................................................................... 17
13.12.2. Filter Measured Data Channel(s)... .............................................................. 18
13.12.3. Update Specification Values ....................................................................... 20
13.13. Plot Preferences ...................................................................................... 21

13.13.1. Overview .................................................................................................... 21
13.13.2. Display Tab ................................................................................................. 22
13.13.2.1.Y-Axis .................................................................................................. 22
13.13.2.2.Legend ................................................................................................. 22
13.13.2.3.Line Color ............................................................................................ 23
13.13.2.4.Annotation Position (X-Axis) ................................................................ 23
13.13.3. X-Axis Tab .................................................................................................. 24
13.13.3.1.Scaling and Range ............................................................................... 24
13.13.3.2.Display ................................................................................................ 24
13.13.3.3.Draw Order .......................................................................................... 24
13.13.4. Left Y-Axis Tab ............................................................................................ 25
13.13.4.2.Mode ................................................................................................... 25
13.13.4.3.Minor Grid ............................................................................................ 25
13.13.5. Right Y-Axis Tab .......................................................................................... 26
13.13.5.2.Mode ................................................................................................... 26
13.13.5.3.Major/Minor Grid .................................................................................. 26
13.13.6. Grid Style Tab ............................................................................................. 27
13.13.7. Custom Title Tab ......................................................................................... 27
13.13.8. Printing Tab ................................................................................................. 28
13.14. Description of the Stored Program Terminology ....................................... 28
14. WinDyn DataLib Program

14.1. Description ................................................................................................ 3
14.2. Test Sequence ........................................................................................... 3
14.3. Add existing record to database ................................................................ 4
14.3.1.
14.3.2.
14.3.3.
14.3.4.
14.3.5.
14.3.6.
Add existing record to database .................................................................... 4

Automatic feature ......................................................................................... 4
Modifying a database record ......................................................................... 4
Adding a picture to a database record. .......................................................... 4
Deleting a picture from a database record ..................................................... 5
Delete record from database ......................................................................... 5
14.4. Database Navigation ................................................................................. 5

14.4.1. Using the database cursor ............................................................................ 5
14.4.2. Viewing data associated with a database record ........................................... 6
14.4.3. Using the database edit control ..................................................................... 6
14.4.3.1. Database edit control .............................................................................. 6
14.4.3.2. Database edit buttons ............................................................................. 6
14.5. Database Reporting .................................................................................. 6

14.5.1.
14.5.2.
Concise Reports ........................................................................................... 6

Column reports ............................................................................................. 7
14.6. Searching the Database ............................................................................ 7

14.7. Sorting the Database ................................................................................. 8
14.8. Database Field Description ....................................................................... 8
14.8.1
14.8.2.
14.8.3.
14.8.4.
14.8.5.
14.8.6.
14.8.7.
Owner Tab ..................................................................................................... 8

Test Device Tab ............................................................................................ 9
Miscellaneous Tab ...................................................................................... 10
Comments Tab ............................................................................................ 10
Test Information Tab .................................................................................... 11
Picture Tab .................................................................................................. 11
Grid Tab ...................................................................................................... 12
14.9. Return to WinDynTM current data screens ................................................. 12

14.10. Return to WinDynTM stored data viewer .................................................... 12
15. Test Editor

15.1. Overview ................................................................................................... 3
15.2. Test Profile Structure.................................................................................. 3
15.3. Test Profile Functions ................................................................................ 4
15.3.1.
15.3.2.
15.3.3.
15.3.4.
What does a test profile do? ......................................................................... 4

Device Control .............................................................................................. 4
Flow Control .................................................................................................. 4
Command Language ..................................................................................... 5
15.4. System Definition Considerations ............................................................. 6

15.4.1. Data Channel Assignment ............................................................................ 7
15.4.1.1. Sensors .................................................................................................. 7
15.4.1.2. Channels To Limit .................................................................................... 7
15.4.2. Operator Interaction in Test Profiles .............................................................. 8
15.4.3. Pause / Stop ................................................................................................. 8
15.5. Operator Data Input ................................................................................... 9

15.6. Data Management in Test Profiles ............................................................. 9
15.6.1.
15.6.2.
15.6.3.
Acquiring Data / Disk Space ......................................................................... 9

Printing ......................................................................................................... 9
Data Displays: WinDyn, PC, Handheld Controller ....................................... 9
15.7. Developing Test Profiles .......................................................................... 10

15.7.1.
Writing the Test Profile ................................................................................ 10
15.7.1.1. Editor Interface ..................................................................................... 10

15.7.1.2. Opening the test profile editor ............................................................... 10
15.7.2. Test Profile Editor Display Screen ............................................................... 11
15.7.2.1. Test Profile Editor Key Functions .......................................................... 11
15.7.2.2. Test Description and Control Configurations .......................................... 11
15.7.2.3. Test profile command entry / editing ...................................................... 12
15.7.3. Saving the test profile ................................................................................. 13
15.8. Test Profile Commands Reference .......................................................... 13

15.8.1. RAMP Commands ...................................................................................... 13
15.8.1.1. Normal Ramp ........................................................................................ 14
15.8.1.2. Mode Change Ramp<R> ....................................................................... 15
15.8.1.3. Custom Ramp ....................................................................................... 15
15.8.2. SET Commands ......................................................................................... 17
15.8.2.1. Set Data Screen ................................................................................... 17
15.8.2.2. Set Data Filter ...................................................................................... 18
15.8.2.3. Set Timer .............................................................................................. 18
15.8.2.4. Set Counter .......................................................................................... 18
15.8.2.5. Set Constant (Specification) ................................................................. 18
15.8.2.6. Set Setpoint .......................................................................................... 19
15.8.2.7. Set Limits On (Not Yet Implemented) .................................................... 20
15.8.3. BRANCH .................................................................................................... 20
15.8.3.1. GOTO ................................................................................................... 20
15.8.3.2. CALL .................................................................................................... 20
15.8.3.3. Repeat .................................................................................................. 21
15.8.3.4. Return ................................................................................................... 21
15.8.3.5. Wait ....................................................................................................... 21
15.8.3.6. Stop ...................................................................................................... 21
15.8.3.7. Input wait .............................................................................................. 21
15.8.4. ACTION ...................................................................................................... 22
15.8.4.1. Display ................................................................................................. 22
15.8.4.2. Display-Define Soft Key Labels ............................................................. 23
15.8.4.3. Print ...................................................................................................... 23
15.8.4.4. Alert ..................................................................................................... 25
15.8.4.5. Pause Test ............................................................................................ 25
15.8.4.6. Inc Counter ........................................................................................... 25
15.8.4.7. Dec Counter .......................................................................................... 25
15.8.4.8. Erase Memory ...................................................................................... 26
15.8.4.9. Roll Messages ...................................................................................... 26
15.8.4.10. Clr Messages ...................................................................................... 26
15.8.4.11. Keep Data ........................................................................................... 26
15.8.4.12. Exit Screen ......................................................................................... 27
15.8.4.13. Clear When Queue .............................................................................. 27
15.8.4.14. Config Cmd Line ................................................................................. 28
15.8.4.15. Graphics Function ............................................................................... 28
15.8.4.16. Load Limits File .................................................................................. 28
15.8.5. IF/WHEN .................................................................................................... 29

15.8.5.1. Overview of IF and WHEN commands .................................................. 29
15.8.5.2. If Data Channel ..................................................................................... 29
15.8.5.3. If Timer ................................................................................................. 30
15.8.5.4. IF counter ............................................................................................. 30
15.8.5.5. If data lines ........................................................................................... 31
15.8.5.6. When Data Channel .............................................................................. 32
15.8.5.7. When Limit Flag .................................................................................... 32
15.8.5.8. When Soft Key ...................................................................................... 33
15.8.6. RECORD .................................................................................................... 33
15.8.6.1. Record data line (Manual) ..................................................................... 33
15.8.6.2. No Automatic Recording ....................................................................... 34
15.8.6.3. Time Interval Recording ........................................................................ 34
15.8.6.4. Data Interval Recording ......................................................................... 34
15.8.6.5. Record a Comment Line ....................................................................... 34
15.9. Examples ................................................................................................. 34
16. Configuration Editor

16.1. Overview of Configuration (DEF) File Function and Creation.................... 3
16.2. Configuration File Editor ............................................................................ 3
16.3. Defining Data Channels ............................................................................ 3
16.3.1. Closed Loop Control Channels ...................................................................... 4
16.3.2. System Channels ......................................................................................... 5
16.3.3. Measured Data Channels .............................................................................. 6
16.3.3.1. Description and application ..................................................................... 6
16.3.3.2. Defining Measured Data Channels .......................................................... 7
16.3.4. Calculated Data Channels ............................................................................. 9
16.3.4.1. Description and application ..................................................................... 9
16.3.4.2. Defining Calculated Data Channels ....................................................... 10
16.3.5. Specification Channels ............................................................................... 11
16.3.5.1. Description and application ................................................................... 11
16.3.5.2. Defining Specification Channels ............................................................ 11
16.3.6. Interpolated Data Channels ......................................................................... 13
16.3.6.1. Description and application ................................................................... 13
16.3.6.2. Defining Interpolated Data Channels ..................................................... 14
16.4. Designing Handheld Controller Screens ................................................. 15

16.4.1.
Changing the handheld display ................................................................... 15
16.5. Designing a Control System .................................................................... 18

16.6. Saving and Loading Configuration Files ................................................. 19
16.6.1.
16.6.2.
Save Configuration File to Disk ................................................................... 19

Loading Configuration Files ......................................................................... 19
17. WinDyn Software Architecture

17.1
WinDyn Software Architecture ........................................................... 3

Executable Components .............................................................................................. 3
Non-Executable Components ....................................................................................... 3
17.2. Executable Components ........................................................................... 3

17.2.1.
Data Acquisition System ......................................................................... 4
17.2.2.
Communication Interface ......................................................................... 4
17.2.3.
DAC740.DLL ............................................................................................. 4
17.2.4.
WinDyn.exe .......................................................................................... 4
17.2.5.
Stored.exe ................................................................................................ 5
17.2.6.
DataLib.exe .............................................................................................. 5
17.2.7.
Editors ...................................................................................................... 5
17.2.8.
Custom Applications ................................................................................. 5
17.2.9.
OLE Interface ........................................................................................... 5
17.2.10.
Excel.exe .............................................................................................. 6
17.2.10.1.Overview ............................................................................................ 6
17.2.10.2.Workbooks ......................................................................................... 6
17.2.11.
Xload16.dll ............................................................................................. 7
17.3. Non-Executable Components (Files) ........................................................ 7

17.3.1.
Initialization File ....................................................................................... 7
17.3.2.
Help Files ................................................................................................ 7
17.3.3.
Comments File ......................................................................................... 8
17.3.4.
Configuration Files .................................................................................... 8
17.3.5.
Limits Files ............................................................................................... 8
17.3.6.
Autotest Files ........................................................................................... 8
17.3.7.
Control System Files ................................................................................ 8
17.3.8.
Switch Files .............................................................................................. 9
17.3.9.
Display Files ............................................................................................. 9
17.3.10.
Test Group Files ...................................................................................... 9
17.3.11.
Stored Data Files ................................................................................... 9
17.3.12.
CSV Files ............................................................................................... 9
17.3.13.
Calibration Files .................................................................................... 10
17.3.14.Specification Files ......................................................................................... 10
18. WinDyn How To...

18.1. Setup WinDyn to run a test ..................................................................... 3
18.1.1.
18.1.2.
18.1.3.
18.1.4.
18.1.5.
18.1.6.
Load a Test Group ......................................................................................... 3

Check the Test Data File Path ....................................................................... 3
Check the Manual Save Data Filename ........................................................ 3
Check the Test Description ........................................................................... 3
Check the Test Specification Values ............................................................. 4
Autozero Sensors ......................................................................................... 4
18.2. Run a Current Data Display using a different Configuration File ............... 4
18.2.1.
18.2.2.
18.2.3.
18.2.4.
18.2.5.
Edit the desired Display Screen .................................................................... 4

Use Save As to save the Display Screen under a new name ...................... 5
Assign the new Configuration to the Display Screen ..................................... 5
Save the Display Screen .............................................................................. 5
Run the new Display Screen ......................................................................... 5
18.3. Modify a WinDyn Calculated Channel ................................................... 6

18.3.1.
18.3.2.
18.3.3.
18.3.4.
18.3.5.
18.3.6.
18.3.7.
18.3.8.
Set the Configuration File Path ..................................................................... 6

Display the Configuration Editor .................................................................... 6
Get (Open) the desired Configuration ............................................................ 6
Determine the Calculated Channels channel number .................................... 7
Edit the Calculated Channel .......................................................................... 7
Keep (Save) the modifications ...................................................................... 7
Exit the Configuration Editor ......................................................................... 7
Reinstall the Modified Configuration .............................................................. 7
18.4. Remove WinDyn Completely from a Computer. ..................................... 8

18.4.1.
18.4.2.
18.4.3.
18.4.4.
18.4.5.
18.4.6.
18.4.7.
18.4.8.
Save Existing Test Group files and Data files ............................................... 8

Close all Running Applications ...................................................................... 8
Run the Uninstall Program ............................................................................ 8
Delete the WinDyn Folder ............................................................................. 8
Delete the file SUPERFLO.INI ...................................................................... 8
Delete the SuperFlow folder from the Windows Registry ............................... 9
Delete the SuperFlow environment variable from autoexec.bat ..................... 9
Restart Windows 95 ...................................................................................... 9
19. Advanced PC Troubleshooting

19.1. Troubleshoot PC device conflicts in Windows 95 ...................................... 3
19.1.1.
19.1.2.
19.1.3.
19.1.4.
19.1.5.
19.1.6.
Viewing the Device Manager ......................................................................... 3

Understanding the Symbols (!, X, and i) ................................................... 3
Viewing the Device Properties Sheet ............................................................ 3
Changing Resource Settings ......................................................................... 4
Viewing and Excluding Resources ................................................................ 4
Disabling a Device ........................................................................................ 4
19.2. Troubleshoot Printing Problems in Windows 95 ........................................ 5

19.2.1.
19.2.2.
19.2.3.
19.2.4.
19.2.5.
19.2.6.
19.2.7.
19.2.8.
19.2.9.
19.2.10.
19.2.11.
19.2.12.
19.2.13.
19.2.14.
19.2.15.
19.2.16.
19.2.17.
19.2.18.
19.2.19.
Read Printers.txt ........................................................................................ 5

Read Online Help .......................................................................................... 5
Reset the Printer ........................................................................................... 5
Use the Print Troubleshooter ......................................................................... 5
Print from an MS-DOS Prompt ..................................................................... 6
Print from Notepad and WordPad .................................................................. 6
Verify Printer Properties ................................................................................ 7
Check the Device Manager Settings ............................................................. 7
Perform Hard Disk Maintenance .................................................................... 7
Use ScanDisk and Disk Defragmenter .......................................................... 8
Remove and Reinstall the Printer Driver ........................................................ 8
Remove and Reinstall the Printer Port .......................................................... 9
Use the Generic/Text Only Printer Driver .................................................... 10
Use the LPT1.DOS printer port ................................................................... 10
Use the Alternate Lpt.vxd File ..................................................................... 10
Change the Printers Emulation Mode ......................................................... 11
Disable the Enhanced Capabilities Port ...................................................... 11
Simplify the Document ............................................................................... 12
If You Can Print from a DOS Command Prompt But Not Windows- ................
Based Programs ......................................................................................... 12
19.2.20. If Printing Problems Occur Only in One Application .................................... 13
19.2.21. Solving Network Printing Problems ............................................................. 13
19.2.22. Solving Printing Speed Problems ................................................................ 15
19.2.23. Using Windows 3.1 Printer Drivers .............................................................. 16

19.2.24. Windows 3.x Required Disabling Fast Printing Direct To Port ...................... 16
19.2.25. Additional Information ................................................................................. 16
19.3. Troubleshoot Startup Problems in Windows 95 ....................................... 17

19.3.1.
19.3.2.
19.3.3.
19.3.4.
19.3.5.
19.3.6.
Try to start Windows 95 in Safe Mode ......................................................... 17

Windows 95 Does Not Start in Safe Mode .................................................. 17
Windows 95 Starts in Safe Mode ................................................................ 18
Check for problems in the System.ini or Win.ini files .................................. 19
Troubleshoot Protected-Mode Driver Problems ............................................ 19
Additional Notes ......................................................................................... 20
19.4. Troubleshoot Video Problems in Windows 95 ......................................... 21

19.4.1.
19.4.2.
19.4.3.
19.4.4.
19.4.5.
19.4.6.
19.4.7.
19.4.8.
Determine if Video Driver is Windows 3.1 or Windows 95 ............................ 21

Using Windows 3.1 Display Drivers ............................................................. 21
Adjust Advanced Graphics Settings ........................................................... 22
Verify the correct Monitor type is selected .................................................. 23
Eliminate Memory Conflicts ........................................................................ 24
Verify the Adapter Driver Files are valid ...................................................... 24
Contact the Manufacturer of the Display Adapter ........................................ 25
Information on specific drivers, hardware, and utilities ................................ 25
20. Maintenance and Service

20.1. Inspection and Maintenance Instructions ................................................... 5
20.2. Maintenance Record ................................................................................. 9
20.3. System Calibration .................................................................................. 12
20.3.1. Calibration Overview ................................................................................... 12
20.3.1.1.Definition of terms ................................................................................. 12
20.3.1.2.Check measurement accuracy .............................................................. 13
20.3.1.3.Perform calibration ................................................................................. 13
20.3.2. Recommended Calibration Schedule ........................................................... 13
20.3.2.1.Calibration schedule for average dynamometer user .............................. 13
20.3.2.2.Calibrate when unexpected readings occur ............................................ 13
20.3.3. Roll Torque Calibration ................................................................................. 14
20.3.3.1.Install calibration arm ............................................................................. 14
20.3.3.2.Verify calibration arm length ................................................................... 15
20.3.3.3.Autozero all channels ............................................................................ 16
20.3.3.4.Calculate actual torque value ................................................................. 17
20.3.3.5.Add calibration weights to arm ............................................................... 17
20.3.3.6. Note displayed torque value .................................................................. 18
20.3.3.7.Enter actual torque value ....................................................................... 18
20.3.3.8.Remove calibration weights ................................................................... 20
20.3.3.9.Add calibration weights again ................................................................ 20
20.3.3.10.Remove calibration weights and arm .................................................... 20

20.3.3.11.Zero torque reading .............................................................................. 20
20.3.3.12.Save Calibration data ........................................................................... 20
20.3.4. Fuel Measurement System ......................................................................... 21
20.3.4.1.Fuel System Weight Calibration ............................................................. 21
20.3.4.2.Fuel System Volume Calibration ............................................................ 22
20.3.5. Barometric pressure sensor (channel 76) .................................................... 23
20.3.6. Pressure transducers (channels 62~71) ...................................................... 23
20.3.7. Temperature channels (type K thermocouples) ............................................ 24
20.3.8. Engine tachometer ...................................................................................... 25
20.3.9. Air flow sensor (SuperFlow air turbine) ........................................................ 25
20.4. Loading a *.prg file into your SF-602 test system ..................................... 26
20.4.1. Install Wizard .............................................................................................. 26
20.4.1.1.Overview ............................................................................................... 26
20.4.1.2.Using ..................................................................................................... 26
20.4.1.3.Functional Description... ........................................................................ 27
20.4.2. From WComNet .......................................................................................... 28
20.5. Dynamometer Cover Plates ..................................................................... 33

20.5.1.
20.5.2.
Cover plate removal .................................................................................... 33

Cover plate replacement ............................................................................. 33
20.6. Bearing Lubrication ................................................................................. 34

20.6.1
Bearing lubrication ...................................................................................... 34
20.7. Roll Lock Maintenance, Service .............................................................. 35

20.7.1.
20.7.2.
20.7.3.
20.7.4.
20.7.5.
20.7.6.
20.7.7.
Roll lock system description ....................................................................... 35

Hydraulic cylinder ....................................................................................... 35
Brake shoe adjustment ............................................................................... 35
Brake shoe removal .................................................................................... 36
Brake shoe installation ............................................................................... 36
Hydraulic cylinder disassembly ................................................................... 37
Hydraulic cylinder assembly ....................................................................... 37
20.8. Packing Gland Maintenance, Service ...................................................... 38

20.8.1.
20.8.2.
20.8.3.

Absorber packing removal .......................................................................... 39
Absorber packing installation ...................................................................... 40
20.9. Load Cell Maintenance............................................................................ 41

20.9.1
20.9.2
Load cell lubrication .................................................................................... 41

Load cell Linkage ........................................................................................ 41
20.10. Speed Sensor Adjustment ....................................................................... 42

20.10.1. Speed sensor adjustment ........................................................................... 42
20.11. Absorber Check Valve ............................................................................. 42

20.11.1. Absorber check valve ................................................................................. 42
20.12. Outlet Water Valve Adjustment ................................................................. 43

20.12.1 Water manifold valve adjustment ................................................................ 43
20.13. Load Control Valve .................................................................................. 44

20.13.1. Water control valve removal ........................................................................ 44
20.13.2. Load control valve cam adjustment ............................................................ 44
20.14. Dynamometer Rollset Repairs ................................................................. 44

20.14.1 Rollset component description .................................................................... 44
20.14.2 Major dynamometer repairs possible within the frame ................................. 45
20.14.3 Major dynamometer repairs that require shaft removal ................................ 45
20.15. Roll Shaft Removal .................................................................................. 46

20.16. Roll Removal from Shaft .......................................................................... 47
20.17. Absorber Disassembly ............................................................................ 48
20.18. Absorber Assembly ................................................................................. 49
20.19. Roll Installation onto Shaft ....................................................................... 51
20.20. Roll Shaft Installation ............................................................................... 52
20.21. Single Roll Shafts Alignment ................................................................... 53
20.22. Dual Roll Shaft Alignment ....................................................................... 54
20.23. Roll Axial Alignment ................................................................................ 55
20.24. Absorber to Frame Assembly................................................................... 55
20.25. Absorber Rotor Clearance Adjustment .................................................... 55
20.25.1. Absorber rotor to stator clearance check .................................................... 55
20.25.2. Absorber rotor to stator clearance adjustment ............................................. 56
20.26. Bolt Tightening Specifications ................................................................. 57

20.27. Service and MaintenanceTips ................................................................. 58
20.27.1. Service and maintenance tipsfuel hose fittings ......................................... 58
21. Control System Setup

21.1. Overview ................................................................................................... 3
21.2. The Control Parameters ............................................................................. 3
21.2.1.
21.2.2.
21.2.3.
Controller Name ............................................................................................ 3

Actuator Phase ............................................................................................. 3
Controller phase ............................................................................................ 5
21.3. Adjusting Control Parameters .................................................................... 6

21.3.1.
21.3.2.
21.3.3.
21.3.4.
21.3.5.
21.3.6.
21.3.7.
21.3.8.
21.3.9.
P-Gain .......................................................................................................... 7
I-Gain ........................................................................................................... 7
D-Gain ......................................................................................................... 8
I-Threshold ................................................................................................... 8
I-Time ........................................................................................................... 9
Feedback filter .............................................................................................. 9
Other control parameters ............................................................................ 10
Saving the Control Parameters to file .......................................................... 10
Quick reference guide ................................................................................. 10
22. Accessories and Options
23. Drawings and Parts Lists
General Information
1. General Information
1.1.
Introduction ................................................................................................ 3
1.1.1.
Copyright .....................................................................................................
1.1.2.
Purpose of Manual ......................................................................................
1.1.2.1. General Manual Explanation ...................................................................
1.1.2.2. Target Audience ......................................................................................
1.1.3.
Manual Conventions ....................................................................................
1.1.3.1. Warning and Suggestion Labels .............................................................
1.2.
3
3
3
3
3
3
Warranty, Liability, Legal Statements ......................................................... 4

1.2.1.
1.2.2.
1.2.3.
1.2.4.
1.2.5.
1.2.6.
1.2.7.
Disclaimer ...................................................................................................
FCC .............................................................................................................
Limited Warranty .........................................................................................
Service Under Warranty ..............................................................................
Service Out of Warranty ..............................................................................
Technical Assistance ...................................................................................
Extended Warranty ......................................................................................
4
4
4
5
5
6
6
1.3.
Product Identification ................................................................................. 6
1.4.
Product specifications................................................................................ 7
1.4.1.
1.4.2.
1.5.
Chassis dyno system .................................................................................. 7

Instrumentation ........................................................................................... 8
Manufacturer and distributors .................................................................... 8
1.1.
Introduction
1.1.1.
Copyright
E N E R A L
N F O R M A T I O N
Copyright 1998 by SuperFlow Corporation. All rights reserved.

No part of this publication may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any
language or computer language, in any form or by any means,
electronic, mechanical, magnetic, optical, chemical, manual,
or otherwise, without the prior written permission of
SuperFlow Corporation, 3512 N. Tejon, Colorado Springs,
Colorado, 80907, USA.
No part of the firmware with this product may be up-graded,
modified, or changed by any means, without the prior written
permission of SuperFlow Corporation, 3512 N. Tejon,
Colorado Springs, Colorado, 80907, USA.
1.1.2.
Purpose of Manual
1.1.2.1.
General Manual Explanation

This manual is provided as a reference that explains the
operations of the SF-602 Series Test System.
1.1.2.2.
Target Audience
This manual is intended to be used by skilled operators that
have been trained in the operation of the equipment by a
SuperFlow Customer Service Engineer.
1.1.3.
Manual Conventions
1.1.3.1.
Warning and Suggestion Labels

The following label(s) are used to indicate items of interest or
concern:
WARNING
NOTE
Indicates a very important consideration or is to draw the users attention to an

action that could cause harm to persons, damage to the equipment, loss of data
or other serious problem.
Indicates a suggestion or comment that may improve your testing.
Section 1 - page 3
SF-602
M a n u a l
1.2.
Warranty, Liability, Legal Statements
1.2.1.
Disclaimer
SuperFlow Corporation makes no representations or warranties with respect to this manual. Further, 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 of SuperFlow to notify any person of such
revisions or changes.
1.2.2.
FCC
Warning: This equipment generates, uses, and can radiate
radio frequency energy, and if not installed in accordance
with the instruction manual, may cause interference to radio
communications. It has been tested and found to comply with
the limits for a Class A computing device pursuant to Subpart
J of Part 15 of FCC Rules, which are designed to provide
reasonable protection against such interference when operated
in a commercial environment. Operation of this equipment in
a residential area is likely to cause interference, in which case
the user, at his own expense, will be required to correct the
interference.
1.2.3.
Limited Warranty
SuperFlow hereby warrants its products to the immediate
purchaser of this product, and to no others in the line of commerce. Any other users, purchasers or bystanders involved
with this product are expressly excluded from this warranty.
SuperFlow hereby warrants its product for fitness for ordinary
purposes for which such good are used. SuperFlow warrants to
the purchaser that each product manufactured to be delivered
hereunder will be free from defects in material, workmanship,
and title. 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 at SuperFlows plant a repaired or replacement
part. It will be the sole decision 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 Superflows product.
Section 1 - Page 4
SF-602 manual V2- 1125 Sect1.PM6.5, 5/1998
E N E R A L
N F O R M A T I O N
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 returning 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 tolled 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.
1.2.4.
Service Under Warranty

If you have any technical problems with your system, call the
SuperFlow Customer Service Department at (719) 471-1746, or
fax to (719) 578-1792. In Europe, call (32) 15-216300, or fax to
(32) 15-219458.
If it is necessary to return the system or components to
SuperFlow, contact the Customer Service Department and
alert them of the return.
The system or components are to be shipped to SuperFlow at
your expense. SuperFlow will repair the system at no cost to
you and pay for shipping it back via the best way surface. Any
other method, such as air express, will be at your expense.
1.2.5.
Service Out of Warranty

If your system is out of warranty, you should follow the same
procedure when requesting service of returning parts. You will
be responsible for all parts, service, and shipping costs. Onsite service is available. Contact the Customer Service Department for current rates.
Should your company require a purchase order for out-ofwarranty repairs, let us know the purchase order number
when you call.
Section 1 - page 5
SF-602
1.2.6.
M a n u a l
Technical Assistance
The Customer Service Department is open Monday through
Friday. If the lines are busy, please leave a message, and your
call will be returned at our first opportunity. Be specific when
describing the problem and failure history. The problem will
be solved more quickly when described in a calm, accurate
manner.
1.2 .7.
Extended Warranty
SuperFlow offers an extended warranty contract. To take
advantage of this extended warranty, you must sign the extended warranty contract and return it, together with full payment to SuperFlow prior to the end of your normal warranty
period. The extended warranty period is one year. To renew
the extended warranty for another year, the same procedure
must be followed. Shipping charges are not included in the
extended warranty, and are the only expenses you incur.
1.3.
Product Identification
Product name: Truck Chassis Dynamometer
The Truck Chassis Dynamometer is a chassis dynamometer
(rolling road) designed to allow testing of heavy trucks,
buses, and similar vehicles within the workshop environment.
Instrumentation-only versions have been derived from the SF602 system. These instrumentation systems can be applied to
engine dynamometers or existing rollsets and comprise the
same components as the equivalent complete chassis dynamometer system, except the SuperFlow rollset.
Model designations
chassis dynamometer system:
instrumentation system only:
NOTE
SF-591
SF-581
SF-592
SF-582
SF-602
SF-612
An instrumentation system upgrade kit is also available for older SF-601/611

systems. This kit is called WinPac. This manual also applies to a WinPac system.
Where necessary, a note will indicate WinPac-specific differences.
Due to the modular concept of the system, SuperFlow has

decided to serialize the main components individually.
Product labels with electrical and mechanical specifications
and serial numbers can be found on:
Section 1 - Page 6
the rollset
the instrumentation system (sensor box)
the fuel measurement system
1.4.
Product specifications
1.4.1.
Chassis dyno system
E N E R A L
N F O R M A T I O N
Roll Diameter
............................................................................ 36 (91,44 cm)
Continuous power absorption (wheel power)
Tandem drive axle ....................................... 1,100 hp (820 kW)
Single drive axle ............................................. 550 hp (410 kW)
Weight capacity
Tandem drive axle ................................. 50,000 lbs (22,728 Kg)
Single drive axle .................................... 25,000 lbs (11,364 Kg)
Speed capacity
Maximum test speed ..................................... 80 mph (128 kph)
Maximum operating speed ......................... 100 mph (160 kph)
Drive Axle Spacing Capacity

.................................................................. 4876" (122193 cm)
Rollset Brakes
Electronically-controlled, air-actuated, hydraulic, shoe-type
system
Independent roll-speed brake lockout
Water Requirements
.................................... 50 gpm @ 50 PSI (190 L/min @ 345 kPa)
...................................................... at maximum power capacity
Section 1 - page 7
SF-602
1.4.2.
M a n u a l
Instrumentation
Boom-mounted sensor box with 6 liquid crystal displays

and:
16 thermocouple inputs
10 pressure sensors
3 serial ports
ECM port
engine dyno torque
engine speed
inputs for other sensors and accessories
1.5.
Stand-alone gravimetric fuel system
Dynamometer interconnect box
Handheld remote controller
Ethernet communication between system components and

PC
Computer console with Pentium PC, monitor, and printer
WinDyn dynamometer software
Switching capability between engine dynamometer and

chassis dynamometer mode
Provision for automatic throttle control
Manufacturer and distributors

SuperFlow Corporation
3512 North Tejon, Colorado Springs, CO 80907-5299
Toll Free:
(800) 471- 7701
Phone:
(719) 471- 1746
Fax:
(719) 471- 1490
Service Department Fax:
(719) 578- 1792
sales@superflow.com
service@superflow.com
Monday through Friday, 8:00 AM - 5:00 PM Mountain Time
Detroit Office
36875 Schoolcraft, Livonia, MI 48150
Phone:
(734) 464- 4333
Fax:
(734) 464- 6704
mwaller@prodigy.net
Monday through Friday, 8:00 AM - 5:00 PM Eastern Time
Section 1 - Page 8
E N E R A L
N F O R M A T I O N
SuperFlow Europe
Generaal De Wittelaan 9, Unit 4, B-2800 Mechelen, Belgium
Phone:
INT+ 32 15- 216300
Fax
INT+ 32 15- 219458
sales@superflow.be
service @superflow.be
Monday through Friday, 9:00 AM - 5:00 PM Central European
Time
Website
www.superflow.com
Our website contains extensive test, service and troubleshooting information and is regularly updated.
Our Sales and Service departments can be accessed via e-mail
directly from our website.
Section 1 - page 9
EC Declaration of Conformity
3512 North Tejon
Colorado Springs, CO 80907
U.S.A.
Tel. (719) 471-1746 Toll Free:(800) 471-7701

Fax. (719) 471-1490
Service Department Fax: (719) 578-1792
Email:
sales@superflow.com service@superflow.com
declares that the following product:
Product designation:
Versions:
Year of construction:
Truck Dynamometer
SF-581, SF-582, SF-591, SF-592, SF-602, SF-612
1998
has been designed and manufactured in respect of the relevant requirements of the following Directives:
89/392/EEC, modified by the Directives 91/368/EEC and 93/44/EEC
89/336/EEC, modified by the Directives 92/31/EEC and 93/68/EEC
73/23/EEC, modified by the Directive 93/68/EEC
Harmonized Standards which have been applied:
EN 292-1
EN 292-2
EN 60204-1
EN 418
EN 614-1
EN 50081-1
EN 50082-1
Safety of Machinery - General principles

Safety of Machinery - Technical principles and specifications
Safety of Machinery - Electrical equipment of machines
Emergency Stops
Ergonomic design
Emission
Immunity
National and International standards and specifications which have been applied:
IEC 417
ISO 7000
NEC
Graphical symbols
Graphical symbols
National Electrical Code (U.S.)
Colorado Springs
G.N. Williams, President
System Overview
2. System Overview
2.1.
Purpose ..................................................................................................... 3
2.2.
Components .............................................................................................. 4
2.3.
Control Console ........................................................................................ 4
2.4.
Sensor Box ................................................................................................ 5
2.5.
Dynamometer rollset.................................................................................. 6
2.5.1.
2.5.2.
BR-600 Rollset description ............................................................................ 6

Load Control Valve ........................................................................................ 6
2.6.
Interconnect Box ........................................................................................ 8
2.7.
Handheld Controller .................................................................................. 9
2.8.
Fuel System............................................................................................... 9
2.9.
Specifications .......................................................................................... 10
Available sensor panels ............................................................................................. 13
2.1.
Y S T E M
V E R V I E W
Purpose
The SF-602 Truck Dynamometer Series is a chassis dynamometer (rolling road) designed to allow testing of heavy trucks,
buses, and similar vehicles within the workshop environment.
Typical applications include:
performance testing
diagnostic testing
durability testing
fleet testing
emissions testing
research and development
vehicle break-in
end-of-production-line testing
Testing on a dynamometer reduces road testing liability,

improves measurement accuracy, and enhances productivity.
The SF-602 Series comprises instrumentation-only versions
which can be applied to Heavy Diesel engine or chassis
dynamometers manufactured by SuperFlow or by other
suppliers. The instrumentation system can be set up for rapid
commutation between an engine and a chassis dynamometer.
NOTE
The SF-602 Series also comprises an instrumentation retrofit kit which

updates the older SF-601/611 systems with the new instrumentation
electronics. This upgrade kit is called WinPac. For all practical purposes, the
information in this manual is applicable to the WinPacs.
Six different system versions are available as follows:

Model No
Rollset
Instrumentation
Fuel
system (with
measurement
handheld controller)
system
Operator
console
Interconnect
box and
sensor boom
Section 2 - page 3
SF-602
2.2.
M a n u a l
Components
The SF-602 Truck Chassis Dynamometer consists of five major
components. These are the rollset, the instrumentation system
(with handheld controller), the fuel measurement system, the
operator console, and the interconnect box (with sensor boom).
These components are shown below.
SF-602 components, figure 2.1
A description of each component follows.
2.3.
Control Console
The control console houses the PC computer , monitor, keyboard, and mouse. It also contains the printer and other
connection devices. The PC computer communicates with the
sensor input box and the fuel system with an Ethernet communication system.
There are two computers in the SF-602 system. One is the PC
computer within the control console. The other is a
SuperFlow-designed computer within the sensor input box.
The sensor input box computer performs the system data
acquisition and control functions. The PC computer displays
data on the monitor, and stores the test data to the hard disk,
floppy disk, or facility network. Communication between the
two computers occurs over a high speed Ethernet network.
Section 2 - Page 4
SF-602 manual V2-1125 Sect2.PM6.5, 5/1998
Y S T E M
V E R V I E W
Monitor
Control console front view, figure 2.2
The operator console is standard on the SF-602 and SF-612

systems only.
SF-582 and SF-592 systems are shipped with a PC and printer
only. SF-581 and SF-591 systems are supplied without PC.
2.4.
Sensor Box
The sensor box is the main interface between the operator, the
vehicle, and the sensors during a test. The signals from the
dynamometer and from the vehicle sensors are connected to
the sensor box. Six liquid crystal displays are available to
observe sensor readings during the test. The handheld connects to the sensor box. The data from the sensor box is
transferred to the control console or PC over the Ethernet
communication network. The sensor box is typically mounted
on a moveable boom. In some system versions, the sensor box
may be mounted directly to the wall, and the interconnect box
hardware is mounted inside the sensor box.
Sensor input box, figure 2.3
Section 2 - page 5
SF-602
M a n u a l
2.5.
Dynamometer rollset
2.5.1.
BR-600 Rollset description

The SF-602 dynamometer rollset utilizes 36" (91 cm) diameter
rolls. The rollset resides in a special concrete area, or pit,
beneath the floor level. The large diameter rolls reduce the
amount of slippage between the tires and the rolls, and reduce
the amount of tire deflection. The result is lower tire temperatures and more accurate test results. Large bearings support
the roll shafts. The absorbers, also called water brakes, are
attached to the end of the shafts. In the unlikely event of a
load cell or rod end breaking, large chains are provided to
prevent the uncontrolled rotation of an absorber. 180-tooth
gears are placed on each roll for speed measurement. A brake
system allows the rolls to be locked.
NOTE
Older rollsets may have different tooth gears.
Rollset top view, figure 2.4
2.5.2.
Load Control Valve

The load control valve regulates the amount of water that is
allowed to enter the absorbers. The valve is controlled by an
electronic 4-20 mA signal from the sensor input box. The
electronic signal controls a pneumatic valve which regulates
the air pressure in the cylinder. When the pressure in the
cylinder increases, the valve opens. As the load control valve
opens, water flow to the absorbers increases and the load
produced by the absorbers increases.
Section 2 - Page 6
Y S T E M
V E R V I E W
Load control valve, figure 2.5.
NOTE
To operate properly, the load control valve must be supplied with the correct air
pressure from the interconnect box. The regulator should be set at 25-35 psi
(170-240kPa). If the air pressure is too low, the valve may not open fully. If the
air pressure is too high, the valve may operate erratically.
The load control valve is mounted on the pit wall. The valve
has a position indicator that is useful when checking the
operation of the system. To view the valve, a rollset cover
plate must be removed.
Load control valve position indicator, figure 2.6.
Section 2 - page 7
SF-602
2.6.
M a n u a l
Interconnect Box
The interconnect box transfer the signals and sensor readings
from the dynamometer to the sensor input box. The interconnect
box has an emergency stop button that will disconnect AC power
from the control console and sensor input box when pressed.
Interconnect box, figure 2.7.
NOTE
Some WinPac systems do not have the Emergency Stop button
The interconnect box also contains two air pressure regulators.

The regulators control the supply pressures to the load control
valve and to the roll lock system.
Interconnect box with door open, figure 2.8.
NOTE
Section 2 - Page 8
On some system versions, the interconnect box electronics and air pressure
regulators are mounted inside the wall-mounted sensor box.
2.7.
Y S T E M
V E R V I E W
Handheld Controller
The handheld is the main operator interface when conducting
a test. Most of the test operations are performed from the
handheld controller. Current data and other status information
can be displayed on the handheld controller. The keys are
shown below.
Handheld with key descriptions, figure 2.9.
NOTE
The Pen
key records one data line manually for each press of the key.
The Data
key alternates the channel data display between actual value,
units, and channel number.

The printer
key is not used in the SF-602.
The Toggle
key shows or hides the manual control command line on the
display.
2.8.
Fuel System
The fuel measurement system accurately weighs a fuel can.
The system calculates the fuel consumption rate by continuously analyzing the can weight as the engine draws fuel from
the can. The fuel measurement system also contains a liquidto-liquid heat exchanger that cools the hot fuel from the engine
before it is returned to the fuel can.
Section 2 - page 9
SF-602
M a n u a l
Fuel measurement system with door open, figure 2.10.
2.9.
WARNING
Only diesel fuel can be used with the SF-602 fuel measurement system. Other
fuels may produce dangerous vapors.
WARNING
The fuel can vent on the side of the cabinet must be open to a safe place in the
atmosphere. A blocked vent could cause the can to burst or leak. A vent cover is
provided to prevent blocking of this vent. Vapors will be released to atmosphere.
If this is not acceptable, you may connect a hose to this vent to route the vapors
back to a fuel tank or filter. Use 3/8 (10 mm) diameter hose if the total length is
less than 3 feet (.91 m). Use (13 mm) diameter hose for longer lengths.
Specifications
The SF-602 Series use SuperFlows New Generation Electronics (NGE) for state-of-the-art data acquisition and control
performance.
The NGE board-set used is the SF-1942/2060 board-set.
Processors
A Processor (1942 board):

- MC 68332 microcontroller
- On-board memory:
Section 2 - Page 10
Y S T E M
V E R V I E W
256k SuperOS ROM

512x16 serial EEPROM
512 k FLASH for application program
256 k battery backed SRAM
up to 12 MB 72-pin SIMM DRAM
NOTE
Note that the board is capable of storing over 44,000 lines of data when
equipped with 12 MB RAM, but the 16-bit architecture of WinDyn V 1.10 only
allows downloading 32767 lines of data. For Heavy Diesel applications, the
maximum number of data lines which can be recorded in memory has been
intentionally limited to 568.
B Processor (1942 board):

- MC 68332 microcontroller
- On-board memory:
256k system ROM
256 k battery backed SRAM
512k FLASH
Clock speed 16.78 MHz
16k Dual port RAM interface
Network communication
IEEE 802.3 MAC Network controller with 10-Base-2 and 10Base-T Ethernet interface
NetBEUI protocol
16k Dual port RAM interface
Data acquisition
6 programmable gain amplifiers

8-channel, 12 bit serial interfaced Analog to Digital Converter (ADC)
Data acquisition rate

Base rate: 2.5 kHz
5 channels at 2.5 kHz
8 channels at 312 Hz
2 groups of 8-128 expansion channels each measured at 1/

8 1/128 of the base rate
frequency channels at 200 Hz
User-selected
8 filter levels
On-board barometric pressure transducer with signal

conditioning
Data filtering
I/O
Section 2 - page 11
SF-602
M a n u a l
Sensor inputs
- analog: up to 269 analog voltage channels (WinDyn V
1.10 limit to 70 channels)
- frequency: up to 11 mag/TTL frequency channels
(WinDyn V 1.10 limit to 6 channels)
- inductive, capacitive, or coil primary spark pick-up signal
circuit
- photo tach input circuit
- input for 2-channel quadrature encoder or additional TTL
frequency channel
Other inputs
- 4 RS232 serial ports
- 6 digital inputs
Outputs
- 8x8-bits DAC
- 8 relay-capable digital outputs
LCD Display drivers

- serial port for up to 4 LCD boards with 2 six-character
LCDs each, daisy-chained
Controller interface
- 1 RS-232 serial port
- 16 TPU lines
- 2x12-bits DAC outputs
- 3 analog feedback signals
Safeties (not implemented on standard SF-602 systems)

- EMS (Emergency Stop command) scanned at 150 Hz
- Loop of series-connected, normally closed switches for
external panic buttons
- Internal loop for panic buttons on SF equipment
- 4 digital inputs configurable for Normally Open (NO), Normally Closed (NC), or TTL input
- one DPDT relay output supplies the EMS signal to external devices
Power supply
Section 2 - Page 12
Type: AT
115/230 VAC, 6/3 Amps
50/60 Hz
Y S T E M
V E R V I E W
Available sensor panels

thermocouple input panel
16 channels
type K, ungrounded
universal panel jacks, accept both standard and miniature

connectors
pressure input panel
10 channels
up to 6 pcb-mounted transducers (of which max. 2 differential sensors)
up to 4 screw-in industrial-grade transducers
1/8 x #4 male fittings for pressure lines
Section 2 - page 13
SF-602
M a n u a l
analog input panel
8 channels
4.096VDC, 5 VDC, 10 VDC excitation voltages
+/- 5 VDC and +/- 12 VDC supply voltages
configurable gain and offset, accepts any analog voltage

between 100 and +100 VDC
color-coded and keyed 10-pin Lemo connectors
system interconnect panel
Section 2 - Page 14
handheld controller serial port
blow-by sensor input
SAE 1587/1708 ECM serial port
engine dyno torque input
ch1/2
engine speed input
ch10
opacity sensor input
ch4 + serial port 2
auxiliary input #3
engine dyno and throttle control outputs
rack point indicator input ch75
ch5/7/8
Packaging and
Handling
3. Packaging and Handling

3.1.
Weights ..................................................................................................... 3
3.2.
Lifting and Handling instructions ............................................................... 3

3.2.1.
3.2.2.
3.2.3.
3.2.4.
Rollset .......................................................................................................... 3
Console ........................................................................................................ 4
Fuel System ................................................................................................. 4
Other components ........................................................................................ 4
3.3.
Packaging of a typical SF-602 system ....................................................... 4
3.4.
Packaging of a typical WinPac system ....................................................... 5
3.5.
Order of unpacking and inspection ............................................................ 5
3.1.
A C K A G I N G
A N D
A N D L I N G
Weights
The SF-602 dynamometer system is shipped in three containers, plus the dynamometer rollset.
Dimensions
Weight
13X84 (396X254X122cm)
8500lb. (3850kg)
with cover plates
Crate with console
41X48X85 (104X122X216 cm)
775lb. (350kg)
Pallet with instrumentation
84X48X30 (213X122X76cm)
400lb. (182kg)
Skid with fuel system
42X33X54 (107X84X137 cm)
435lb. (200kg)
Rollset (uncrated)
Rollset (crated)
3.2.
Lifting and Handling instructions
3.2.1. Rollset
The main dynamometer frame must be lifted with a crane
capable of supporting at least 10,000 lbs (4500 kg). Pay close
attention to following instructions and warnings:
WARNING
Use only a lifting sling to raise the rollset. Verify that the sling is rated for at least
10,000 lbs (4500 kg). Do not use a sling that shows signs of fraying or damage.
NOTE
A suitable lifting sling is available from SuperFlow. Contact your local Sales or
Service Representative for details.
WARNING
You must use the pick-up points indicated below. Failure to do so may result in
tipping and falling of the dynamometer resulting in damage, severe injury, or
death.
Section 3 - page 3
SF-602
3.2.2.
M a n u a l
Console
3.2.3.
Fuel System
3.2.4.
Other components
The sensor box, sensor boom, interconnect box, and accessories, do not require any special lifting instructions.
3.3.
Packaging of a typical SF-602 system

Following list can be used as a check sheet when your system
arrives. A similar document should be attached to the outside
of the box or crate.
NOTE
Section 3 - Page 4
Your system packaging may differ slightly from the standard system packaging
due to variations in components ordered with the system.
3.4.
A C K A G I N G
A N D
A N D L I N G
Packaging of a typical WinPac system

WinPac systems are custom-built for each installation and may
or may not include a PC, a sensor boom, and some accessories. Following list assumes a WinPac system with all the
available components. Your system may not come with all the
components listed.
3.5.
Order of unpacking and inspection

In most cases, the system will not be completely unpacked
and installed the day it arrives at your facility.
NOTE
These unpacking and inspection instructions should be used if you are

checking the delivery of the goods without proceeding with the actual
installation.
If the dynamometer can be immediately installed in its final

location, see also Installation (Section 5) of this manual.
NOTE
If there is any shipping damage to report, note it on the shipping receipt and
notify SuperFlow immediately.
Section 3 - page 5
Room Requirements
4. Room Requirements
4.1.
Introduction to dynamometer testing .......................................................... 3
4.2.
Accuracy of dynamometer testing .............................................................. 3
4.3.
Test room recommendations ...................................................................... 4
4.4.
Facility Recommendations ........................................................................ 8

4.4.1.
4.5.
Water System........................................................................................... 22
4.5.1.
4.5.2.
4.5.3.
4.5.4.
4.6.
Types of water systems .............................................................................. 22

Minimum flow requirements ........................................................................ 22
Water supply test ........................................................................................ 22
Fuel measurement system water requirements ........................................... 23
Electrical Requirements, Connections .................................................... 23

4.6.1.
4.6.2.
4.6.3.
4.6.4.
4.7.
Facility construction drawings ....................................................................... 8
Overall electrical requirements .................................................................... 23

Control console and sensor input box requirements .................................... 23
Fuel measurement system requirements .................................................... 24
Telephone line requirements ........................................................................ 24
Safety Precautions .................................................................................. 24

4.7.1.
4.7.2.
4.7.3.
4.7.4.
4.7.5.
General precaution ...................................................................................... 24

Interconnect box emergency stop button .................................................... 24
Protective equipment .................................................................................. 24
Press stop key on handheld to reset system .............................................. 25
The Hazards of Dynamometer Testing ........................................................ 25
4.1.
O O M
E Q U I R E M E N T S
Introduction to dynamometer testing

The SF-602 brings advanced vehicle testing and troubleshooting capabilities to the truck industry.
Although it is very easy to obtain test results with the SF-602, it
takes some effort to ensure the accuracy of these results. As
scientific practice teaches us, measurement accuracy is
largely determined by the level of control over the test conditions during the test. While the system can to a certain extent
compensate for atmospheric variations, it cannot measure,
control, or compensate for each possible variable in the
environment or the installation.
In addition, dynamometer testing involves running vehicles or
engines at road speed and power levels, which also creates
certain safety hazards.
This section provides some information and advice on how to
install your SF-602 in order to achieve the highest possible
level of accuracy and safety during your tests.
4.2.
Accuracy of dynamometer testing

Accurate measurement of the output of internal combustion
engines is only possible under tightly controlled test conditions. The power output of the engine will be directly affected
by the quantity and quality of the combustion air, the quality
and temperature of the fuel, the thermal conditions during the
test, and the atmospheric conditions.
While it is possible to correct the measured power to existing
standards, these standards only correct (within limits!) for the
fuel density and the atmospheric conditions during the test.
Variations in the oxygen content of the combustion air, excessive pressure losses in the air inlet system, variations in
exhaust back-pressure, variations in the temperatures of aircooled cylinders, oil, water, or fuel, or variations in tire pressures and temperatures may have a significant impact on the
accuracy and repeatability of your measurements.
To keep as many of these variables under control as possible,
adequate ventilation and exhaust extraction systems must be
installed. The test system itself should allow the operator to
verify the various pressures and temperatures of the engine
during the test. Finally, the test procedures should be standardized and consistent, particularly on chassis dynamometers.
Whereas the SF-602 can provide you with all the engine data
needed to verify the conditions of your test (depending on
configurations), the dynamometer needs to be installed in a
proper environment which provides the additional services
required for accurate testing.
The automated test procedures of the SF-602 will result in the
best test results achievable within the test environment.
Section 4 - page 3
SF-602
4.3.
M a n u a l
Test room recommendations

The test room must provide optimum control over test conditions and must also address the safety hazards. A typical test
room includes following equipment:
Equipment
Room
Walls, doors, window
Floor
Room ventilation
Exhaust gas extraction
Fire equipment
Purpose
restrict access to test area
protect other personnel from
projections, exhaust gases, hot
parts, noise
sound insulation between dynamometer and rest of workshop;
fire resistance
support dynamometer + vehicle

+ operator
easy maintenance
supply of combustion air
cooling of engine and exhaust
system
Requirements
adequate size for easy and safe
access to test equipment and
engine or vehicle
adequate lighting
25 dB sound reduction
typical
wide doors for easy access,
opening outwards for emergency evacuation
adequate strength
easy cleaning, antislip
Sufficient capacity for engine
power. To be determined as a
function of max. expected
engine power, the use of air- or
water-cooled engines,
Maintain a slight negative
pressure in the test room
(typically 1 (2.5cm) of H2O)
Sufficient capacity for max.
expected engine power.
prevent leakage of noxious

fumes to the rest of the
building
evacuate exhaust gas to prevent
contamination of engine inlet air
and to protect the operator
first response to a developing fire fire blanket, fire extinguisher
suitable for gasoline, diesel fuel
and electric fires
The test room should also provide a convenient space for the
computer and printer and adequate storage space for the
dynamometer accessories (such as sensors, cables, or calibration equipment).
The handheld controller can be positioned in a special hanger
on the sensor box when not in use. Alternatively, you may
prefer to provide a handheld support in a convenient location.
The following details are guidelines for your dynamometer
room construction and are offered to aid you in making your
dynamometer facility a safe, clean, and convenient place to
test trucks. These specifications and recommended sizes are
based on existing successful SuperFlow installations and are
required to install the SF-602 Chassis Dynamometer. Local
codes and building requirements may not be met by our
recommendations. A local architect should be employed to
provide you with the final designs for your facility.
Section 4 - Page 4
O O M
ROOM
The room should be of good quality construction, concrete or
concrete block wall construction works well for noise suppression. Walls should be finished in a high gloss epoxy paint for
ease in cleaning and durability against rock chips thrown by
vehicle tires.
The room should be approximately 50 long, 25 wide and 2224 high (15m long, 7,5m wide, 7m high).
FLOOR
The floor should have at least a 6 (15 cm) reinforced concrete
slab with a smooth steel-trowelled finish. If a non-metallic floor
hardener, such as Stenson Color Hard, is applied (60#/100
square feet) chipping is reduced and cleaning is easier. Epoxy
paint should be considered for the floor, with an abrasive
material mixed with paint for improved traction.
PIT
The dynamometer pit should be constructed in accordance
with SuperFlow Corporation installation drawings.
TIE-DOWNS
Front tie-down rails must be installed as per installation
drawings 3 and 4. The front tie-down rails are used as safety
restraints while testing trucks. Care should be taken to keep
the rails parallel with the roll centerline of the dynamometer.
WARNING
Be sure that the centerline of the tie-down rails is lined up with the centerline of
the dynamometer rolls and NOT with the centerline of the pit.
It is recommended that only a qualified cement contractor

install and finish the pit and tie-down rails. For the sake of
appearance and to prevent chipping and rough edges, care
should be taken in finishing off the trough for the rails. The
front tie-down anchor clips attach to these.
Floor, tie-down rails, and troughs should be sloped towards a
drain. A 6 (15cm) drain trench with a diamond safety plate
cover works quite well. The tie-down rail trough should
intersect this trough.
The drain trough can be routed back to the pit sump with a 4
(10cm) drain pipe. Reference installation drawing number 4.
Some users will eliminate the drain trench by extending the
tie-down rails to the pit edge, and have individual drain tubes
from the rails to the pit. In this configuration the floor would be
sloped towards the pit edge.
Rear tie-down anchors should be installed as per installation
drawing number 4. These are the primary restraints for the
trucks, so care should be taken to anchor the rear tie-downs
into the concrete slab when laying out reinforcement for the
slab. A grounding wire must be run from the rear tie-down to
the pit grounding rod.
Section 4 - page 5
SF-602
M a n u a l
DOORS
Overhead doors should at least be 14 (4,2m) high X 14 (4,2m)
wide and provided with a sign on the wall that they should be
opened all the way or use a motor operator that opens the
doors fully without stopping in between so that high projections on trucks such as log booms will not damage the door.
NOTE
Doors should be of the type to prevent interference with the ventilation system
when open.
VENTILATION
Ventilation should be provided to evacuate the room of hot air
and exhaust gases and to allow cool air to enter so that the
truck radiator can take advantage of it. A ceiling mounted fan
of 30,000 to 50,000 CFM (50000 to 85000 m3/hr) capacity can be
used. One possibility is a Grainger P/N 7C982. The exhaust fan
should have motor or gravity operated dampers to keep room
heat in when not in use. A vent hood should be installed, 12
to 14 wide (3,6 to 4,2 m) x 14 to 16 long (4,2 to 4,8 m) x 4 to
8 high (1,2 to 2,4 m), located on the tie-down rail centerline.
The hood location, with respect to the pit, should be above the
tie-down rails, with the rear of the hood directly above the
forward pit wall (see drawing number 3). The hood opening
should be 16 (4,8m) from floor level at the dynamometer
(installation drawing number 10). Velocity or motor operated
shutters of sufficient area, mounted in the wall approximately
6 from the floor should be provided to allow fresh air into the
dynamometer room, if the dynamometer is to be run with the
overhead door closed in winter.
In cold climates at least 2 ea. 60,000 BTUH (18 kWh) infrared
space heaters should be provided with thermostatic control.
This type of heater seems to work better than forced air
heating when the dynamometer is in frequent use in winter
time. One should be located above on the left side of vehicle
near the sensor boom location.
WATER
WARNING
The importance of a proper water supply system is often underestimated.

Although it is possible to use either an open loop or a closed loop water supply
system to the dynamometer, our experience shows that open water systems are
much more likely to result in water supply problems. Such problems typically
have an effect on load capability, control stability, or durability of the
dynamometer. SuperFlow always recommends a closed loop water system.
In open water systems where the water supply is adequate, 50

gpm at 50 psi (190 l/min at 350 kPa), and drainage is not a
problem, the 4 (10cm) elevated drain in the pit is adequate for
the clean water from dynamometers. It must be at least 2 (5
cm) below the outlet of the dynamometers. If this is not possible, a sump pump of sufficient capacity must be provided.
The second floor drain at the rear of the pit collects all water,
and vehicle fluids that are washed into the pit. This second
Section 4 - Page 6
O O M
drain should be directed to the facility oil separation system, or

be handled in an approved method.
In closed water systems where water is stored in a storage tank
or run through a cooling system, pit drainage should still be
provided. The capacity of the sump pump, if required, only
needs to be sufficient to remove run-off water from the floor
and the pit during wash down.
Closed water systems, in many cases, are required because of
insufficient water supply, inadequate drainage, or by local water
use laws. (See installation drawing number 7). The least expensive system in most cases is the water storage method. In most
climates, a storage tank of 4,000 to 8,000 gallons (15 000 L to
30 000L) is of sufficient capacity to adequately cool the dynamometer, depending upon usage and the number of shifts. It is
suggested that when the storage tank is set in place, an additional suction and return line be run to the tank and stubbed for
a pump and radiator if needed for supplementary cooling.
The water supply pump should be a Berkely B 1-1/2 TPL 5Hp
(3,7kw) or equivalent. An explosion proof motor is only
required if the pump is installed in a hazardous location.
Check local electrical codes. A 3/8 bleed line from the outlet
housing of the pump to the top of the tank or return line should
be provided to prevent localized boiling when the control valve
is closed. See installation drawing number 7 for details. When
underground storage is used, a good quality foot valve should
be provided in a 3 diameter (7,5cm) suction line, as well as a
check valve at the pump.
The sump tank and pump should be installed as outlined in
installation drawing number 7 and 9. The sump tank has an
explosion proof motor and switch and should be wired in
accordance with local codes.
LIGHTS
Halogen, or fluorescent fixtures can be hung from the walls or
ceiling 18 (5,4m) from the floor, parallel to the tie-down rails,
1 to 3 (0,3 to 1,0m) from the sidewalls of the room. Do not
install lights over the dynamometer or in line with the truck
tires. Rocks imbedded in tires come out at speeds of up to 80
MPH (130 km/h) and shorten the life of light fixtures.
ELECTRICAL
Provide at least 2 ea. 120v (240v), 15 amp. outlets in the
dynamometer room. One shall be located adjacent to the
interconnect box and shall be a low noise, dedicated outlet. All
additional outlets in the dynamometer or control room should
be on a separate circuit.
TELEPHONE LINE
SuperFlow supplied PC computers come equipped with a
circuit board that features a Fax/Modem for transfer of computer files, and software support. A telephone line should be
located near the Computer Console or PC computer, depending upon equipment configuration.
Section 4 - page 7
SF-602
M a n u a l
AIR
The minimum requirement for air pressure is 100 PSI (700kPa).
The plumbing requirement consists of a 3/8 pipe ending at
the interconnect box. While SuperFlow does provide an air
dryer, the shops air supply should be clean and dry.
APPEARANCE
A storage cabinet placed near the sensor boom is useful for
storage of extra hoses and cables provided by SuperFlow, as
well as for the various fuel, pressure and temperature fittings
collected over time for the different engine families being tested.
A hose bib and garden hose should be provided so that the
dynamometer room can be washed down. Trucks bring in and
leave a considerable amount of dirt in a fairly short period of
time. Provide a hook or a reel on the wall for the hose.
Brackets to hold tie-downs and calibration arm are a nice
finishing touch to keep material off the floor for ease of cleaning.
OPTIONAL CONTROL ROOM
The majority of SF-602 installations include a separate control
room for the PC computer. This provides a cleaner, controlled
environment for the PC, the printer & reports, any software
diskettes, microfiche reader, and location to allow customers to
view the test from a safe environment. Suggestions for the
control room include a telephone, appropriately sized desk, and
air conditioner / heater unit. This can be accomplished in a foot
print as small as 4 x 8 (1,2 x 2,4 m). Please contact SuperFlow
Diesel Sales for input on your specific room configuration.
4.4.
Facility Recommendations
4.4.1.
Facility construction drawings

A complete set of facility design drawings is available. Detailed information is available regarding all facets of the
dynamometer installation. Reduced-size copies of the drawings are shown on the next pages. Full size drawings are
available from SuperFlow.
Section 4 - Page 8
SF-602
M a n u a l
4.5.
Water System
4.5.1.
Types of water systems

The dynamometer uses water to produce a load. Providing the
proper quality and quantity of water is important for successful
testing. There are two types of water systems: closed and open.
A closed water system (also called a recirculating system)
typically includes a large storage tank, a supply pump, a sump
tank with a return pump, and the necessary valves. A cooling
tower may be added for extra testing capacity. Water loss only
occurs due to evaporation and leakage past the dynamometer
packing glands.
An open water system (also called a total loss system) is
typically fed from a local water main supply. After the water
passes through the dynamometer, it is typically routed to the
sewer system.
4.5.2.
WARNING
The importance of a proper water supply system is often underestimated.

Although it is possible to use either an open loop or a closed loop water supply
system to the dynamometer, our experience shows that open water systems are
much more likely to result in water supply problems. Such problems typically
have an effect on load capability, control stability, or durability of the
dynamometer. SuperFlow always recommends a closed loop water system.
NOTE
Open water systems results in large quantities of heated water to be drained

into the sewers. This is not only wasteful but may be illegal in your area. Consult
your local environmental agency or utility company for information
Minimum flow requirements

For maximum capacity and optimum performance, the dynamometer requires a water supply of 50 gallons per minute (190
l/min) at 50 psi (345 kPa). Before the dynamometer is installed, it is suggested that the water supply be tested to be
sure these requirements are met. The test applies to both
closed and open water systems.
4.5.3.
Water supply test
Section 4 - Page 22
1.
Attach a one-inch (25 mm)(minimum) pipe tee fitting to the

pipe supplying water to the dynamometer at the pit wall.
Install a 0-100 psi (0-690 kPa) water pressure gauge in this tee.
2.
Attach a one-inch (25 mm) (minimum) gate valve to the outlet

of the tee fitting and connect a length of hose to the valve.
3.
Shut the valve. Turn on the water supply.
4.5.4.
O O M
4.
Note the static water pressure. It should be 50-100 psi (345 to 690 kPa)
5.
Open the valve slowly and adjust it until the pressure gauge
reads 50 psi (345 kPa).
6.
With a suitable drum or other container of known volume,

measure the water quantity and the time required to collect
that quantity. Calculate the water flow rate. This should be a
minimum of 50 gpm (190 l/min).
7.
If the static water pressure is too low, check the supply pump, or
check with the public water company to determine the cause.
8.
If the dynamic flow rate is too low, but the static pressure is
adequate, check for an inadequate supply pipe size, an excessively long pipe length to the supply, an undersize water meter,
or other flow restrictions. Excessively long pipe runs may lead
to control problems. For 2" (51 mm) diameter pipe, it is recommended that the developed length be less than 100' (30.5 m).
Fuel measurement system water requirements

The fuel measurement system contains a liquid-to-liquid heat
exchanger that cools the hot fuel from the engine before it is
returned to the fuel can. To provide the best cooling capability, the fuel cooler should be connected to the city water
supply, rather than the closed water system. City water is
typically colder than water in a closed system. Refer to the
facility design drawings for additional information.
4.6.
Electrical Requirements, Connections
4.6.1.
Overall electrical requirements
NOTE
Electrical requirements for water system pumps, exhaust fans, and accessories
which are not part of SuperFlows supply are not discussed in this manual. Refer
to the Facility Drawings for basic suggestions. In all cases, consult your
electrical contractor and local electrical code.
The SF-602 system requires two dedicated 15 Amp circuits for

110 Volt operation. For 230 Volt operation, two 7.5 Amp
circuits are required. One circuit supplies the control console
and sensor input box through the interconnect box. The other
circuit supplies the fuel measurement system. If other outlets
are provided within the room, they should be connected to
different circuits. It is also recommended that a telephone line
be available for modem service assistance.
WARNING
The ground connection should be properly tied to earth in all installations. GFI
circuits should be provided on all outlets in the test area
Section 4 - page 23
SF-602
4.6.2.
M a n u a l
Control console and sensor input box requirements

One electrical outlet should be placed near the uninterruptible
power supply (UPS) or interconnect box. The use of a UPS is
recommended for the control console and sensor input box
power. In the event of a power failure, the UPS will allow the
computer to be shut down properly.
4.6.3.
NOTE
SuperFlow does not supply the UPS as standard
Fuel measurement system requirements

One electrical outlet should be placed near the operating
position of the fuel measurement system.
4.6.4.
Telephone line requirements

A telephone line outlet should be placed near the control
console. When the line is connected to the control console for
service via modem, all other devices on the line should be
disabled, so only the control console answers the call from
SuperFlow.
The phone line should be a direct line to the telephone service.
4.7.
Safety Precautions
4.7.1.
General precaution
The operating instructions are provided as a reference or
reminder for people who have been trained on the operation of
the equipment. If you cannot find the answer to a problem or
explanation for a procedure within this manual, please contact
the SuperFlow Customer Service Department.
WARNING
4.7.2.
Dynamometer testing can be dangerous. Proceed cautiously, and investigate

any conditions that may be abnormal before starting or continuing a test.
Interconnect box emergency stop button

An emergency stop button is located on the wall-mounted
interconnect box. In the event of an emergency, press the button.
This will disconnect the AC power that supplies the sensor input
box, and the control console (depending on the installation). To
release an emergency stop, twist the button clockwise. The
button will pop out, and the AC power will be restored.
Section 4 - Page 24
4.7.3.
O O M
Protective equipment
It is recommended that proper eye and ear protection devices
be worn at all times during a test. Depending on the environment, it may be advisable to wear such devices at all times.
4.7.4.
Press stop key on handheld to reset system

To reset the system at any time, or to stop a test under way,
press the stop key on the handheld, as shown below. This will
remove the load from the dynamometer.
4.7.5.
The Hazards of Dynamometer Testing

Dynamometer testing involves running internal combustion
engines, resulting in the presence of hot or rotating parts,
fluids under pressure, fuel, high ignition voltage, and exhaust
gases. In the case of chassis dynamometer testing, additional
risks associated with rotating transmission parts, wheels, and
rolls, are present.
The dynamometer operator will be exposed to a number of
hazards such as noise, heat, rotating parts, gases, or electric
shock. These risks are generally associated with the engine or
vehicle under test rather than with the dynamometer itself and
it is thus not possible for SuperFlow to protect the operator
against all these hazards by the design of the dynamometer.
The dynamometer will have to be installed in an environment
which is specifically designed for this type of testing and
which provides the additional safety required to provide
maximum protection for the operator.
In all cases, dynamometer testing should be confined to a
restricted area. Only the operator should be allowed within
this area during testing.
A list of possible hazards and the recommended protection
against these hazards follows.
Hazard
Exhaust gas
Fuel (vapors)
Fuel (fire)
Rotating parts
Projections
Hot parts
Noise
NOTE
Protection
exhaust gas extraction
adequate ventilation
no fuel containers in the test area
no smoking policy
fire blanket and fire extinguisher
restricted access, no loose clothing, guards
guards, safety glasses
guards, protective equipment (gloves)
hearing protection for the operator
Sound insulation of the test area for other
personnel
A typical enclosed and ventilated test room and proper test procedures will
provide adequate protection against these hazards.
Section 4 - page 25
Installation
5. Installation
5.1.
Placement of Dynamometer into Pit .......................................................... 3

5.1.1.
5.2.
Load Control Valve Installation .................................................................. 5

5.2.1
5.3.
Control console installation ......................................................................... 13
Handheld Connection.............................................................................. 14
5.8.1
5.9.
Interconnect box mounting .......................................................................... 12

Interconnect box connections ..................................................................... 12
Control Console Installation .................................................................... 13

5.7.1
5.8.
Boom installation .......................................................................................... 8

Cable installation .......................................................................................... 9
Sensor input box installation ....................................................................... 10
Interconnect Box Installation .................................................................... 12

5.6.1
5.6.2.
5.7.
Sump pump installation ................................................................................ 7
Sensor Input Box Installation ..................................................................... 8

5.5.1
5.5.2
5.5.3
5.6.
Sump tank installation (closed water system only) ....................................... 6

Open water system connections ................................................................... 7
Sump Pump Installation ............................................................................. 7

5.4.1
5.5.
Load control valve mounting ......................................................................... 5
Sump Tank Installation ............................................................................... 6

5.3.1
5.3.2
5.4.
Dynamometer installation ............................................................................. 3
Handheld connection .................................................................................. 14
Fuel System Installation .......................................................................... 15

5.9.1
5.9.2.
Unpack fuel system .................................................................................... 15

Fuel cooler .................................................................................................. 15
5.10. Configuration ........................................................................................... 16

5.10.1. Computer Communication ........................................................................... 16
5.10.2. Computer Setup .......................................................................................... 16
5.10.2.1.Install network card ............................................................................... 17
5.10.2.2.Install network cable .............................................................................. 17
5.10.2.3.Configure PC for NetBEUI communications ........................................... 17
5.10.2.4.Install WinDyn ........................................................................................ 18
5.10.2.5.Run WinDyn ........................................................................................... 18
5.10.2.6.How to configure your system for US units or Metric units ..................... 19
5.11. Description of sensor connections ........................................................... 20

5.11.1.
5.11.2.
5.11.3.
Thermocouple Connections ......................................................................... 20

Pressure Connections ................................................................................. 21
SF-602
5.11.4.
5.11.5.
5.11.6.
5.12
M a n u a l
Blowby sensor ............................................................................................ 22

Opacity sensor ........................................................................................... 22
Rack point sensor ....................................................................................... 23
Basic System Tests .................................................................................. 23

5.12.1
5.12.2
5.12.3
5.12.4
5.12.5
5.12.6
5.12.7
Turn system on ........................................................................................... 23

Basic roll lock test ...................................................................................... 24
Brake system bleeding ............................................................................... 24
Roll lock over-ride test (due to presence of vehicle speed) ......................... 24
Load control valve test ............................................................................... 25
Full flow water test (closed water system only) ........................................... 25
5.13. Calibration ............................................................................................... 27
Section 5 - Page 2
5.1.
Placement of Dynamometer into Pit
5.1.1.
Dynamometer installation
N S T A L L A T I O N
1. Clean the pit thoroughly.

2. Measure the pit for the proper dimensions as detailed in
the pit drawings. Check for the proper placement of the
support and thrust pads.
3. Remove the cover plates from the dynamometer as shipped.
4. Attach an adequate lifting sling to the lifting holes located
at the corners of the rollset, as shown in figure 4.1. The
dynamometer assembly without cover plates weighs
approximately 8,500 lbs. (3,856 kg).
NOTE
Use only a lifting sling to raise the dynamometer. Verify the sling is rated for at
least 10,000 lbs. (4,536 kg). Do not use a sling that shows signs of fraying or
damage.
NOTE
A custom lifting sling can be borrowed from SuperFlow for the dynamometer
installation. Contact the SuperFlow Customer Service Department to reserve a
sling. Part number T1200A-0610)
5. Lower the dynamometer into the pit.

6. Adjust the leveling screws so the frame top is flush or 1/8"
(3 mm) above the edge of the pit. Adjust the screws for
equal pressure. The resultant torque is approximately 26
lb-ft. (35 N-m).
Section 5 - page 3
SF-602
WARNING
M a n u a l
Verify that all leveling screws are equally supporting the weight of the
dynamometer, and that the dynamometer height is adequate. The dynamometer
should never be suspended by the cover plates.
Rollset with lifting sling
Pit edge
7. Position the dynamometer in the pit with equal clearance

from the front and rear walls, and 29.25 inches (743 mm)
from the left wall. (For a pit without a sump area, consult
the factory).
8. Adjust the four horizontal thrust screws on the dynamometer frame so that they just touch the thrust plates in the
walls of the pit. Then tighten the upper screws an additional turn. Tighten the lower screws with a torque
wrench to 150 lb-ft (203 N-m).
Section 5 - Page 4
Rollset thrust screws
9. Connect the dynamometer frame to the pit grounding rod.
5.2.
Load Control Valve Installation
5.2.1
Load control valve mounting
1. Unpack the load control valve components.

2. Rigidly mount the control valve to the pit wall per figure below.
Load control valve installation
Section 5 - page 5
SF-602
M a n u a l
3. Connect the control valve inlet to the water supply with a

2" pipe (50 mm) (minimum). Reduce the pipe size to 1
(38 mm) only at the valve with a 1 x 2 bell reducer.
4. Connect the control valve outlet to the water manifold on
the frame using a 1 (38 mm) inside diameter hose.
WARNING
Use only flexible hose to connect the control valve to the dynamometer. Do not
use rigid plumbing. Vibrations from the dynamometer may disturb the stability of
the control valve.
5. Install a (13 mm) liquid tight flexible conduit between

the control valve and the dynamometer junction box that is
located on the dynamometer frame.
WARNING
Dynamometer signal and control wires are considered to be intrinsically safe,

but local codes may require explosion proof conduit to be used for all pit wiring.
6. Locate the 50' (15.24 m) 1200A-1981 pit signal cable.

Starting from the interconnect box, pull the un-terminated
end of the cable through the 1" (25 mm) conduit to the
dynamometer junction box. Leave the extra cable length
coiled at the junction box. The cable will be connected by
a SuperFlow Customer Service Engineer during the
commissioning of the equipment.
5.3.
Sump Tank Installation
5.3.1
Sump tank installation (closed water system only)

Most customers with closed water systems choose to use a
sump tank and pump assembly that is available from
SuperFlow (part number T1200A-0646). The standard pump is
a 5 horsepower explosion proof unit. If the piping length to the
storage tank is excessive, or located on an upper floor level, a
larger pump may be required.
NOTE
The sump tank is also called the return tank. The tank receives the dynamometer
outlet water. The tank is part of SuperFlows optional closed water system.
A liquid level relay assembly is included with the sump tank.

Two probes are placed within the sump tank to detect the
water level. Most customers choose to supply AC power to the
liquid level relay circuit and the pump control circuit at all
times. The pump should not come on until the water level
reaches the upper probe. Keeping the system on at all times
helps avoid accidental flooding of the pit.
1. Install the sump tank into the pit according to the facility
design drawings.
Section 5 - Page 6
Sump Tank
2. Connect the two (19 mm) drain fittings on the dynamometer frame to the sump tank using flexible hoses.
3. Connect the water pump to the return water plumbing.
Connect the liquid level relay sensor to the pump control
circuit. Circuit schematics are available in the appendix.
WARNING
5.3.2
Explosion proof wiring is recommended for all sump tank and level sensor
components. The standard sump tank pump is explosion proof.
Open water system connections

For open water systems, connect the dynamometer drain
fittings to the system drain. The connections should allow
gravity draining of the absorbers
5.4.
Sump Pump Installation
5.4.1
Sump pump installation

The sump pump differs from the sump tank and its pump. The
sump pump is required to remove waste liquids from the lowest
portion of the pit. The output of the pump is usually connected
to an oil separator or water treatment system. The common
sources of liquid include absorber packing leakage, tie-down
rails drainage, engine and vehicle leakage, and test room washdown drainage. A sump pump is also required if the sump tank
pump fails to empty the tank adequately.
The sump pump is not provided by SuperFlow.
Section 5 - page 7
SF-602
M a n u a l
Sump Pump installation
5.5.
Sensor Input Box Installation
5.5.1
Boom installation
1. Unpack the boom assembly.
2. Choose the location for the boom to be mounted to the wall.
The length of the flexible tubing between the interconnect
box and the sensor input box is 5' 6" (1.68 m). The bottom of
the boom is typically 85 (2,159 mm) above the floor, which
equates to 89 (2261 mm) between the floor and the center
of the upper holes of the lower bearing mount.
Sensor input box boom
Section 5 - Page 8
3. Drill the mounting holes in the wall. The bearing mounts

can be used as a template to mark the holes. The facility
drawings also contain an actual size paper template.
4. Loosely bolt the lower bearing mount to the wall with 7/
16 (11 mm) diameter bolts.
WARNING
The boom must be firmly attached to the wall using expandable collars or
similar devices. If the wall does not offer adequate material, bolts should extend
through the wall, with nuts placed on the outside.
5. Place the nylon disk on the lower shaft of the boom and
position the boom into the lower bearing mount.
6. Place the upper bearing mount onto the boom, and loosely
bolt the mount to the wall.
7. Rotate the boom while tightening the bearing mount bolts.
8. Loosen the bolt on the friction lock. Slide the friction lock
onto the lower boom shaft. Install the friction lock and
tighten the bolt.
9. Slide the rubber bellows into the outer boom section.
Connect the outer boom to the knuckle. Connect the
ground safety wire between the boom sections. Do not
cover the knuckle with rubber bellows at this point.
5.5.2
Cable installation
1. Locate the sensor input box cables. The standard SF-602
sensor input box requires the following cables:
Two Ethernet extension cables (1200A-1902-25)
AC power cable (1200A-2178)
Serial communication cable (1200A-2180)
Signal cable #1 (1200A-2175)
Signal cable #2 (1200A-2176)
Ground wire
2. Note the cable labels. Bundle the sensor input box cable ends
together in preparation for pulling them through the boom.
Stagger the ends of the cables by three inches (70 mm)
3. Pull the cables through the interconnect box hole, the
flexible conduit and its connector rings (not yet permanently attached), the inner boom section, the center of the
knuckle, the outer boom, and finally through the sensor
input box hole.
NOTE
The cables can be pulled through the boom with less difficulty when using a
wire fish tape.
Section 5 - page 9
SF-602
5.5.3
M a n u a l
Sensor input box installation

1. Unpack the sensor input box assembly.
2. Open the sensor input box front panel.
3. Disconnect the front panel from the rear housing by
removing the hinge lock screw and sliding the hinged
components apart.
4. Remove the green wire from the Back Panel
5. Install the supplied O ring on the sensor box mounting post
6. Mount the sensor input box rear housing to the boom. Install
the bearing, thrust washers, lock nut, and anti-rotation bolt.
7. Reconnect the sensor input box front panel to the rear
housing. Install the hinge lock screw. Leave the front panel
door open.
NOTE
If the hinge lock screw is not installed, the door may fall off!
8. Connect the two Ethernet cables to the 1200A-1942 board

with a T connector. It may be best to route one cable on
the left, and the other cable on the right. See the diagram
below.
Section 5 - Page 10
Sensor input box cable connections
9. Connect the 1200A-2175 cable to the J6 port on the 1200A2060 board.

10. Connect the 1200A-2176 cable to the J11 port on the 1200A2060 board.
11. Connect the 1200A-2180 cable to the J6 port on the 1200A1942 board. J6 is two ports to the right of the Ethernet port.
12. Connect the 1200A-2178 cable to the power supply.
13. Reconnect the green wire to the back panel
14. Carefully close the sensor input box door, making sure the
cables do not bind or pull loose.
15. Close the door latches.
16. Tighten the plastic fittings that secure the flexible conduit
(between the boom and the interconnect box).
17. Connect the 1200A-2175 cable to the J40B port on the
1200A-1049 board within the interconnect box.
18. Connect the 1200A-2176 cable to the J40A port on the
1200A-1049 board within the interconnect box.
19. Plug the 1200A-2180 cable connector into the port inside
the interconnect box.
20. Connect one of the 1200A-1902-25 Ethernet cables to the
NET 1 port that is connected to the control console
21. Connect the other 1200A-1902-25 Ethernet cable to the NET
2 port that will be connected to fuel measurement system.
22. Connect the 1200A-2178 cable to the AC power socket
within the interconnect box.
23. Connect an AC power cord to the System AC Power In
port at the interconnect box. Do not apply power yet.
NOTE
The 110/230 Volt AC ground must be connected to earth ground or bonding wire.
Section 5 - page 11
SF-602
M a n u a l
5.6.
Interconnect Box Installation
5.6.1
Interconnect box mounting

The interconnect box should be rigidly mounted on the wall
near the sensor input box boom. The length of the flexible
tubing between the interconnect box and the sensor input box
is 5' 6" (1.68 m). This length should be considered when
locating the interconnect box.
5.6.2.
Interconnect box connections

1. Auxiliary pumps, fans, or other accessories may be connected to the relay contacts on the terminal strip of the
interconnect board within the interconnect box. The relay
contacts change state when the dynamometer rolls are
unlocked.
Interconnect box with door open
Section 5 - Page 12
2. Pull two 3/8" (10 mm) plastic air lines through the second 1"
(25 mm) conduit running between the pit and the interconnect box. Purge the lines with shop air before connecting.
3. Connect the blue 3/8" (10 mm) plastic air line to the control
valve connection in the interconnect box and the load
control valve in the pit.
4. Connect the red 3/8" (10 mm) plastic air line to the roll
lock connection in the interconnect box and the roll lock
master cylinder on the dynamometer frame.
5. Install the cover plates over the dynamometer rolls. Do not
install the absorber cover plates at this point.
6. Connect the supplied filter to the air supply connection at
the interconnect box. Connect a 3/8" (10 mm) shop air line
to the filter.
WARNING
Only clean, dry shop air is recommended for interconnect box use. Excessively
dirty or moist air may lead to brake circuit or load control valve damage.
5.7.
Control Console Installation
5.7.1
Control console installation
1. Unpack the SF-602 control console.

2. Unpack the computer, monitor, printer, and miscellaneous
cables.
3. Locate the computer connection cables within the control
console. The standard SF-602 console includes the
following cables:
Ethernet extension cable (1200A-1902-10)
Mouse extension cable (1200A-2167)
Serial port extension cable (1200A-2168)
Keyboard extension cable (1200A-2169)
Monitor extension cable (1200A-2185-1)
Sound jack extension cable (1200A-2235)
Printer parallel cable (E4190P-1053)
4. Place the computer onto the top shelf of the lower section.
Connect the cables within the SF-602 console to the
computer according to the cable and port labels.
5. Connect the keyboard and mouse to the extension cables.
6. Prepare to install the computer monitor into the monitor
housing. Push on the glass cover while releasing the
levers. Carefully remove the glass cover.
Section 5 - page 13
SF-602
M a n u a l
WARNING
Use caution when removing the monitor housing glass. The glass is only
retained by lanyards, and is free to fall when the lanyards are removed.
7. Connect the monitor to the cables within the housing.

Make sure the monitor is secured by the mounting pins.
Replace the housing glass, the lanyards and lock the
levers.
8. Connect the monitor housing to the control console with
the following cables:
Monitor extension cable (1200A-2185-2)
9. Place the printer into the control console drawer. Connect
the AC power cord and the parallel interface cable to the
printer. Load the printer with paper.
10. Connect the following cables to the control console:
Ethernet extension cable (1200A-1902-25)
Serial communication cable (1200A-2181)
11. Connect the Ethernet cable to the NET 1 port at the interconnect box.
12. Connect the 1200A-2181 cable to the TEST 1 RS232
connection at the interconnect box.
13. Connect the 1200A-2177 AC power cable to the System AC
Power Out port at the interconnect box.
NOTE
The 110/230 Volt AC ground must be connected to earth ground or bonding wire.
5.8.
Handheld Connection
5.8.1
Handheld connection
1. Unpack the handheld.
WARNING
Turn the sensor input box off when connecting or removing the handheld cable.
2. Connect the handheld cable to the sensor input box front

panel as shown below.
Section 5 - Page 14
Sensor input panel, handheld port
5.9.
Fuel System Installation
5.9.1
Unpack fuel system

1. Unpack fuel system.
2. Open the fuel system front door. Remove all the packing
material from the can area. The fuel can will be connected to the hanger assembly by a SuperFlow Customer
Service Engineer during the commissioning of the system.
5.9.2. Fuel cooler

Position the fuel system in the desired location. Attach the city
water supply hose and the drain hose to the fuel cooler connections as shown.
Fuel system water connections
Section 5 - page 15
SF-602
M a n u a l
Whenever using the fuel measurement system, water must

flow to the fuel cooler to maintain the fuel temperature. It is
recommended to install a solenoid valve in the water supply
line and connect it to the roll lock system. The water flow is
then controlled by the roll lock signal.
Call SuperFlow Customer Service for details.
5.10.
Configuration
5.10.1.
Computer Communication
The Sensor Box will communicate with a computer using a
LAN connection. This is an acronym for Local Area Network.
This is an Ethernet network connection and you will need a
network card in your personal computer. There are two
connection types available for all models. They are: 10Base-2
coaxial line or 10Base-T twisted pair line. The 10Base-2 or
Thin-Ethernet connections are typically the most common.
The system comes from SuperFlow configured for 10Base-2.
The 10Base-2 network line will be connected to the P1 BNC
connector located inside of the Sensor Box. You must insure
both ends of your Ethernet line are terminated via a 50-ohm
BNC terminator. SuperFlow has already terminated the end
inside the sensor box for you.
If 10Base-T is used, it will be connected to the RJ-45 connector
inside the Sensor Box. If you plan to use this type of Ethernet
connection, please call a SuperFlow Customer Service Engineer to assist you.
5.10.2.
Computer Setup
SuperFlow has provided a set of floppy disks that contain the
WinDyn operating system. From Windows95, run a:setup.
Follow the Setup Wizard steps to properly install your software. If you are unfamiliar with Windows95 or Networks,
SuperFlow strongly recommends that you have this done professionally. The installation of WinDyn is typical of any program installation, however the Network configurations MUST
be done properly. If the Network is not running correctly, you
will NOT be able to receive data from the Sensor Box.
Note that the following instructions are necessarily vague. This
is because of the variability in computer hardware/software in
the PC computer industry. The fundamental requirements are:
Section 5 - Page 16
1.
The computer and the sensor box must be properly

connected to each other using either 10baseT or
10base2 Ethernet cable.
2.
The computer must be running Windows 3.1, Windows95, or Windows NT.
3.
5.10.2.1.
The computer must have NetBEUI installed and

selected as the default protocol. These instructions
assume that you will be using 10base-2 (50-ohm coaxial) cable and running Windows95.
Install network card

With the computer off, install a 10base-2 network card with a
BNC connector on it into the computer. Follow the instructions
that came with the network card for installation. We suggest
using a PCI network interface card such as the 3COM PCI
Combo (SuperFlow part number 4800P-2010)
5.10.2.2.
Install network cable

The sensor box systems are typically shipped for use with
10base-2 cable. Connect a length of coaxial cable from the P1
BNC connector of the sensor box to the network card installed
in your computer. The ground lug can be connected to the
screw that secures the network card, or any convenient screw
on the PC chassis.
NOTE
Each end of the cable must have a T and a terminator or you will experience
unreliable communications.
MDI/MDIX network cabling

Networks using 10Base-T cabling are typically connected
using a star topology, with a hub at the center of the star.
Each device is then connected to the hub using a length of
10Base-T cable. This cable is terminated so that all of the pins
on one end connect to the corresponding pins at the other end.
Cables terminated in this manner are known as MDI cables.
If the network consists of only two devices (for example a sensor
box and a computer), the hub can be eliminated from the network
by connecting them together using an MDIX cable. An MDIX cable
consists of 10Base-T cabling that is terminated so that corresponding pairs of wires are swapped at each end of the cable.
Revised versions of sensor box boards will have two 10 Base-T
connectors, one for MDI and one for MDIX connections
5.10.2.3.
Configure PC for NetBEUI communications

Turn on the computer and select Start|Settings|Control
Panel.
Double-click on the Network icon.
If NetBEUI is not listed:
Click Add,
Click Protocol
Click Microsoft from the Manufacturers list
Click NetBEUI from the Network Protocols list

Section 5 - page 17
SF-602
M a n u a l
Click OK and follow the on-screen instructions
If more than one protocol is listed:
5.10.2.4.
Select NetBEUI
Click on Properties
Click on the Advanced tab
this
In the lower-left corner, place a checkmark in Set

protocol to be the default protocol
box
Select OK to dismiss the NetBEUI Properties dialog
Select OK to dismiss the Network dialog box
Insert disk 1 into the computer

Select Start|Run
Enter a:setup.exe (assuming the disk was inserted in
drive a:)
Follow on-screen instructions
Install WinDyn
5.10.2.5.
Run WinDyn
You should now be able to run WinDyn by double-clicking its
icon, or by selecting it from the Programs|SuperFlow WinDyn
menu.
Selecting the LAN Adapter
To communicate on the network, the SuperFlow WComNet
program needs to know which computer LAN adapter to use.
This issue is somewhat complicated by the fact that Windows95 and WindowsNT will assign LAN adapter numbers to
the various communications protocols which are capable of
carrying NETBIOS frames. There is no way for the software to
know which LAN adapter number corresponds to the NetBEUI
protocol required for communication to the SuperFlow dynamometer system.
The default LAN adapter is set to LAN adapter 0 (Lana 0). If
you find that you cannot connect with the dynamometer
system using this default setting, you may need to select a
different LAN adapter number.
A utility has been included as part of the WComNet program to
aid in selecting the appropriate LAN adapter. This utility is
accessed by selecting Configure|Lan Adapter from
WComNets main menu.
Follow the following steps to select the appropriate LAN adapter:
1. Make sure that the dynamometer system is turned on and
connected to the network interface card in the computer.
2. Open the LAN adapter setup utility by selecting
Configure|Lan Adapter from the main menu.
3. Select a LAN adapter number by clicking on the corresponding radio button.
Section 5 - Page 18
4. Click on the Test button to see if WCOMNET can connect

to the dynamometer system.
5. If Comm Status in the main window changes to Connected, you have found the correct LAN adapter number
and you are done (select the Done button). If Comm
Status still displays Disconnected, select the next LAN
adapter number and click on the Test button again.
Repeat this process until the correct LAN adapter number
is found.
6. If you still cannot connect to the dynamometer system,
then the problem lies elsewhere. Check that the cables are
hooked up (also inside the sensor box), and that they are
making good connection. Make sure that the dynamometer
system is turned on, that the network names are correct,
and that the NetBEUI protocol is bound to your installed
network interface card.
If you cannot get WinDyn to communicate with the sensor box,
contact a SF customer service engineer for assistance
5.10.2.6.
How to configure your system for US units or Metric units

The SF-602 is completely configured by software. At the time
of installation of WinDyn on your PC, you will be asked to
select the language and units system of your choice. The
configuration files appropriate for these selections will then be
installed in the main system directories. Other configuration
files will be copied to inactive directories.
We have made the selection of appropriate configuration
files based on the most common combinations of languages
and units systems. You will find that following configuration
choices are available as standard:
Language
Units
Language
Units
English
US
English
Metric
Dutch
Metric
French
Metric
German
Metric
The Units system is applied consistently. This means US unit
configurations will use all Imperial units and Metric unit
configurations will use all S.I. units.
Changing from one units system to the other or from one
language to another is possible by simply loading the appropriate Test Group. This Test Group will load configurations and
screens as appropriate.
NOTE
The system configuration files are essential to the operation of the system and
most of the other files (such as display files, test files, limits files, etc.) are linked
to specific configuration files. To avoid selecting incompatible files, we
recommend the use of the Test Group function which automatically loads
compatible files. Refer to the Test Group section (Section 12.2. Design Test
Group) of the WinDyn instruction manual for more details.
Section 5 - page 19
SF-602
M a n u a l
For specific measurements, some customers may wish to use

different units than the ones defined in the default configurations.
Example:
metric configurations systematically use kilowatt (kW) for
power, but you may wish to have horse-power (HP) instead,
while keeping all other metric units.
In that case, the standard configuration file that most closely
fits your requirements should be selected and then modified
where desired, using the channel configuration editor. Refer to
the Configuration Editor section (Section 16 Configuration File
Editor) of the WinDyn instruction manual for detailed instructions.
NOTE
Screen display files (*.CDF), Specifications files (*.CST), and Autotest files
(*.TPF) are linked to specific configuration files. If you have saved a modified
configuration file under a new name, you will have to rebuild those links for the
screen, specifications, and test files to work with the new configuration file.
5.11.
Description of sensor connections
5.11.1.
Thermocouple Connections
The Sensor Box has inputs for up to 16 type K thermocouples.

Provided with the system are eight closed tip thermocouples*.
Open tip thermocouples have a faster response time due to the
smaller mass. These are typically used for exhaust gas temperature measurement. Closed tip thermocouples are typically
used for fluid measurement. Plug the thermocouple into the
extension cable (if needed) or directly into the thermocouple
panel. The channel will now produce a reading. This reading
will be recorded during any test or when manually recording
data.
*Depending on configuration
Section 5 - Page 20
5.11.2.
Pressure Connections
The Sensor Box has inputs, for ten different pressures. Simply
connect the #4 hose to the appropriate pressure.
5.11.3.
Engine speed sensor
The SF-602 comes with a magnetic tachometer pick-up

suitable for detection of flywheel teeth. An optional optical
tachometer is available. Both sensors connect to this input.
The engines of some manufacturers (such as Caterpillar) have
standard mounting holes for the magnetic pick-up on the
flywheel housing. The correct number of teeth per revolution
must be entered in the system for the engine speed reading to
be accurate. This setting is accessed via the C-key (Cts/Rev)
in the Start menu on the handheld controller.
The optical tachometer is mostly used when the magnetic
pick-up cannot be used. The sensor is best mounted to the
frame of the truck with a magnetic base. Tripod mounting on
the floor underneath the engine is also acceptable but may
lead to loss of engine speed signal if the truck moves somewhat during the test. A piece of reflective tape is attached to
the crankshaft damper or pulley and the optical tachometer is
aimed at the tape. The sensor is equipped with a LED indicator for easy aiming.
Section 5 - page 21
SF-602
5.11.4.
M a n u a l
Blowby sensor
An optional blowby sensor is available from SuperFlow. This is

a volumetric flow measurement device, which must be installed in-line with the crankcase breather. It is best installed
vertically to reduce accumulation of fluids and deposits inside
the sensor tube.
The sensor tube should be kept clean at all times for best
accuracy.
More detailed instructions are provided with the sensor.
5.11.5.
Opacity sensor
An optional exhaust gas opacity sensor (smoke meter) is

available from SuperFlow. This sensor is a full-flow device,
which must be installed on the exhaust stack itself.
More detailed instructions are provided with the sensor.
Section 5 - Page 22
5.11.6.
Rack point sensor
The SF-602 connects to this Caterpillar-specific sensor, using two

alligator clips. It measures a voltage that is a function of the
governor rack position. Caterpillar has determined a rack point
which is the average of the rpm at 10% rack and at 70% rack.
5.12
Basic System Tests
5.12.1
Turn system on
1. Verify that the emergency stop button on the interconnect
box is released. Turn on the control console and the
sensor input box.
NOTE
For additional information, please refer to section 6 (Operating Instructions).
NOTE
Only a completely installed dynamometer system can be checked with the Basic
System Tests. All connections within the dynamometer junction box must be
made. These connections are typically performed by a Customer Service
Engineer. Call SuperFlow Customer Service if you would like to make the
connections before the Customer Service Engineer arrives.
2. Observe the handheld screen to confirm the system is

functioning and communicating properly.
3. Observe the PC computer monitor to confirm the sensor input
box and the computer are communicating. Check the
Ethernet cable connections if any problems are encountered.
Section 5 - page 23
SF-602
5.12.2
M a n u a l
Basic roll lock test

The main purpose for the roll lock circuit is to install and
remove the vehicle safely. The roll locks are not intended to
slow a moving vehicle, or perform any braking when the rolls
are spinning.
1. Lock the dynamometer rolls from the handheld. When the
rolls are locked, the relay in the interconnect box will
change states, thereby activating the pneumatic roll lock
solenoid.
2. Release the roll locks from the handheld. Verify that you
can easily rotate the rolls with your feet.
WARNING
5.12.3
Rotating the rolls with your feet requires clean rolls, clean rubber-soled shoes, a
good sense of balance, and a support for your hands, such as the side rails.
Only place your feet at the top of a roll. Never place your feet where the roll
nearly touches the cover plate.
Brake system bleeding

1. Remove the cover from the brake master cylinder. Verify the
fluid level is near the top. If the level is low, add automotive
brake fluid, and check the tightness of all brake fittings.
2. Lock the rolls from the handheld. This will apply pneumatic pressure to brake master cylinder, which then applies
hydraulic pressure to the brake slave cylinder. Briefly
loosen the stainless steel brake hose at the output fitting of
the master cylinder to bleed any air from the system.
3. Release the roll locks.
4. Repeat steps 2-3 until no air is released from the hose
fitting. Add replacement brake fluid as necessary.
5. Lock the rolls.
5.12.4
Roll lock over-ride test (due to presence of vehicle speed)

When the rolls are rotating above approximately 3 mph (4.8
kph), the roll lock circuit is disabled. Test the operation of this
circuit with the following steps.
1. Unlock the rolls.
2. Using your feet to rotate the front rolls, accelerate the rolls
until approximately 6 mph (10 kph) is obtained.
WARNING
Section 5 - Page 24
Rotating the rolls with your feet requires clean rolls, clean rubber-soled shoes, a
good sense of balance, and a support for your hands, such as the side rails.
Only place your feet at the top of a roll. Never place your feet where the roll
touches the cover plate.
3. With the rolls still rotating, lock the rolls from the
handheld. The roll lock should not engage.
4. As the roll speed decreases toward 3 mph (4.8 kph), you
will hear the roll lock relay click several times before the
rolls lock.
5. Perform steps 2-4 with the rear rolls.
5.12.5
Load control valve test

1. The load control valve (located within the pit) has a position
indicator that is useful when checking the operation of the
system. Locate the position indicator as shown below.
Load control valve position indicator
2. From the handheld, in the manual mode, set the load

position to 50%. Verify the valve travels to approximately
half open. This test can be performed with or without
water flowing through the valve.
3. Set the load control valve position to 100%. Verify the
valve goes fully open.
4. Set the load control valve position to 0%. Verify the valve
goes fully closed.
5.12.6
Full flow water test (closed water system only)

For a closed water system, it is important to verify that the
return water pump can adequately keep up with the water
supply. For this test, watch the vent fitting at the top of the
sump tank to see if any overflow occurs.
1. Check the settings of the absorber outlet flow control valves.
Both gate valves should be set at 1 to 2 turns open.
2. Verify the sump tank pump and liquid level control systems are turned on.
Section 5 - page 25
SF-602
M a n u a l
3. Turn on the water supply pump (if the pump is connected

to the roll lock circuit, unlock the rolls).
4. From the handheld, set the load control valve position to
100%. Allow the system to stabilize for several minutes.
5. Verify there are no water leaks at the hose connections or
the sump tank vent.
NOTE
If the absorber packing glands have not yet been adjusted, they may leak
significantly during the full flow test. Either ignore the leakage, or watch the
sump tank carefully when adjusting the packing in the next section.
6. Verify that the return pump cycles properly and pumps

water to the supply tank.
5.12.7
Absorber packing adjustment

The absorbers use a Teflon coated packing material in the
water seal packing glands. The glands are designed to leak a
small amount, and do require periodic adjustment. It is
acceptable to operate the vehicle on the dynamometer without
water flowing through the absorbers for short periods. To
adjust the packing, perform the following steps.
1. Lock the rolls. Install a vehicle onto the dynamometer.
See section 6 for additional information.
2. Unlock the rolls and run the vehicle at approximately 5
mph (8 kph).
3. From the handheld, set the load control valve position to
100%.
4. While rolls are rotating, adjust the packing glands on the
absorbers, as shown below. Tighten the nuts evenly, 1/4
turn at a time. Tighten so there is only a slight continuous
trickle or a few drops per second leaking from the glands.
Absorber packing glands
Section 5 - Page 26
WARNING
Use extreme caution when making adjustments near rotating machinery.
5. Allow the dynamometer to operate for several minutes to

verify a consistent leakage rate.
WARNING
If the area around the seal becomes hot, loosen the gland ring nuts evenly.
Allow the dynamometer to operate for several minutes with the glands leaking
significantly before readjusting.
6. Set the load control valve at 0% and stop the truck.

7. Lock the rolls, and turn off the water supply pump.
5.13.
Calibration
NOTE
Prior to first use of the SF-602, the torque measurement system of the rollset
should be calibrated. Please see Section 20 Service and Calibration for
instructions.
Section 5 - page 27
Operating Instructions
6. Operating Instructions
6.1.
Quick Start ................................................................................................. 3
6.2.
General precaution .................................................................................... 5

6.2.1.
6.2.2.
6.2.3.
6.2.4.
6.2.5.
6.3.
Turn System On ......................................................................................... 7

6.3.1.
6.3.2.
6.3.3.
6.4.
Zero (AutoZero) channels ........................................................................... 19
Activate Facility Systems ......................................................................... 20

6.8.1.
6.8.2.
6.9.
Check installation ....................................................................................... 18
Zero Sensor Readings ............................................................................ 19

6.7.1.
6.8.

Pressure connections ................................................................................. 14
Temperature sensors .................................................................................. 15
Diesel Fuel measurement system ............................................................... 16
Verify Proper Installation of Vehicle ......................................................... 18

6.6.1.
6.7.
Vehicle installation procedure ........................................................................ 9

Tie-down strap installation procedure .......................................................... 11
Truck rear axle tie-down methods ................................................................ 12
Connect Sensors ..................................................................................... 13

6.5.1.
6.5 .2.
6.5.3.
6.5.4.
6.6.
Control console ............................................................................................. 7

Sensor input box ........................................................................................... 7
Fuel system .................................................................................................. 8
Install Vehicle............................................................................................. 9
6.4.1
6.4.2.
6.4.3.
6.5.
Emergency stop button ................................................................................. 5

Handheld stop key ........................................................................................ 6
Protective equipment .................................................................................... 6
Consider hazards .......................................................................................... 6
Static Electricity ........................................................................................... 6
Water supply system pump (closed water system) ..................................... 20

Ventilation system (enclosed test room) ..................................................... 20
Select Automated Test ............................................................................. 20

6.9.1.
6.9.2.
Description of standard automated tests ..................................................... 20

Select test .................................................................................................. 20
6.10. Start Engine. ............................................................................................ 21

6.10.1.
6.10.2.
Engine starting ........................................................................................... 21

Alignment check ......................................................................................... 21
6.11. Perform Automated Test ........................................................................... 22

6.11.1.
View handheld data screen ......................................................................... 22
6.12. Analyze Test Results ............................................................................... 23
SF-602
6.12.1.
6.12.2.
6.12.3.
M a n u a l
Test data description ................................................................................... 23

View current test from handheld .................................................................. 23
Storing and analyzing the test results ......................................................... 24
6.13. Remove Vehicle ...................................................................................... 25

6.13.1.
6.13.2.
6.13.3.
Disconnect fuel system .............................................................................. 25

Disconnect sensors .................................................................................... 26
Remove vehicle from dynamometer ............................................................ 26
6.14. Test Tips .................................................................................................. 26

6.14.1.
6.14.2.
6.14.3.
Section 6 - Page 2
Running a Manual Test ................................................................................ 26

Running an Auto Test .................................................................................. 28
Cylinder Cutout test for the new SF602 testing systems ............................. 30
6.1.
P E R A T I N G
N S T R U C T I O N S
Quick Start
NO TE
This is an abbreviated set of instructions for trained operators. Do not attempt to

use the Dyno unless you have received appropriate training. Severe injury,
death, and/or property damage may result from improper use.
Setting up the truck

1. Inspect the trucks driveline to determine whether it is
sound. If repairs are needed, perform the repairs before
performing the dyno run because the dynamometer will
test the trucks ability to produce rated power.
2. Make sure the roll set is locked. If necessary, press the
Stop key to return to the Start menu, followed by the A
key to lock the rolls.
3. Back the truck onto the dyno. Position the front wheels
evenly between the outer tie-down rails. Position the rear
wheels on top of the rolls.
4. Set the truck brake.
5. Attach the rear safety chain, leaving a small amount of slack.
6. Release the truck brake and slowly move the truck forward
to tighten up the chain. The rear tires should contact the
rolls at or slightly forward of the centerline. Be sure the
truck is positioned correctly before proceeding.
7. Unlock the rolls; wait five seconds, then run the truck in a
low gear at low idle to center the rear wheels on the rolls.
8. Turn off the engine, lock the rolls, and set the truck brakes.
9. Tie down the front wheels.
10. Check engine oil and coolant levels. Use caution if engine
is hot.
11. Attach sensors as required for the test.
12. If necessary, press the Stop key or the E key (Exit) to
return to the Start menu. Press the F key for Autozero
followed by the B key for All channels before starting
the engine.
NOTE
All pressure lines must be at zero pressure when you autozero.

return to the Start menu. If fuel measurement is required
for the test, press the D key followed by the B key to
empty the fuel canister and then the A key to fill the fuel
canister. The API value is calculated when the canister
goes from empty to full, not from low to full.
14. Close the hood (to direct airflow across radiator and
engine); be careful not to pinch wires and hoses.
Section 6 - page 3
SF-602
M a n u a l
15. Running the truck on the Dyno without load for an extended period of time will scorch the absorber packing
material, so decide what information you want and which
test to run before spinning the rolls.
16. Get into the truck. Set:
Truck brakes OFF
Fan override ON
Air conditioner OFF
Cruise control OFF
Power divider LOCKED
return to the Start menu. Press the B key to unlock the rolls
18. Press the C key for Cts/Rev. and enter the correct
number of teeth for the engine tach.
return to the Start menu. Press the I key for Configure
followed by the C key for Dyno
20. Select the Roll mode :
A) Tandem Axle
B) Single Axle
I) Front Axle
II) Rear Axle
21. Press the Stop key or the E key (Exit) to return to the
Start menu. Start the engine. Check for correct RPM
indication, oil pressure, and other required parameters.
22. Assuming the engine is cold, start a warm-up cycle. Put the
truck in 1:1 gear; run the engine at a moderate speed, slowly
engage the clutch. The wheels will spin the rolls easily
because no load is applied by the dynamometer. When you
have reached 3/4 speed, continue to the next step.
Press the G key for Test and press the C key for a
Manual test. Select VehSpd followed by the J key for
Done. The present vehicle speed will be displayed as
the speed set point. Using the throttle pedal, increase the
vehicle speed by about 5 mph. Observe the vehicle power
display (not the corrected power display) and use the
throttle to control to approximately 1/4 of rated power.
NO TE
Never apply the brakes or turn the steering wheel while a test is in progress.
Applying the brake will place backward force on the truck. Turning the steering
wheel will apply lateral force to the rear wheels. If something goes wrong (e.g.
turbo boot blows) release the throttle, disengage the clutch, and press the
Stop key on the Handheld Controller.
23. Monitor the trucks temperature gauges. These may

include water, oil, and differential temperatures. When
they reach the levels required for proper warm-up, as
defined by your company, end the warm-up cycle by
pressing the Stop key. Perform the required test by
choosing Test, Select Test and so on.
Section 6 - Page 4
P E R A T I N G
24. When you have completed the test, release the throttle
pedal. Shift to neutral at approximately 30 mph (50 kph)
and allow the rolls to coast to a stop.
25. Allow the engine (and turbo) to cool at low idle before
shutting down the engine.
26. Make sure the roll set is locked. If necessary, press the
Stop key to return to the Start menu, followed by the A
key to lock the rolls. Set the truck brake.
24. The Automated Test usually stores the test automatically
on the hard disk of the PC. This also opens the Datalib
database dialog box. Enter all required data in the database
Fields. Analyze and print the test data as required.
return to the Start menu. Press the D key for access to
the fuel pump control screen and empty the fuel canister if
it was used.
26. Remove all fuel lines, sensors, sensor cables, and pressure
lines from the vehicle.
27. Remove the tie-down straps and chain.
28. Release the truck brake and drive the truck off the rolls.
6.2.
General precaution
These instructions are provided as a reference or reminder for
people who have been trained on the operation of the equipment. If you cannot find the answer to a problem or explanation for a procedure within this manual, please contact the
SuperFlow Customer Service Department.
WARNING
6.2.1.
Dynamometer testing can be dangerous. Proceed cautiously, and investigate

any conditions that may be abnormal before starting or continuing a test
Emergency stop button

An emergency stop button is located on the wall-mounted
interconnect box. In the event of an emergency, press the
button. This will disconnect the AC power that supplies the
sensor input box, and the control console (depending on the
installation). To release an emergency stop condition, twist
the button clockwise. The button will pop out, and the AC
power will be restored.
NO TE
The emergency stop button may not be available on systems with the WinPac
upgrade.
Section 6 - page 5
SF-602
6.2.2.
M a n u a l
Handheld stop key

To reset the system at any time, or to stop a test under way,
press the stop key on the handheld, as shown below. This will
remove the load from the dynamometer.
Handheld stop key
6.2.3.
Protective equipment
It is recommended that proper eye and ear protection devices
be worn at all times during a test. Depending on the environment, it may be advisable to wear such devices at all times.
6.2.4.
Consider hazards
Before starting a test, all potential hazards should be identified
and fully considered (see Section 4.7.4.) Some hazards are
corrected by proper actions or procedures, others by protective
equipment. Not all SF-602 installations are the same, so your
facility may present other hazards to consider.
6.2.5.
Static Electricity
The rotation of rubber tires on steel rolls causes static electricity build-up. This electric charge must be provided with a path
to earth ground. If the rear tie-down chain is wrapped directly
around the rear axle or a frame cross member, no further
grounding should be necessary. In all other cases, it will be
necessary to use a grounding clamp attached to the dyno
frame or other suitable connection point to earth ground.
Section 6 - Page 6
6.3.
Turn System On
6.3.1.
Control console
P E R A T I N G
Press the power switch that is located at the right rear upright
of the control console.
SF-602 control console
6.3.2.
NO TE
It is acceptable to keep the computer equipment switched on at all times. The

computer and monitor will enter a sleep mode during periods of no usage,
and will automatically resume operation when the space bar is pressed on the
keyboard or the mouse is moved.
Sensor input box

Press the power switch on the face of the sensor input box.
The voltage indicator lights will illuminate.
Sensor input box
Section 6 - page 7
SF-602
M a n u a l
NOTE
It is recommended to keep the sensor input box switched on at all times. This
will provide continuous power to the dynamometer roll lock circuit. The rolls will
unlock if the sensor input box is turned off. For some installations, the water
supply pump and/or the room exhaust fan may activate when the rolls are
unlocked. An interlock relay will disable these accessories when main power to
the system is turned off.
NOTE
If the control console or sensor input box do not turn on, check the emergency
stop button at the interconnect box (if available). Twist the button clockwise to
release an emergency stop condition.
6.3.3. Fuel system

If the fuel system will be used during the test, press the power
switch that is located on the left side of the system.
NOTE
Section 6 - Page 8
A circuit breaker has been provided to protect the fuel pumps. This circuit
breaker is located underneath the fuel system power switch. If the fuel system
pumps do not operate properly, check the circuit breaker and reset it if
necessary. If the circuit breaker trips again, switch off the fuel system and call
SuperFlow Customer Service to troubleshoot the problem.
6.4.
Install Vehicle
WARNING
6.4.1
P E R A T I N G
It is extremely important to properly secure the vehicle on the dynamometer at

all times. Never operate the vehicle without both front tie-down straps and the
rear chain. Always set the vehicle parking brakes and the dynamometer roll
lock when not executing a test.
Vehicle installation procedure

1. Lock the dynamometer rolls by pressing the keys on the
handheld in the order shown below.
NOTE
In all illustrated handheld steps, the STOP key is pressed to start the sequence
from the START screen. In many cases, the STOP step is not required, and the
desired functions can be accessed directly.
2. Drive the vehicle onto the rolls. Place the centerline of the
forward drive axle slightly ahead of the centerline of the roll.
Section 6 - page 9
SF-602
M a n u a l
Truck installation
3. Set the vehicle parking brakes.

4. Attach a chain between the rear axle of the vehicle and the
tie-down anchor in the floor. Starting from the tie-down
anchor, route the chain under the axle, over the differential
yoke, under the other side of the axle, and back to the tiedown anchor or chain binder. If the rear axle is not
accessible, attach the chain to a sturdy section of the
vehicle frame.
WARNING
The rear tie-down chain is the first restraint to be installed, and the last to be
removed. Do not wrap the rear tie-down chain around brake lines or other items
that may be easily damaged.
5. Release the vehicle parking brakes and allow the vehicle

to settle forward. The chain will tighten. Verify there is at
least 2 (50 mm) clearance between the tires and the cover
plates. If the tires are too close, reposition the vehicle.
6. Unlock the dyno and the brakes.
7. Place the vehicle in a low gear and spin the rolls to allow
the vehicle to center on the dyno.
WARNING
If the vehicle is equipped with a tag axle, it is critical to center the vehicle very
carefully when driving it onto the rolls. Because the front and rear rolls of the
dynamometer are independent, the tag axle will not rotate when attempting to
center the vehicle by spinning the rolls, thereby preventing the vehicle from
centering. The lateral forces exerted during the test will then cause premature
failure of the roll shaft bearings.
8. Allow the vehicle to STOP, lock rolls.

9. Set the vehicle parking brakes again.
10. Install the tie-down straps on both front wheels.
Section 6 - Page 10
WARNING
6.4.2.
P E R A T I N G
The front tie-down straps are the primary restraints that provide safety in the event
of a problem. The rear chain prevents forward movements, but side-to-side
movements may occur at the rear of the vehicle. Never stand next to the vehicle.
Tie-down strap installation procedure

1.
Lay the tie-down straps onto the front tires with the chain
hooks pointing outward. Position the tie-down chains beneath
the tire, and connect the hooks to the chains.
Tie-down strap on wheel
WARNING
Both front wheel tie-down straps must be installed for proper testing safety.
WARNING
Always inspect the tie-down straps and ratchet mechanisms for wear. Do not
use excessively worn or damaged parts.
2.
Pull the webbing through the shaft to eliminate excessive

slack. Some slack is required to provide at least two full wraps
of webbing when fully tightened. This assures no slippage.
Tie-down ratchet assembly
3.
Tighten each tie-down assembly with a socket wrench tool.
Section 6 - page 11
SF-602
M a n u a l
Tighten ratchet assembly
4.
To release or loosen a tie-down strap, place a small pry bar

(screwdriver) between the ratchet lock bar and the webbing.
Slide the lock bar away from the webbing.
Release ratchet assembly
6.4.3.
NOTE
The tie-down may release with less effort if you tighten the strap while prying the
lock bar loose. Tightening the strap (without engaging the next tooth) reduces
the pressure on the lock bar.
Truck rear axle tie-down methods

There are several ways to secure the rear axle on the rolls.
These are three examples:
1.
Section 6 - Page 12
30 foot 3/8 inch grade 8 chain, with optional binder or ratchet

to adjust length.
The chain has a clevis hook at each end, allowing it to hook
onto an individual link in the chain. One end of the chain
connects to the rear tie down hook. The chain is routed under
the rear axle, over the drive-shaft yoke of the differential and
then back on the opposite side of the differential. The clevis
hook is used to connect the loose end of the chain to the main
body of it at least 1 meter from the differential so that when the
chain is pulled tight both short sections equally share the load.
A binder or ratchet is a tightening device which can be used to
adjust the chain tightness, or the positioning of the vehicle on
the rollset without having to move the truck. This device also
avoids having to back off the truck when you are ready to
remove the vehicle from the rollset after the test.
2.
3.
6.5.
6.5.1.
P E R A T I N G
3/8 inch, grade 8 chain with one or two nylon straps used to
connect the chain to the axle.
This method is recommended to avoid scratching the paint.
The straps should be rated for at least 8,000 pounds (4000 kg).
A single strap, 8 feet long, can be dropped from above the
differential, with one end on each side of the drive shaft yoke.
Both ends should be pulled towards the rear and connected to
the chain using a D ring connector, or something similar. A
ratchet with a 2 meter chain can be attached to the primary 3/
8 inch link chain. The loose end of the 2 meter chain is
attached to the D ring and the ratchet is used to pull the
vehicle to the rear until it is in the proper position for testing.
Custom 5th wheel attachment. At least one customer uses this
arrangement. This is a piece that attaches to the vehicles 5th
wheel receiver, and is supported by a cross brace that rests on
the frame rails.
This is a quick method of attachment, but:
1. If the 5th wheel is out of adjustment it can be difficult
to insert or remove.
2. Vehicles without a 5th wheel mount can not use this
method.
Connect Sensors
NOTE
It is always recommended to provide a proper ground path between engine,

vehicle, and test system. If you experience erractic sensor readings, connect
ground straps between your engine and the sensor boom.
Engine speed sensor

1.
Connect the engine speed sensor, sensor adapter cable, or

optical speed sensor to the engine. For an engine with an
existing magnetic sensor, connect the adapter cable to the
sensor. For an optical speed sensor, attach a piece of reflective
tape to the crankshaft damper, and rigidly mount the optical
sensor to the vehicle frame. For a magnetic sensor, install the
unit and its connection cable.
2.
Enter the number of pulses per revolution at the hand-held.

For a sensor that measures the flywheel, this is the total
number of flywheel teeth (generally between 100 and 200). For
an optical speed sensor, this is the number of tape pieces on
the crankshaft (typically one). Perform the steps below.
Section 6 - page 13
SF-602
M a n u a l
Handheld engine speed steps
6.5..2.
Pressure connections
1.
NOTE
Connect the pressure adapters to the pressure sources.
The most common method to adapt the #4 AN pressure hose to the pressure
source is with a #4 AN to 1/8" NPT adapter. The SuperFlow part number for the
adapter is 3500P-20210204.
2.
Channel
62
63
64
65
66
67
68
69
70
71
Choose an input port for each pressure to be measured. The following pressures ranges are available with the standard SF-602:
Range
Channel Name
Abbreviated Name
0-300 psi (gauge)

0-150 psi (gauge)
-100 to 100 psi (gauge)
0-5 psi (gauge)
0-300 psi (gauge)
0-150 psi (gauge)
-5 to 5 psi (differential)
-5 to 5 psi (differential)
3.
Section 6 - Page 14
Rail pressure
Fuel pressure
Manifold pressure
Fuel suction
Crankcase pressure
Coolant pressure
Oil pressure
Turbo pressure
Inlet restriction
Exhaust pressure
Rail P
Fuel P
Man P
FulScP
CrankP
Cool P
Oil P
TurboP
ArlnDP
ExhBP
Connect the pressure hoses between the input panel and the
pressure adapters.
P E R A T I N G
Pressure input panel
WARNING
6.5.3.
Carefully observe the range of each pressure transducer. Applying a pressure

that is greater than the transducers maximum rating may permanently damage
the sensor.
Temperature sensors
1.
Connect the thermocouples to the temperature sources. Use

only closed end thermocouples to measure the temperature of
fluids. Open end thermocouples are generally used to measure air and exhaust temperatures, although closed end
thermocouples can also be used in these applications.
Thermocouple
NOTE
It is recommended that only SuperFlow thermocouples and extension cables be

used. If other thermocouples are used, make sure they are Type-K, ungrounded
thermocouples only.
2.
Connect the thermocouples to the extension cables. Connect

the extension cables to the thermocouple input panel.
Section 6 - page 15
SF-602
M a n u a l
Thermocouple input panel
NOTE
When using Swagelok compression fittings (SuperFlow part number 3500P2012) to adapt to the temperature source, the ferrule may become permanently
locked to the thermocouple shaft.
NOTE
The thermocouple shaft can only be bent once. Forcing it may break the shaft.
6.5.4.
Diesel Fuel measurement system

1.
The diesel fuel measurement system accurately analyzes the

change in the can weight to calculate the fuel consumption
rate. Place the cabinet on a flat, stable surface that is not
subject to vibrations. Connect the hoses to the vehicle according to the colors listed below.
Fuel system front view
Section 6 - Page 16
P E R A T I N G
WARNING
Keep sparks and open flames away from the fuel measurement system and the
output of the vent connection. It is also recommended that protective clothing be
worn to prevent diesel fuel contact with the skin or eyes.
WARNING
Only diesel fuel can be used with the SF-602 fuel measurement system. Other
fuels may produce dangerous vapors. The system is NOT explosion proof.
NOTE
Depending on the installation, the fuel supply is typically the vehicle fuel tank, or
a facility fuel storage tank. If a facility storage tank is used, it is recommended
that a valve be placed between the fuel source and the measurement system.
2.
Attach the city water supply hose and the drain hose to the
fuel cooler connections. Water will not flow through the cooler
until the temperature of the fuel returning from the engine
exceeds an adjustable level.
Fuel system water connections
3.
Confirm the fuel vent port is unobstructed and open to the

atmosphere. A vent cover should be installed to prevent
obstruction
Section 6 - page 17
SF-602
M a n u a l
Fuel system vent
WARNING
The fuel can vent on the side of the cabinet must be open to a safe place in the
atmosphere. A blocked vent could cause the can to burst or leak.
4.
5.
Connect the fuel system to a 115V, 10A power supply (230V,

5A for export versions) and switch the system on.
Fill the fuel measurement system by performing the steps below.
Handheld fuel system fill steps
6.6.
Verify Proper Installation of Vehicle
6.6.1.
Check installation
Section 6.4. and 6.5., explain the procedures to install and
prepare the vehicle for testing. Check the following conditions
before continuing.
Section 6 - Page 18
P E R A T I N G
1. Verify the vehicle is parallel with the dynamometer tiedown rails.

2. Verify that both tie-down straps have been properly installed.
3. Verify that the rear tie-down chain is secure. Further
tightening of the chain at this point may pull the vehicle
rearward, which is not desired.
4. Verify that all sensor connections have been fully made at
the vehicle and the sensor input box.
5. Verify that all potential hazards have been identified, and
that preventative measures and equipment are in place.
6.7.
Zero Sensor Readings
6.7.1.
Zero (AutoZero) channels

1.
2.
Unlock the rolls.

Before starting the engine, zero the channel readings by
performing the steps below.
Handheld autozero seensors steps
NOTE
If the engine had been run previously with a pressure sensor line connected,
there may be residual pressure within the line, even with the engine not
running. For maximum accuracy, crack the hose fitting at the pressure input
panel. Allow the residual pressure to be fully released before tightening the
hose and autozeroing.
Section 6 - page 19
SF-602
M a n u a l
6.8.
Activate Facility Systems
6.8.1.
Water supply system pump (closed water system)

Turn on the water supply pump.
6.8.2.
NOTE
For many installations, the water supply pump and/or the room exhaust fan will
turn on automatically when the rolls are unlocked.
Ventilation system (enclosed test room)

Turn on the ventilation system.
WARNING
Engine exhaust fumes can be lethal. Never run the engine or conduct a test
without proper room ventilation and evacuation of exhaust fumes.
6.9.
Select Automated Test
6.9.1.
Description of standard automated tests

Several standard automated tests are included with an SF-602.
Custom tests can also be created by the user with the test
profile editor. See the WinDyn section of this manual for
details on how to load, edit, create, or save tests.
6.9.2.
Select test
To select an automated test, perform the steps below.
Section 6 - Page 20
P E R A T I N G
Handheld select test steps
6.10.
Start Engine.
6.10.1.
Engine starting
Start the engine. Check for any leaks from the sensor connections. Verify the correct engine speed reading on the handheld
and sensor input box. If the engine speed is incorrect, enter
the correct number of pulses per revolution at the handheld. If
the engine speed reading is zero, reposition the sensor.
6.10.2.
Alignment check
1.
2.
WARNING
Release the vehicle parking brakes and the roll lock. Place the
vehicle in a low gear, release the clutch, and rotate the rolls
slowly. If the vehicle was not perfectly aligned on the rolls, it
may move from one side to the other. If movement occurs, confirm that the tires are adequately centered on the rolls. If the
tire extends over the edge of the roll, the truck must be repositioned (see vehicle removal and installation instructions).
Accelerate the vehicle, while shifting up through the gears,
until direct gear is reached. If operating a governed engine,
increase the throttle to 100%.
Never use the vehicle brakes when the rolls are spinning. Use of the brakes will
cause the truck to move backward. The rear tie-down chain only prevents
forward movements. Never operate the vehicle in reverse gears while on the
dynamometer.
Section 6 - page 21
SF-602
6.11.
M a n u a l
WARNING
Always remain in the drivers seat of the vehicle when conducting a test.
WARNING
Do not turn the vehicle steering wheel when performing a test. This may cause
the vehicle to change its position on the dynamometer.
WARNING
Never allow observers to be in the test room or near the vehicle when the rolls
are spinning.
Perform Automated Test

1.
To start the test that was selected in section 6.9.2. perform the
steps listed below. Follow the test instructions displayed on
the handheld controller, and enter data when prompted.
Handheld start test steps
6.11.1.
View handheld data screen

Up to nine data screens are available to view the current
readings during the test. Each screen contains nine channels.
Screen number 1 contains the most commonly connected
sensors and calculated channels. Other screens contain
groups of similar channels, such as temperatures or pressures.
To access a current data screen from the handheld during a
test, press the screen number as shown below. The screen
can be changed by simply pressing the next desired screen
number.
NOTE
Section 6 - Page 22
The data screens on the handheld controller can be customized. See the
WinDyn Configuration Editor section of this manual.
P E R A T I N G
Handheld view data screen step
2.
3.
4.
At the conclusion of the test, release the throttle, allow the

vehicle to coast down to approximately 30 mph (50 kph), then
shift into neutral. Permit the vehicle to coast to a stop in
neutral.
When the rolls stop spinning, set the vehicle parking brakes,
and lock the rolls.
Exit the vehicle.
6.12.
Analyze Test Results
6.12.1.
Test data description

After a test is completed, the data is held within the sensor
input box in battery-backed memory. It will remain in memory
until another automated test is started or until the data is
erased by the operator.
NOTE
Some automated tests may also automatically copy the test results to the
computer hard disk.
In the SF-602 WinDyn program, Current Test refers to test data

that is stored in the sensor input box memory. Saved Test refers
to test data that has been stored to the computer hard disk.
6.12.2.
View current test from handheld

Only current test data that resides in the sensor input box can
be viewed from the handheld. Saved test data (on the PC computer) can not be viewed from the handheld. To access the current test data from the handheld, perform the following steps.
Section 6 - page 23
SF-602
M a n u a l
Handheld view data screen
Records (C) indicates total number of lines recorded

Number (D) indicates the current data line being displayed.
Use the Up (H), Down (I) keys to scroll through data lines.
Use the First (F), Last (G) keys to move to the first or last line of
the test.
Use the Screen x (J) key to select one of the nine data screens.
Use the Erase (B) key to erase the data from system memory.
Use the Save (A) key to save the test data to the PC.
6.12.3.
Storing and analyzing the test results

1. Go to the WinDyn computer.
2. All automated tests provided by SuperFlow will save the
test data automatically on your computer and a dialog box
will be displayed prompting you for the database storage
information for this test.
3. Enter the Test Description information and any other
pertinent information on the tabbed sheets.
4. Click on the Save button (with the checkmark) to save the
test information in the database.
5. Click on the Test Data button (with WinDyn logo and
magnifying glass) to start the Stored Data Analysis program
of WinDyn and display the results of the test in tabular
format. Use the numeric keys or the mouse to select any of
ten available screens.
6. Click on the Plot Test button (with the graph) or the F11
key to display the results in graphical format. Push the F12
key for a side-by-side view of the tabular and graphical
display. Use the numeric keys or the mouse to select any
of ten available screens.
Section 6 - Page 24
P E R A T I N G
7. Click on the Print Test button (with printer) to print the

tabular data or select File | Print Plot to print the graph.
NOTE
Refer to the WinDyn Help screens or the WinDyn section of this manual for more
information on how to use the Database and Test Analysis features of WinDyn.
6.13.
Remove Vehicle
6.13.1.
Disconnect fuel system

1. Turn the engine off.
2. If using the vehicle fuel supply, return any unused fuel
within the fuel measurement system by performing the
steps below. The pump will automatically stop.
Handheld fuel system empty steps
NOTE
If the fuel system circuit breaker trips when returning fuel to the vehicle, inspect
the vehicle for a check valve between the fuel tank and the fuel system
connection.
3. Disconnect the hoses from the vehicle.

4. Insert plugs into the hose ends to prevent leakage and
contamination.
Section 6 - page 25
SF-602
6.13.2.
M a n u a l
Disconnect sensors
1. For sensors that are connected to hot fluids, allow the
engine and vehicle to cool adequately.
2. Remove the sensors or their connections from the vehicle.
WARNING
Sensors may be connected to fluids under pressure, or may still be hot after a
cool-down period. Use extreme caution when disconnecting sensors.
3. Install the original fittings that may have been removed

when the sensor was installed.
6.13.3.
Remove vehicle from dynamometer

1. Confirm the rolls are locked.
2. Confirm the vehicle parking brakes are set.
3. Confirm all sensors and fuel lines are disconnected
and stored out of the way.
4. Remove the tie-down straps from the front wheels.
5. Remove the rear tie-down chain.
6. Release the vehicle parking brakes and drive the
vehicle off the dynamometer.
6.14.
6.14.1.
Test Tips
NOTE
The following procedures are quick reference procedures to be used only by

personnel trained in the use of the dynamometer by SuperFlow instructors. All
personnel using the dynamometer should be aware of potential danger if the
dynamometer is used improperly.
Running a Manual Test

NOTE
This is an abbreviated set of instructions. For safetys sake, refer to your SF-602
manual for complete instructions. Do not attempt to use the Dyno unless you
have received appropriate training. Severe injury, death, and/or property
damage may result from improper use. Do not use the cruise control on the
truck you are testing.
If you need assistance at any time during this process, please

call SuperFlow Customer Service at (719) 471-1746.
1.
Section 6 - Page 26
AutoZero All channels

On the first Hand Held screen press the F key for Autozero
Select All. Make sure there are no pressures applied to the dyno.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
P E R A T I N G
Clear all Data

On the Hand Held press the H key for Data.
On the Hand Held press the B key for Erase Data.
On the Hand Held press the C key for Yes.
On the Hand Held press the E key to Exit.
Configure the dyno.
On the Hand Held press the I key for Configure.
On the Hand Held press the C key for Dyno.
Select the Roll mode:
Tandem Axle
Single Axle: Front or Rear
On the Hand Held press the E key twice to Exit.
Fuel System (optional)
On the Hand Held press the D key for Fuel Pumps
Check the % of fill. Fill if necessary.
Set Tach (Count/rev)
On the Hand Held press the C key.
Enter the number of teeth on the flywheel.
On the Hand Held press the Enter key.
Unlock the rolls.
Start the engine. Check for correct RPM indication, oil pressure, and other required parameters. Put the truck in 1:1
(direct) drive and slowly release clutch.
Lock the fan ON. (optional)
Starting a manual test.
On the Hand Held press the G key to Test.
On the Hand Held press the C key to Manual.
Warm the engine.
On the Hand Held press the A key to select either
Vehpwr or VehSpd.
On the Hand Held press the J key for Done.
On the Hand Held press the A key and enter the desired
Vehpwr or VehSpd set point.
Running the test.
On the Hand Held press the A key and enter the first desired
control mode.
On the Hand Held press the A key and enter the first desired
lug point.
Allow the engine to stabilize.
Section 6 - page 27
SF-602
M a n u a l
12.
13.
14.
15.
16.
17.
18.
6.14.2.
Record one line of data.

On the Hand Held press the A key and enter the second
desired lug point.
Repeat until all Lug points are collected.
Manual test is complete.
Release the throttle pedal. Shift to neutral at approximately 30
mph and allow the rolls to coast to a stop.
Allow the engine (and turbo) to cool at low idle before shutting
down the engine.
On the Hand Held press the B key for Data then the A
key for Save Data
At the PC your DataLib should be waiting for you to enter the
vehicle information.
After all information is entered Choose File and go down to
Reports and hit Enter. Verify that the mark is in front of the
word Concise. Choose Setup and on the next screen choose
the Button after the word Data . On the next screen choose
the screen of your choice, press the Enter key then click the
OK on the next screen. Now the test can be printed by
pressing Print. After completion of the print press Cancel.
Close DataLib , now the screen should return to Real Time
Running an Auto Test

NOTE
This is an abbreviated set of instructions. For safetys sake, refer to your SF-602
manual for complete instructions. Do not attempt to use the Dyno unless you
have received appropriate training. Severe injury, death, and/or property
damage may result from improper use. Do not use the cruise control on the
truck you are testing.
If you need assistance at any time during this process, please

call SuperFlow Customer Service at (719) 471-1746.
1.
2.
3.
Section 6 - Page 28

On the first Hand Held screen press the F key for
Autozero.
Select All. Make sure there are no pressures applied to the
dyno.
Clear all Data
Configure the dyno.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
P E R A T I N G

Tandem Axle
Unlock the rolls.
Start the engine. Check for correct RPM indication, oil pressure, and other required parameters. Put the truck in 1:1
Warm the engine.
On the Hand Held press the A key to select Vehpwr.
VehPwr setpoint.
Running the test.
On the Hand Held press the A key to Select Test.
Enter the test number.
On the Hand Held press the B key to Start Test.
Enter the correct information when prompted.
Allow the test to complete.
Auto test is complete.
mph and allow the rolls to coast to a stop.
key for Save Data
down the engine.
After all information is entered choose File and go down to
Reports and hit Enter. Verify that the mark is in front of the
Section 6 - page 29
SF-602
M a n u a l
17.
6.14.3.
word Concise. Choose Setup and on the next screen choose

the Button after the word Data. On the next screen choose the
screen of your choice, press the Enter key then click the OK
on the next screen. Now the test can be printed by pressing
Print. After completion of the print press Cancel.
Close DataLib , now the screen should return to Real Time.
Cylinder Cutout test

These steps will guide you through the necessary steps for
running a cylinder cutout test using the SF 602.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Section 6 - Page 30
Connect the engine tach pickup to the engine magnetic pickup.

On the first Hand Held screen press the F key for Autozero.
Select All.Make sure there are no pressures applied to the
dyno.
Clear all Data
Configure the dyno.
Tandem Axle
Unlock the rolls.
Start the engine. Check for correct RPM indication, oil
pressure, and other required parameters. Put the truck in 1:1
Starting a manual warm-up.
Warm the engine.
12.
13.
14.
15.
16.
17.
18.
19.
20.
P E R A T I N G
On the Hand Held press the A key to select either

Vehpwr or VehSpd.
Vehpwr or VehSpd set point.
Running the test.
On the Hand Held press the A key and enter EngSpd as the
desired control mode.
On the Hand Held press the A key and enter the desired lug
point, i.e. 1600 rpm.
Use the ECAP and cut out cylinder #1.
Allow the engine rpm to stabilize and record one line of data
Repeat steps until all cylinders have been cut out.
Record one additional line of data with no cylinders cut out.
Test is over. On the Hand Held press the E key twice.
mph (50 kmh) and allow the rolls to coast to a stop.
key for Save Data
down the engine.
After all information is entered Choose File and go down to
Reports and hit Enter. Verify that the mark is in front of
the word Concise . Choose Setup and on the next screen
choose the Button after the word Data . On the next screen
choose the one labeled Cylinder Cutout, press the Enter
key then click the OK on the next screen. Now the test can
be printed by pressing Print. After completion of the print
press Cancel .
Close DataLib , now the screen should return to Real time
Section 6 - page 31
Handheld Manual
7. Handheld Manual
7.1.
System power-up choices ......................................................................... 3
7.2.
Start menu choices .................................................................................... 5

7.2.1.
Autozero functions ........................................................................................ 6
7.2.2.
Test functions ............................................................................................... 7
7.2.3.
Stored Data display choices ....................................................................... 11
7.2.4.
Configuration choices ................................................................................. 12
7.2.4.1. Configuration of Specifications ............................................................... 13
7.2.4.2. Configuration of Calibration ..................................................................... 15
7.2.4.3. Configuration of Limits ............................................................................ 20
7.2.4.4. Configuration of system .......................................................................... 20
7.2.5.
Help choices ............................................................................................... 23
7.2.6.
Dynamometer controls ................................................................................ 23
7.2.6.1. Roll lock controls .................................................................................... 23
7.2.6.2. Counts / revolution control ...................................................................... 24
7.2.6.3. Fuel System controls ............................................................................. 25
7.3.
Other handheld controller keys ................................................................ 26
7.1.
A N D H E L D
System power-up choices

System power-up screen (this screen displays at system
power-up and whenever the softkey sequence F-A-D-E is
pressed)
SuperFlow SF-602 system

Date: Sun Jan 1,
0
Start Set time System
menu & date Status
A
B
C
J
0:00:00.00am
System
check
D
Color
E
Set Time & Date screen
G
H
Time/Date Setup
TIME:
0:00:00am
hours:[ 0]
minutes:[00]
seconds:[ 0]
A
DATE:
Sun Jan 1,
0
month:[ 1]
day:[ 1]
year:[
0]
C
Exit
E
System status screen

Case #1: no nodes connected
F
G
H
I
J
System Status:
0:00:00.00am
System type: CHASSIS
Operating system version: 8.24
Program version: 3.19
Nodes connected = 0
BProc
A
Exit
E
Section 7 - Page 3
E N U
SF-602
M a n u a l
Case #2: nodes connected
F
G
H
I
J
System Status:
0:00:00.00am
System type: CHASSIS
Program version: 3.19
Nodes connected = 2
BProc
A
Nodes
B
Exit
E
Pressing Nodes will display connected node information
F
G
H
System Status:
Connected Nodes: <2>
Connected to NameofNode
Connected to NameofNode
I
J
0:00:00.00am
type-1,1
type-3,0
Exit
E
B Processor screen
F
G
H
I
J
System Status:
0:00:00.00am
B Processor status: Running
Application : Running, ver -> 2.07
Exit
E
System check screen
H
I
J
System Diagnostics Results:
RAM test: No Errors, size =
12.250 Meg
Operating System version: 8.24
System (.prg) version = 3.19, Name:
<SF-602 System Master Node>
Section 7 - Page 4
Exit
E
SF-602 manualV2- 1125 Sect7.PM6.5, 5/1998
A N D H E L D
Screen color: this function allows the selection of normal or

reverse mode for the display

Date: Sun Jan 1,
0
menu & date Status
A
B
C

Date: Sun Jan 1,
0
menu & date Status
A
B
C
7.2.
J
0:00:00.00am
System
check
D
Color
E
J
0:00:00.00am
System
check
D
Color
E
Start menu choices

Start Menu screen (this screen will also display whenever the
red stop key is pressed)
F
Autozero
Ch#1
Ch#4
Ch#7
G
Test
H
Data
0 Ch#2
0 Ch#5
0 Ch#8
---- Rolls ---- Counts

Lock [Unlock] /rev.
A
B
C
I
J
Configure Help
0 Ch#3
0 Ch#6
0 Ch#9
0
0
0
- Fuel System Pumps

Status
D
E
Section 7 - Page 5
E N U
SF-602
7.2.1.
M a n u a l
Autozero functions
Autozero screen
Ch#1
Ch#4
Ch#7
0 Ch#2
0 Ch#5
0 Ch#8
0 Ch#3
0 Ch#6
0 Ch#9
Autozero: All
Single
channels channel
A
B
C
0
0
0
Exit
E
Autozero all channels (timed message)
F
Autozero
G
Test
H
Data
I
J
Configure Help
Zeroing all sensor channels

Lock
Unlock /rev.
A
B
C
- Fuel System Pumps

Status
D
E
Autozero single channel screen (note: it is not required to use

the |Select |command; by pressing the channel # key the
channel will be selected)
F
Select
<Ch#1
<Ch#4
<Ch#7
<Ch#10
<Ch#13
PageUp
A
Section 7 - Page 6
G
H
channel to zero..
>=xx
<Ch#2 >=xx
>=xx
<Ch#5 >=xx
>=xx
<Ch#8 >=xx
>=xx
<Ch#11 >=xx
>=xx
<Ch#14 >=xx
PageDn
B
J
<Ch#3
<Ch#6
<Ch#9
<Ch#12
<Ch#15
Select SortList
C
D
>=xx
>=xx
>=xx
>=xx
>=xx
Exit
E
A N D H E L D
Autozero single channel selection screen
F
Select
<Ch#1
<Ch#4
<Ch#7
<Ch#10
<Ch#13
G
H
channel to zero..
>=xx
<Ch#2 >=xx
>=xx
<Ch#5 >=xx
>=xx
<Ch#8 >=xx
>=xx
<Ch#11 >=xx
>=xx
<Ch#14 >=xx
J
<Ch#3
<Ch#6
<Ch#9
<Ch#12
<Ch#15
Enter Channel Number : [ 0]

A
B
C
D
>=xx
>=xx
>=xx
>=xx
>=xx
E
Autozero single channel (timed message)
Autozeroing channel xx [ChName]

Autozero: All
Single
channels channel
A
B
C
7.2.2.
Exit
E
Test functions
Test screen
F
G
H
Current test: None.
Ch#1
Ch#4
Ch#7
Select
test
A
0 Ch#2
0 Ch#5
0 Ch#8
Start
test
B
0 Ch#3
0 Ch#6
0 Ch#9
Manual
test
C
0
0
0
Exit
E
Section 7 - Page 7
E N U
SF-602
M a n u a l
Select test screen (no computer nodes connected)
F
G
H
Current test: None.
************ WARNING! ****************

No computer nodes connected
cannot perform the requested function
Select
test
A
Start
test
B
Manual
test
C
Exit
E
Select test file screen (no computer nodes connected)

Case #1: no files found in specified WinDyn path
F
G
H
***No Files Found***
Press any key
Case #2: files found in specified WinDyn path

(note: it is not required to use the Select command; by
pressing the test # key the test file will be selected)
F
G
H
I
J
File Selection
<xxx files found>
1=<TSTNAME1> 6=<TSTNAME6>
2=<TSTNAME2>
3=<TSTNAME3>
4=<TSTNAME4>
5=<TSTNAME5>
PageUp
A
Section 7 - Page 8
PageDn
B
Select
C
Exit
E
A N D H E L D
Select Test file number screen
F
G
H
I
J
File Selection
<xxx files found>
1=<TSTNAME1> 6=<TSTNAME6>
2=<TSTNAME2>
3=<TSTNAME3>
4=<TSTNAME4>
5=<TSTNAME5>
Enter File Number : [ 0]
A
B
C
Test Start screen (no test loaded in system)
F
G
H
Current test: None.
************ Warning! ****************

No Valid Test profile found
Cannot perform requested function
Select
test
A
Start
test
B
Manual
test
C
Exit
E
Test Start screen (test loaded in system)
F
G
H
Current test: TESTNAME
Ch#1
Ch#4
Ch#7
Select
test
A
0 Ch#2
0 Ch#5
0 Ch#8
Start
test
B
I
0 Ch#3
0 Ch#6
0 Ch#9
Manual
test
C
J
0
0
0
Exit
E
Section 7 - Page 9
E N U
SF-602
M a n u a l
Test control screen

(note: data displays may be overwritten by test messages and
softkeys are labeled by the test)
F
G
H
Stop
Pause Continue
[TESTNAME] is running at
Ch#1
0 Ch#2
0
Ch#4
0 Ch#5
0
Ch#7
0 Ch#8
0
step xxx
Ch#3
Ch#6
Ch#9
F
G
H
I
Stop
Pause Continue
[TESTNAME] is running at step xx
0
0
0
<test messages may appear here>
Manual Test screen

(note: pressing either A or B softkey will scroll control
modes; press Done to activate mode, Exit to cancel and
return to previous screen)
Section 7 - Page 10
G
H
I
Select Control Modes
---- Load
----Load %
eEngSpd
FRlSpd
eV.Spd
EngSpd
FRlTrq
J
Done
Select: Load %
A
B
Exit
E
A N D H E L D
If there are 2 control modes, the screen will look like this:
G
H
I
J
Select Control Modes
Done
---- Load
-------- Throttle ---Load %
eEngSpd
Throt %
FRlSpd
eV.Spd
FRlTrq
EngSpd
FRlSpd
FRlTrq
Select: Load %
A
B
Throt %
D
Exit
E
Manual test control screen (pressing Exit returns the controllers to zero state (no load / no throttle), removes the command
line and returns to the Test Start screen)
F
Ch#1
Ch#4
Ch#7
0 Ch#2
0 Ch#5
0 Ch#8
J
Modes
0 Ch#3
0 Ch#6
0 Ch#9
0
0
0
---- Load
controlling to: Manual ----0.00
-5.00
+5.00
Medium
Exit
A
B
C
D
E
7.2.3.
Stored Data display choices

NOTE
Each of the 9 data display screens can be customized to show the data which is
important to your application. See Section 16 for more information.
Data screen (J or a direct keypad number entry will scroll

through screen 1-9, Records displays total lines of data in
test, Number displays current line #)
F
First
Ch#1
Ch#4
Ch#7
Save
Data
A
G
Last
H
Up
0 Ch#2
0 Ch#5
0 Ch#8
Erase
data
B
Records
0
C
I
Down
J
Screen#
0 Ch#3
0 Ch#6
0 Ch#9
0
0
0
Number
0
D
Exit
E
Section 7 - Page 11
E N U
SF-602
M a n u a l
Save Data screen (timed message)

(note: this command will cause a WinDyn Database window to
display on your PC)
F
First
G
Last
H
Up
I
Down
J
Screen#
Save data command sent to all

computer nodes
Save
Data
A
Erase
data
B
Records
0
C
Number
0
D
Exit
E
Erase Data screen
F
Ch#1
Ch#4
Ch#7
G
0 Ch#2
0 Ch#5
0 Ch#8
Erase Data
Are you sure?
A
B
7.2.4.
0 Ch#3
0 Ch#6
0 Ch#9
Yes
C
No
D
0
0
0
Configuration choices
Configuration screen
F
G
H
I
J
Select required configuration function:
Ch#1
Ch#4
Ch#7
Specs
A
Section 7 - Page 12
0 Ch#2
0 Ch#5
0 Ch#8
Calibr.
B
0 Ch#3
0 Ch#6
0 Ch#9
Dyno
C
Control
D
0
0
0
Exit
E
7.2.4.1.
A N D H E L D
Configuration of Specifications
Specifications screen
F
G
H
I
J
Current specifications file: SPECNAME
Ch#1
Ch#4
Ch#7
0 Ch#2
0 Ch#5
0 Ch#8
Select
new file
A
Save
file
B
0 Ch#3
0 Ch#6
0 Ch#9
Edit
C
0
0
0
Exit
E
Select specifications file screen

Case #1: no files found in specified WinDyn path
F
G
H
***No Files Found***
Press any key
Case #2: files found in specified Windyn path

pressing the specifications # key the specifications file will be
selected)
F
G
H
I
J
File Selection
<xxx files found>
1=<SPCNAME1> 6=<SPCNAME6>
2=<SPCNAME2>
3=<SPCNAME3>
4=<SPCNAME4>
5=<SPCNAME5>
PageUp
A
PageDn
B
Select
C
Exit
E
Section 7 - Page 13
E N U
SF-602
M a n u a l
Select Specifications file number screen
F
G
File Selection
1=<SPCNAME1>
2=<SPCNAME2>
3=<SPCNAME3>
4=<SPCNAME4>
5=<SPCNAME5>
H
I
J
<xxx files found>
Enter File Number : [ 0]

A
B
C
I
channel:
>=xx
<Ch#3
>=xx
<Ch#6
>=xx
<Ch#9
>=xx
<Ch#12
>=xx
<Ch#15
Edit specifications file screen
F
Select
<Ch#1
<Ch#4
<Ch#7
<Ch#10
<Ch#13
PageUp
A
G
H
specification
>=xx
<Ch#2
>=xx
<Ch#5
>=xx
<Ch#8
>=xx
<Ch#11
>=xx
<Ch#14
PageDn
B
Select SortList
C
D
>=xx
>=xx
>=xx
>=xx
>=xx
Exit
E
Select Specifications channel screen
F
Select
<Ch#1
<Ch#4
<Ch#7
<Ch#10
<Ch#13
G
H
specification
>=xx
<Ch#2
>=xx
<Ch#5
>=xx
<Ch#8
>=xx
<Ch#11
>=xx
<Ch#14
I
channel:
>=xx
<Ch#3
>=xx
<Ch#6
>=xx
<Ch#9
>=xx
<Ch#12
>=xx
<Ch#15

A
B
C
D
J
>=xx
>=xx
>=xx
>=xx
>=xx
E
Edit Specifications channel screen (1)
F
G
H
I
Edit specification channel: ChName
Current value:
xxxx.xx
Enter new value: [xxxx.xx]
A
Section 7 - Page 14
A N D H E L D
Edit Specifications channel screen (2)
G
H
I
Specification editor
Edit specification:
#Ch, <ChName = xxxx.xx>
Next
chan.
A
7.2.4.2.
Prev.
chan.
B
Return
Edit
to list channel
C
D
Exit
E
Configuration of Calibration
Calibration function selection screen
F
G
H
I
J
Select required calibration function:
Ch#1
Ch#4
Ch#7
Sensors
A
0 Ch#2
0 Ch#5
0 Ch#8
0 Ch#3
0 Ch#6
0 Ch#9
0
0
0
---- Fuel System ---Weight

Volume
B
C
D
Exit
E
Sensor Calibration screen
G
H
I
Select channel to calibrate
<Ch#1 >=xx
<Ch#2 >=xx
<Ch#3
<Ch#4 >=xx
<Ch#5 >=xx
<Ch#6
<Ch#7 >=xx
<Ch#8 >=xx
<Ch#9
<Ch#10 >=xx
<Ch#11 >=xx
<Ch#12
<Ch#13 >=xx
<Ch#14 >=xx
<Ch#15
PageUp
A
PageDn
B
Select SortList
C
D
J
>=xx
>=xx
>=xx
>=xx
>=xx
Exit
E
Section 7 - Page 15
E N U
SF-602
M a n u a l
Select calibration channel screen

pressing the channel # key the channel will be selected)
Select
<Ch#1 >=xx
<Ch#4 >=xx
<Ch#7 >=xx
<Ch#10 >=xx
<Ch#13 >=xx
I
channel to calibrate
<Ch#2 >=xx
<Ch#3
<Ch#5 >=xx
<Ch#6
<Ch#8 >=xx
<Ch#9
<Ch#11 >=xx
<Ch#12
<Ch#14 >=xx
<Ch#15

A
B
C
D
J
>=xx
>=xx
>=xx
>=xx
>=xx
E
Calibration method selection screen
G
H
I
Sensor Calibration
Calibrating <ChName>
Calibrate by:
A
B
CurrVal.
C
Coeff.
D
Exit
E
Calibration screen using Current Value
G
H
I
Sensor Calibration
Enter Current value
Section 7 - Page 16
[xxxxx.x]
A N D H E L D
Calibration confirmation screen using Current Value
G
H
I
Sensor Calibration
Calibrate channel # (ChName)
to xxxxx.x
Is this correct?
Yes
A
No
B
G
H
I
Sensor Calibration
Calibration screen using Coefficient
Enter calibration coefficient
[xxxx.xxx] Unit/Unit
A
Calibration confirmation screen using Coefficient
G
H
I
Sensor Calibration
Set ChName coefficient to xxxx.xxx
Unit/Unit
Is this correct?
Yes
A
No
B
G
H
I
Sensor Calibration
Calibrate other channels screen
Calibrate channel: #xxx <ChName>
Next
chan.
A
Prev.
chan.
B
Return Perform
to list calibr.
C
D
Exit
E
Section 7 - Page 17
E N U
SF-602
M a n u a l
Fuel System weight calibration screen (step 1)
F
Default
J
Abort
Emptying tank to LOW float

weight = xx.xx lbs
Low float is WET
F
G
H
I
J
Default
Abort
Press any key when zero cal weight
is stable :
xx.xxxx lbs.
F
G
H
I
J
Default
Abort
is stable :
xx.xxxx lbs.
Press any key when full-scale cal
weight is stable :
xx.xxxx lbs.
Enter calibration Weight
[xx.xx]
A
F
G
H
I
J
Default
Abort
is stable :
xx.xxxx lbs.
Press any key when full-scale cal
weight is stable :
xx.xxxx lbs.
Enter Calibration Weight:
[xx.xx]
Calibration complete.
Press any key
A
B
C
D
E
Section 7 - Page 18
A N D H E L D
Fuel System weight: default calibration
Are you sure you want to set

calibration to default values?
Yes
D
No
E
Fuel System volume calibration (step 1)
J
Abort
Fuel volume calibration:

Filling tank, weight =
xx.xx lbs
Fuel System volume calibration (step 2)
J
Abort
Fuel volume calibration:

Enter API of fuel in tank :
[xx.xx]
Save calibration screen
F
G
H
I
J
Ch#1
Ch#4
Ch#7
0 Ch#2
0 Ch#5
0 Ch#8
Changes have been made,

save in computer file?
A
B
C
0 Ch#3
0 Ch#6
0 Ch#9
Yes
D
0
0
0
No
E
Section 7 - Page 19
E N U
SF-602
M a n u a l
Saving calibration message screen
F
G
H
I
J
Sending file save request
to computer nodes(s)
Reload
file
A
7.2.4.3.
Save
file
B
Edit
C
Exit
E
Configuration of Limits
***** Note: for future implementation *****
Limits screen
Limits file selection screen
Select Limits file screen
Limits channel selection screen
Select limit channel screen
Limit value edit screen
***** End of Note ****
7.2.4.4.
Configuration of system
G
H
I
Dyno roll configuration
Current Mode:
Single axle, front roll
Select the required roll mode:

Tandem
Axle
A
-Single AxleFront
Rear
B
C
Exit
E
Control screen
F
G
H
I
J
Select Control calibration function:
Ch#1
Ch#4
Ch#7
PID
A
Section 7 - Page 20
0 Ch#2
0 Ch#5
0 Ch#8
Step
Save
Values settings
B
C
0 Ch#3
0 Ch#6
0 Ch#9
0
0
0
Exit
E
A N D H E L D
Step Values screen
G
H
I
J
Calibrate Step values
Manual
Load
controller
Modes for the Load controller:
Select the required control mode
Press J for manual
Mode1
A
Mode2
B
Mode3
C
Mode4
D
Mode5
E
Step Values screen for Manual mode
G
H
I
J
Manual
Load
controller
Calibrating Step values for Manual
COARSE step size : [xxxx.xx]
MEDIUM step size : [xxxx.xx]
FINE step size : [xxxx.xx]
Calibrate another mode?
A
B
C
Yes
D
No
E
Step Values screen for Closed Loop mode
G
H
I
J
Manual
Load
controller
Calibrating Step values for Mode1
COARSE step size : [xxxx.xx]
MEDIUM step size : [xxxx.xx]
FINE step size : [xxxx.xx]
A
B
C
Yes
D
No
E
PID control screen 1
G
H
I
Edit Control Parameters
Load controller setup

Actuator phase (0=pos) : [0]
Section 7 - Page 21
E N U
SF-602
M a n u a l
F
G
H
I
Modes for the Load controller:
Select the required control mode
Mode 1
A
Mode2
B
Mode3
C
Mode4
D
F
G
H
Parameters for: Load
I
Mode1
Edit parameters for which dyno roll

Control Mode?
Tandem
Axle
A
Single
Axle
B
Exit
E
F
G
H
I
J
Parameters for: Load -> FRlSpd Tandem
Phase..[0]
Open Rate..[
0] Close Rate..[
0]
P-Gain..[
0.000] I-Time..[
0]
I-Gain..[
0.000] I-Threshold.[ 0.00]
D-Gain..[
0.000] D-Time..[
0]
Delay..[
0] Filter Rate.[0]
Exit
A
B
C
D
E
F
G
H
I
J
Parameters for: Load
FRlSpd Tandem
Phase..[0]
Open Rate..[
0] Close Rate..[
0]
P-Gain..[
0.000] I-Time..[
0]
I-Gain..[
0.000] I-Threshold.[ 0.00]
D-Gain..[
0.000] D-Time..[
0]
Delay..[
0] Filter Rate.[0]
YES
NO
A
B
C
D
E
Section 7 - Page 22
A N D H E L D
Saving Control Settings message screen
F
G
H
I
J
Select Control calibration function:
Sending file save request
to computer nodes(s)
PID
A
7.2.5.
Step
Save
Values settings
B
C
Exit
E
Help choices
***** for future implementation *****
7.2.6.
Dynamometer controls
F
Autozero
Ch#1
Ch#4
Ch#7
G
Test
H
Data
0 Ch#2
0 Ch#5
0 Ch#8
0 Ch#3
0 Ch#6
0 Ch#9

Lock [Unlock] /rev.
A
B
C
7.2.6.1.
I
J
Configure Help
0
0
0
- Fuel System Pumps

Status
D
E
Roll lock controls

Roll lock cannot be activated while the roll is still turning.
F
Autozero
G
Test
H
Data
I
J
Configure Help
************* Warning ******************

Stop Rolls before using
that function
Lock [Unlock] /rev.
A
B
C
- Fuel System Pumps

Status
D
E
Section 7 - Page 23
E N U
SF-602
M a n u a l
When Roll lock is activated with a stopped roll:
F
Autozero
G
Test
H
Data
I
J
Configure Help
Rolls Locked
[Lock] Unlock
/rev.
A
B
C
- Fuel System Pumps

Status
D
E
When Roll Unlock is activated:
F
Autozero
G
Test
H
Data
I
J
Configure Help
Rolls Unlocked
Lock [Unlock] /rev.
A
B
C
7.2.6.2.
- Fuel System Pumps

Status
D
E
Counts / revolution control

This control is used to configure the system for the correct
engine speed signal. The number of pulses per revolution for
your engine must be entered here.
G
H
I
Configure Tachometer Input
Enter the # of pulses per revolution

[0] disables tachometer input
ECM tach ON enables ECM engine speed
Current Setting:
A
B
Section 7 - Page 24
60
C
ECM tach
on [off]
D
Exit
E
A N D H E L D
Pressing the C key allows you to enter a new number:
G
H
I
Configure Tachometer Input
Enter the # of pulses per revolution

[0] disables tachometer input
ECM tach ON enables ECM engine speed
Enter new value: [xxx]
Current Setting:
60
A
B
C
7.2.6.3.
ECM tach
On [Off]
D
Exit
E
Fuel System controls

Fuel pump controls:
G
H
I
J
Fuel System Pump Controls
FILL/EMPTY to pump fuel from/to tank
PRIME to prime engine fuel system
STOP will turn Fuel System OFF!
Fuel Level: xxx%
mode = <status>
Fill
A
Empty
B
Prime
Stop
ON [OFF] pumps!
C
D
Exit
E
Fuel system status:
H
I
Fuel System Status Controls
ON/OFF to control automatic refill

SET API to manually enter API
Status: [OFF]
On
Off
A
B
Set
API
C
Level
xxx%
D
Exit
E
Section 7 - Page 25
E N U
SF-602
M a n u a l
Set API manually:
G
H
I
J
Fuel System Status Controls
API is normally measured by system!
Enter API manually to override
measured value.
Current fuel API 35.0

Enter new value: [35.0]
A
B
C
7.3.
Exit
E
Other handheld controller keys
STOP
returns to start menu, stops running tests,

removes load from the EC absorber, aborts all
menu actions without saving.
RECORD
records one data line for each time it is pressed.
DISPLAY
alternates the current data screens display of

units, channel number, measured values.
PRINT
not currently active.
TOGGLE
toggles between normal operation and load

control command line.
Section 7 - Page 26
data entry keys.
CLEAR
clears last keystroke entered in an input field.
ENTER
confirms data entry in an input field.
Theory of Testing
8. Theory of Testing
8.1.
Chassis Dynamometer testing ................................................................... 3

8.1.1.
8.1.2.
Engine dynamometer .................................................................................... 3

Chassis dynamometer .................................................................................. 3
8.2.
Loaded testing ........................................................................................... 4
8.3.
SF-602 absorber theory of operation ......................................................... 5
8.4.
Load control ............................................................................................... 7
8.5.
Torque measurement ................................................................................. 7
8.6.
Typical applications of the SF-602 Test System ......................................... 8

8.6.1.
8.6.2.
8.6.3.
8.6.4.
8.6.5.
8.6.6.
8.6.7.
8.6.8.
8.6.9.
8.6.10.
Performance Testing ...................................................................................... 8

Diagnostic Testing ......................................................................................... 8
Used Truck Certification ................................................................................ 9
Durability Testing ........................................................................................... 9
Fleet Testing ................................................................................................. 9
Emissions Testing ......................................................................................... 9
Research and Development ........................................................................ 10
Engine or Vehicle Break-in .......................................................................... 10
End-of-production-line Testing ..................................................................... 10
Education ................................................................................................... 10
8.7.
Tire-roll interface ...................................................................................... 10
8.8.
Interpreting power measurements ........................................................... 11

8.8.1.
8.8.2.
8.8.3.
8.9.
Vehicle Torque ............................................................................................. 11

Vehicle Power ............................................................................................. 12
Corrected Vehicle Power ............................................................................. 12
Power correction factors .......................................................................... 12
8.10. SF-602 Test Modes .................................................................................. 14

8.10.1.
8.10.2.
8.10.3.
8.10.4.
8.10.5.
Manual control mode (position control) ........................................................ 14

Engine speed control mode ......................................................................... 15
ECM engine speed control mode ................................................................ 16
Vehicle speed control mode ........................................................................ 16
Vehicle power control mode ........................................................................ 16
8.1.
H E O R Y
O F
E S T I N G
Chassis Dynamometer testing

Dynamometer tests can be performed on an engine alone or on
an engine installed in a vehicle. Both methods have advantages
and disadvantages and corresponding typical applications.
8.1.1.
Engine dynamometer
Advantages
measurement of engine output at the flywheel, no mechanical losses to be corrected / measured
very good control over test parameters and conditions
greatest precision
full access to the engine for installation of sensors and

instrumentation or for adjustments and changes
necessity to remove engine from vehicle
necessity for specific engine installation hardware (adapters)
possible problem of electronic engine control wiring
necessity for a specific environment (test cell) replacing all

services to the engine (coolant, fuel supply, exhaust,)
engine research and development, engine tuning
reliability, endurance testing
all tests requiring accurate measurement of engine output

(such as standards)
stationary engines (no vehicle available)
Disadvantages
Applications
8.1.2.
Chassis dynamometer
Advantages
fast and easy measurement (no engine removal)
actual vehicle performance
measurement takes into account the influence of the

installation factors
simplified measurement environment
difficult to measure mechanical losses
variations in mechanical losses due to transmission oil and

tire temperature, tire pressure and vertical force (axle load)
variations
limited access to engine
less control over test parameters
more difficult sensor installations
Disadvantages
Section 8 - page 3
SF-602
M a n u a l
Applications
8.2.
vehicle tests for diagnostic purposes
in addition to engine dynamometer for development

purposes
measurement of driveline losses by comparison with an

engine dynamometer
tests requiring accurate measurements of vehicle output
tests requiring a complete vehicle for measurement of fuel

consumption or emissions
Loaded testing
Loaded tests are performed by connecting the engine (or vehicle)
to an external device which will apply a (controlled) load to the
engine. This device is typically called a power absorption unit
(PAU); PAUs can operate on hydraulic (water brake) or electric
(eddy current brake and AC or DC motors) principles.
When an external load is applied to an engine, the test is
called a dynamometer test because it will allow actual measurement of the work performed by the engine.
NOTE
There occasionally is some confusion over the terms used in dynamometer

testing, so a quick reminder might be required:
FORCE is expressed in pounds (usually referred to as pounds-force or lbf) or
in Newtons (N)
TORQUE = FORCE x MOMENT OF FORCE and is expressed in pound-feet
(lb.-ft) or Newton-meters (Nm)
WORK = FORCE x DISTANCE and is expressed in foot-pounds (ft-lbf) or Joule (J)
POWER = WORK / TIME or TORQUE x ANGULAR SPEED OF ROTATION and
is expressed in Horsepower (HP) or kilowatt (kW)
The load applied by the dynamometer results in a torque. If

torque is applied without rotation, no work is accomplished.
On dynamometers, the torque and the speed of rotation are
measured. Power is a calculated variable.
Controlled load dynamometers have a number of characteristics in common:
the presence of a PAU with operator-controlled load

the presence of some method of measuring the load
(torque) applied by the PAU
the presence of some method of measuring the rotational
speed of the PAU
a cooling medium to dissipate the absorbed power
As mentioned, PAUs can be of the hydraulic, Eddy Current, or
AC / DC electric motor type. The SF-602 Truck Chassis Dynamometer uses variable fill, inlet controlled hydraulic power
absorbers.
Section 8 - Page 4
8.3.
H E O R Y
O F
E S T I N G
SF-602 absorber theory of operation

The absorber shaft carries a cylindrical rotor which revolves in
a watertight casing. Toroidal recesses formed half in the rotor
and half in the casing (stator) are divided into pockets by radial
vanes set at an angle to the axis of the rotor. When the rotor is
driven by the dynamometer rolls, the centrifugal force sets up
an intensive toroidal circulation which transfers momentum
from rotor to stator. A torque resistant to the rotation of the
shaft is developed and this torque is balanced by an equal and
opposite torque reaction in the stator. (Figure 1). The amount of
water in the dynamometer and the speed of the rotor determine the amount of load that is produced.
The forced vortex of toroidal form leads to high rates of turbulent shear in the water and the dissipation of power in the
form of heat to the water. For a given flow rate, the temperature increase of the water is fairly linear with speed increase
and relatively independent of load (water level). To maintain
the temperature at acceptable levels* at high speeds, it is
necessary to increase the flow rate.
*160 F (70 C) should not be exceeded for reliability, 180 F (80 C) for
proper operation of the absorber
Hydrokinetic dynamometer: principle of operation: (a) section

through dynamometer; (b) end view of rotor; (c) development of
section a-a of rotor and casing; (d) representation of toroidal vortex
The center of the vortex is vented to atmosphere. Due to the

complex nature of velocity profiles and pressure phenomena
the rotor cavity will however remain pressurized when the
rotor is driven.
Section 8 - page 5
SF-602
M a n u a l
Proper design of the rotor and stator eliminates cavitation and

erosion problems. Note that the rotor and stator have a different number of pockets to reduce vibration levels.
The characteristic torque curve of a hydraulic absorber is
theoretically a square function (x2) of speed. As a consequence,
the absorber has zero torque at zero speed and is relatively
inefficient at low speed. However, as speed increases, the
hydraulic absorber is capable of very high torque.
Performance curves: hydraulic dynamometer
The SF-602 power absorbers are of the variable fill, inlet

controlled type.
This means that the inlet flow is regulated and the outlet
orifice is constant. The outlet flow is determined by outlet
orifice area and rotor cavity pressure. Note that on the SF-602,
it is possible to modify the outlet orifice area by adjusting the
outlet valves on the absorbers. These outlet valves are adjusted
during initial commissioning of the dynamometer and do not
typically require readjustment.
As these absorbers have a - significant - constant leak,
increasing torque response speed is limited by the difference
in flow between inlet valve 100% open and constant outlet.
Decreasing torque response speed is determined by the rate of
drain through the constant outlet with a fully closed inlet
valve. Should you want to improve the decreasing torque
response speed by increasing the outlet orifice, you will
reduce the increasing torque response speed by the greater
leak. And vice-versa. These absorbers consequently have a
relatively slow response and are primarily suited for lower
speed engines such as Heavy Diesel engines. Their main
advantage is their ability to shut off water flow to the absorber
completely and thus create a (near) zero-load condition, which
is a necessity for testing Diesel engines.
Hydraulic absorbers have a high power density, i.e. they are
compact for the amount of torque they can produce. They have
an excellent cost/capacity ratio, low inertia, low maintenance
costs, and excellent reliability.
Section 8 - Page 6
8.4.
H E O R Y
O F
E S T I N G
Load control
The SF-602 uses an inlet control valve to regulate the water
level. In the closed-loop control mode, the valve is continuously adjusting its position to maintain the setpoint.
With a computer-controlled test program, the setpoint will be
continuously adjusted by the system to run a test profile.
Most engine test programs consist of sequences of engine
throttle (or governor) and dynamometer load setpoints. The
dynamometer load (torque) will be controlled by the automatic
load controller and the engine throttle either by hand (pedal) or
by an automatic throttle controller.
Either control can be used to control engine speed or engine
torque. Due to the nature of its controlled actuator (the engine
throttle), the throttle controller is normally capable of less
precise control than the dynamometer load controller.
For any given setting of the throttle the engine has its own
inherent torque-speed characteristic and similarly for any given
setting of the load the dynamometer has its own torque-speed
curve. The interaction of these two characteristics determines
the inherent stability of the engine / dynamometer combination.
Note that this also explains why a dynamometer is not capable
of controlling to engine power by itself: each engine power
setpoint represents an infinite number of torque / speed combinations. Controlling to engine power using a single controller
consequently results in an undefined control state.
Various combinations of engine throttle and dynamometer load
control modes can be chosen depending on the test requirements.
8.5.
Torque measurement
The amount of load produced by the absorber is measured
very accurately with a load cell. A load cell uses strain gauge
sensors to measure the forces acting on the metal. These strain
gauges are highly sensitive devices which require periodic
calibration.
On the SF-602, the torque reaction of the rear absorber is
coupled to the front absorber and to the single load cell with a
torque transfer bar. Some chassis dynamometers use dual load
cells. The SuperFlow NGE system is capable of interfacing
with two load cells.
Section 8 - page 7
SF-602
8.6.
M a n u a l
Typical applications of the SF-602 Test System

The original SF-601 Truck Chassis Dynamometer system, and its
current successor the SF-602, have been designed for diagnostic
and maintenance purposes in truck dealerships. Their reputation for accuracy, durability, and advanced instrumentation,
resulted in the installation of hundreds of systems in a wide
variety of applications. Some of the most common applications
are described below. They may provide you with ideas on
additional revenue-generating tasks for your system.
8.6.1.
NOTE
A typical Return On Investment sheet is available from SuperFlow. Contact your

local Sales or Service Representative for more information.
Performance Testing
The SF-602 is a very high performance chassis dynamometer
which can be used to test the power output of any single or
dual axle truck up to 550 HP / 410 kW per axle for continuous
testing and 750 HP (560 kW) per axle for intermittent testing.
Performance testing can be used to verify factory power claims
or governed power adjustments. Some of our customers have
organized horsepower competitions.
8.6.2.
NOTE
The maximum power number quoted for a chassis dynamometer pertains to

wheel power. Maximum engine power will be 10~20% higher (due to the losses
in the driveline.) For the SF-602, this means trucks with engines of up to
625~700HP (465~520kw) can be tested continuously.
Diagnostic Testing
The most common applications all fall in the diagnostic
category. Common complaints for which the dynamometer
provides excellent troubleshooting capabilities are:
NOTE
Section 8 - Page 8
low power
Engine ratings are frequently confusing people. Manufacturers rate their

engines for a certain specification and to a certain power measurement
standard. This rating is based on the nominal (design) output of a given engine
model for that specification. The rating will normally be made official (and
binding) by a type approval procedure. To cope with the variability of production,
there is necessarily a tolerance band for the output of that same engine
configuration. The tolerance band must at least be within the range allowed by
the type approval procedure, and some manufacturers define narrower
production tolerances. Still, actual production engines will typically have power
output variations of 3~5 %.
The SF-602 is a great tool to identify engines which err on the low side of rated
output due to normal production tolerances and to bring those up to spec.
8.6.3.
H E O R Y
O F
E S T I N G
excessive fuel consumption

overheating
engine or driveline vibration
speedometer errors
leaks appearing under load and at operating temperature
Used Truck Certification

Used truck dealers benefit from objective test reports verifying
the condition of trucks they buy and demonstrating the condition of trucks they sell. The (optional) blowby measurement is
recommended for this application.
8.6.4.
Durability Testing
Because hydraulic absorbers allow continuous duty testing
without efficiency loss (provided the water supply system is
capable of evacuating the heat generated by the power absorption), and because the large single rolls do not cause excessive
tire temperature and wear, the SF-602 is very well suited for
long-term testing of vehicles, engines, and their components.
8.6.5.
Fleet Testing
Fleet owners have a strong economic incentive to keep their
vehicles at optimum power and fuel consumption performance. A SF-602 is an ideal tool for preventative maintenance
programs verifying this performance at regular intervals
independent of any complaints.
As an example, if the average fuel consumption for a USoperated fleet which covers 20,000,000 miles per year can be
reduced by only 2%, the fuel cost savings over 2 years could
approximately cover the investment in a SF-602. With the
much higher fuel costs in other countries such as in Europe,
this could be accomplished in less than one year.
8.6.6.
Emissions Testing
Some emission standards for Diesel trucks require exhaust gas
opacity measurement during a loaded test. The SF-602 is well
suited for this task. An opacity meter is available as an option
from SuperFlow Corporation; the measurement results are
then part of the dynamometer data printouts.
NOTE
The optional opacity meter supplied by SuperFlow conforms to the SAE J1667
standard which is now widely accepted.
Section 8 - page 9
SF-602
8.6.7.
M a n u a l
Research and Development

With its extensive data acquisition and test automation capabilities, the SF-602 is suitable for many vehicle or engine R&D
tasks requiring vast amounts of data collection under controlled conditions. With the (optional) throttle controller, the
system can run fully automated tests.
8.6.8.
Engine or Vehicle Break-in

To reduce the risks of engine overload with a brand-new
vehicle or after engine rebuilding, it is possible to perform a
break-in cycle on the dynamometer under controlled conditions. For engine rebuilding shops, this will also allow them to
verify engine operation and performance at the end of the
cycle and prior to delivery, reducing potential exposure to
warranty claims.
8.6.9.
End-of-production-line Testing
Vehicle manufacturers commonly install chassis dynamometers at the end of the production line for quality control
purposes. The SF-602 can be set up for automated pass/fail
analysis using vehicle- or engine-specific test profiles.
8.6.10.
Education
The SF-602 is an excellent tool for educating students (engine
and vehicle performance, driveline efficiency, emissions),
workshop mechanics (troubleshooting techniques), and truck
drivers (influence of driving style on fuel consumption).
8.7.
Tire-roll interface
One of the main drawbacks to chassis dynamometer testing is
the tire-to-roll interface. On an engine dynamometer, the
engine output is directly measured at the flywheel. On a
chassis dynamometer the driveline, wheels and tires will have
an influence on the measurement results.
None of these mechanical components has an efficiency of
100%, so each of them will sap some engine power and
convert it to heat. Some of the net power produced by the
engine will be lost in the clutch, some in the gearbox, some in
the drive shaft, some in the bearings, some in the differential
and half-shafts, and some will be lost in the wheels and tires.
Most of these mechanical losses are fairly predictable. The tire
losses are the biggest variable. When a tire rolls on a surface,
the deformation of the carcass and rubber in and around the
contact patch requires some energy which is converted into
Section 8 - Page 10
H E O R Y
O F
E S T I N G
heat. The source of this energy is the engine power, so some of

this power will be lost as heat. It is unfortunately not possible
to measure this power loss except by very sophisticated and
expensive means accessible to R&D labs only.
Following variables have an impact on the magnitude of this loss:
8.8.
Relative radius of the contact surface to the tire radius. On

a flat road, the radius of curvature of the road is infinite
and the tire deformation is determined by load, tire structure and tire pressure. The smaller the diameter of the
dynamometer roll, the greater the deformation and thus
losses in the tire. This explains why a large roll is better
than a small one and a single roll is better than a cradle
roll system (which results in two successive deformations
per revolution). SuperFlows SF-602 rollset has a large 36
(91.5 cm) diameter single roll per axle, resulting in much
lower tire losses than a cradle roll system.
Downforce on the tire. The greater the weight on the tire,

the greater the tire deformation and thus the power losses.
There is a common misconception that the vehicle should
be weighted or pulled down to avoid tire slip on the roll.
While it is true that there is a traction limit, beyond which
loss of traction may result, our testing shows that this is not
a significant problem on any truck up to the power limits
of the dynamometer. The rolls have a smooth surface to
provide minimum losses and maximum grip once the tire
surface has been warmed up. Adding weight to the driven
axle of the vehicle will greatly increase the tire losses,
increase the risk of tire damage (due to the build-up of heat
in the carcass), and reduce the accuracy of the power
measurement. The SF-602 automatically compensates for
wheel slip which may occur during the test.
Tire pressure and temperature. The tire pressure will have

an effect on the deformation, and the tire temperature will
have an effect on the rate of increase of the heat build-up.
For best results, the tire should be inflated to its highest
nominal pressure (as for high speed road use) and the tire
temperature should be kept constant. The tire pressure will
have a more significant effect on the accuracy and repeatability of the power measurement than the tire temperature.
Interpreting power measurements

Your SF-602 displays Vehicle Torque, Vehicle Power and
Corrected Vehicle Power.
8.8.1.
Vehicle Torque
This is the torque measured at the roll surface in the conditions prevailing on the day of the test.
No atmospheric or fuel density corrections are applied.
Section 8 - page 11
SF-602
8.8.2.
M a n u a l
Vehicle Power
This is the power measured at the roll surface in the conditions prevailing on the day of the test.
It is the power calculated from vehicle torque and roll speed.
No atmospheric or fuel density corrections are applied.
8.8.3.
Corrected Vehicle Power

Because a certain amount of tire slip is always present under
load, the SF-602 corrects for the difference between wheel
speed and roll speed. Corrected Vehicle Power is the power at
the rear wheels of the truck. No atmospheric or fuel density
corrections are applied.
8.9.
NOTE
See the section Description of the configuration file (Section 9 Description of

the Configuration File) for details on the actual calculation formulas used in
your system.
Power correction factors

The power output of an internal combustion engine is significantly influenced by barometric pressure, ambient air temperature, and air humidity. For Diesel engines, fuel density is an
important additional factor.
Section 8 - Page 12
lower ambient barometric pressure reduces the density of

the air, thus reduces the amount of oxygen filling the
cylinder for each cycle, resulting in lower power output.
Conversely, higher barometric pressure increases power.
lower ambient air temperature results in increased density

of the air, thus increases the amount of oxygen filling the
cylinder for each cycle, resulting in higher power output.
Conversely, higher air temperature reduces power output.
lower air humidity (= less water vapor) leaves more room

for oxygen per cubic foot of air, thus increases the amount
of oxygen filling the cylinder for each cycle, resulting in
higher power output. Conversely, higher air humidity
reduces power output.
there is a reasonably constant correspondence between a

Diesel fuels calorific value and its density. Lower fuel
density thus means lower fuel calorific value which
reduces power output. Conversely, higher fuel density
increases power output (but at the expense of higher
particulate emissions!). Because Diesel fuel density is also
proportional to fuel temperature, a fuel temperature
correction may be required if the temperature changes
significantly between the point where density is measured
and the point of injection. A significant temperature
increase is typical on a chassis dynamometer testing.
H E O R Y
O F
E S T I N G
Several Standards Organizations have determined methods for

estimating engine power under reference conditions. The bestknown organizations are:
ISO (International Standards Organization), worldwide
SAE (Society of Automotive Engineers), USA
ECE (European Community), Europe
JIS (Japanese Institute for Standardization), Japan
DIN (Deutsche Industrie Norm), Germany
There are power correction standards for gasoline and Diesel

engines, for applications in road vehicles, stationary engines,
for marine engines, etc. For a Truck Chassis dynamometer,
relevant standards are those generally intended for Heavy
Diesel engines in road vehicles. These standards usually
distinguish between naturally aspirated (NA) engines and
turbocharged (TC) engines. In addition, they apply a correction
factor for fuel delivery.
The standard SF-602 configuration files do not include any
such power correction calculations because, as opposed to the
fair degree of standardization existing for passenger cars, there
is a wide variety of power correction methods for Heavy Diesel
engines. The power correction algorithms also vary depending
on the application.
Most manufacturers have defined their own standards for
power correction. Should you wish to apply atmospheric or
fuel density power corrections, the SF-602 has ample capabilities for adding these calculations.
NOTE
Caterpillar automatically applies its own corrections in the PAR software.
NOTE
Power correction standards try to estimate what engine power would be under
reference conditions. They cannot actually calculate exactly what power output
would be. The greater the difference between the ambient conditions during the
test and the reference conditions, the greater the error in the estimate. Most
power correction standards include limits on their applicability. This limit is
typically +/- 10%. This means if the correction factor is greater than (>) 1.10 or
less than (<) 0.90, the corrected power numbers are not officially considered to
be acceptable, and the test should be performed again under conditions which
are closer to the reference conditions.
For private applications this is less of a problem, and corrected

power numbers are still the best basis for comparisons. However, please keep this into consideration when comparing test
results obtained under considerably different test conditions.
NOTE
Power corrections are only valid for Wide Open Throttle (WOT) tests. You should
disregard corrected power numbers for any test performed under partial throttle
conditions.
Section 8 - page 13
SF-602
8.10.
M a n u a l
SF-602 Test Modes

The SF-602 has several load control operating modes called
test modes. A test mode is defined by tying a particular sensor
input to the load control output. Typical inputs controlling the
load output in a SF-602 system are:
manual
engine speed
ECM engine speed
vehicle speed
vehicle power
A description of each mode and its typical application follows.
8.10.1.
NOTE
In controlled load conditions, following terms are commonly used:

setpoint: the value you want to control some measured channel to (e.g. engine
speed)
feedback signal: the actual measured value of that channel
error: the difference between the setpoint and the feedback signal
Manual control mode (position control)

In the manual control mode, the load on the dynamometer is
determined by the position of the load control valve. The
operator determines a % of load value which sets the valve
to a particular percent of its operating range. The resulting
load on the dynamometer is purely a function of water flow
through the valve at that position, which combines with the
rotational speed of the absorber to create a resisting torque on
the roll surface. The valve position is not affected by any
feedback signals. This control mode is called open loop
control.
The % of load setting does not correspond to any specific
torque value but rather to a torque curve as a function of
speed.
In this mode, the operator can easily stall the engine by
applying excessive load.
The manual mode is typically used for diagnostic purposes.
and absorber packing gland adjustment.
Some operators use this mode to warm up the engine; this is
only practical if the appropriate valve position is known by
experience.
Section 8 - Page 14
8.10.2.
H E O R Y
O F
E S T I N G
Engine speed control mode

This is the most common mode during automated tests.
Engine speed is measured by a magnetic pick-up off the
flywheel teeth or by an optical tachometer off the crankshaft.
The load control valve is controlled by the system in order to
maintain a desired engine speed (the setpoint). The valve
position will be modulated so the load applied by the absorber
matches the output of the engine at the current operating
point. The result is typically engine speed control to better
than 10 rpm of the setpoint.
Engine speed control is used in all automated tests which step
through the engine rpm band while recording data; in this
case the gear selection is irrelevant as tests will always be run
in the same rpm band.
NOTE
Test results based on engine rpm steps can be directly overlaid, independent of
gear. However, the gear selection will have an effect on losses in the driveline
so wheel power results may differ slightly from test to test when run in different
gears. Always run comparison tests in the same gear. Given stable operating
conditions, the engine will produce exactly the same power throughout its RPM
band regardless of gear selection. The transmission is in fact a torque multiplier.
Therefore we suggest all tests are run in direct (1:1) gear.
Engine speed control can also be used to maintain the engine

at a constant rpm while the throttle is varied.
The engine speed control mode is an example of a closed
loop control system because the feedback signal and the error
influence the control output.
NOTE
In any closed loop control mode, the SF-602 usually only controls the load
valve, and the operator controls the throttle. If the throttle is not opened
sufficiently for the engine even to reach the setpoint, load control will never be
activated. Only when the setpoint is near will the load control valve start to vary
the load to the rolls in order to bring the feedback signal to the setpoint. This
means there will usually be a transition phase where the setpoint will be
exceeded before the feedback signal will settle back to the desired value. This is
called overshoot and is a normal phenomenon. The control parameters (See
Section 21) can be adjusted for faster or slower system response and more or
less overshoot.
NOTE
All the following control modes are examples of closed loop control systems.
Section 8 - page 15
SF-602
8.10.3.
M a n u a l
ECM engine speed control mode

The ECM engine speed control mode is similar to the engine
speed control mode, except the engine speed signal is read
directly off the Engine Control Module (ECM) via a serial link.
This test mode is only available on electronically controlled
engines.
8.10.4.
Vehicle speed control mode

The vehicle speed control mode effectively acts as a cruise
control system, but operated by the dynamometer load rather
than by the throttle position. The operator commands a vehicle
speed setpoint (in mph or km/h) and the roll speed signal is
the feedback signal.
This mode is useful if the vehicle must be maintained at a
certain speed while the throttle is varied in order to simulate
some throttle transition problem. It can also be used as an
alternative to engine speed control for an automated test which
steps through the engine rpm band; however, in that case the
relationship between engine rpm and vehicle speed must be
known for the selected gear. Vehicle speed control is well
suited for step tests with automatic transmissions.
8.10.5.
Vehicle power control mode

The vehicle power control mode is useful if a defined engine
power output is desired (e.g. simulate PTO power for a known
accessory drive). It is also commonly used as a warm-up
mode; in that case, the operator selects a given power value
suitable for rapid warm-up without overload.
Power is not a measured variable but is calculated from torque
and speed. Any given power setpoint can theoretically be
attained by countless different combinations of throttle position
(torque) and speed (rpm) points. If the speed is low, the
dynamometer will try to compensate by applying a high load
in order to achieve the desired power. This means that a
vehicle power control mode is potentially unstable and can
easily result in a stalled engine if the operator selects an
unrealistically high power setpoint for that engine, at the
current rpm and throttle position.
Section 8 - Page 16
Description of the
Configuration File
9. Description of the configuration

File
9.
Channel Functions .................................................................................... 3

9.1.
9.2.
9.3.
9.4.
9.5.
Sensor Channels .......................................................................................... 3

Specifications ............................................................................................... 8
Calculations .................................................................................................. 8
Interpolation Tables ..................................................................................... 10
System Channels ....................................................................................... 10
9.
9.1.
E S C R I P T I O N
O F
T H E
O N F I G U R A T I O N
Channel Functions
NOTE
Values in italic and -or (between brackets ) are for metric configurations
Sensor Channels
Channel 2 - VehTrq
Channel 2 is used to measure the torque from the Dynamometer power absorber. It senses the voltage from the strain gauge
and converts it into torque for calculations and power measurement. The strain gauge calibration coefficient is approximately 2000 (2720 Nm) lb-ft per volt.
0.000
0.000
4.096 volts
8000 lb-ft (10840 Nm)
Channel 4 - Opacty
Channel 4 is used for the optional opacity meter. The output of
the opacity meter is 0 - 1 V for the full 0 - 100% operating range
0.000
0.000
1 volts
100 %
Channel 5 - BlowbA
Channel 5 is used for the optional blowby sensor, when this
sensor is configured for a 0 - 5 V analog output. Channel 74 is
used to display blowby.
0.000
0.000
5 volts
16 cfm (453 l/min)
Channel 6 - AxVlt 1
Channel 6 is used for auxiliary voltages for expansion.
0.000
0.000
10.000 volts
10.000 volts
Channel 7 - BlowbF
Channel 7 is used to measure the frequency from a blowby
sensor with a frequency output. Channel 74 is used to display
blowby.
210.0 Hz
0.800 (22.65 l/min)
2155.0 Hz
8.000 cfm (226.50 l/min)
Channel 8 - Air9V
Channel 8 is used to measure the frequency output from an air
flow measurement turbine. SuperFlow has several air flow
measurement turbines available to attach to this input. The
default value is for the 9 air turbine, which is most commonly
used for large Diesel engines.
7.100 Hz
25.100 cfm (11.8 l/s)
202.90 Hz
594.90 cfm (280.70 l/s)
Section 9 - Page 3
I L E
SF-602
M a n u a l
Channel 10 - EngFrq
Channel 10 is used to measure the frequency of the engine
rotation from an optical tachometer or from a magnetic pick-up
attached to the starter gear on the engine flywheel.
0.000
0.000
5000 Hz
5000 Hz
Channel 11 - VehSpd
Channel 11 is used to measure the speed of the front roll from
a magnetic pickup attached to a tach gear on the front chassis
dynamometer roll. This channel is scaled to produce a mph
(km/h) reading from the frequency received
0.000
0.000
1680.7 Hz
(for 180 tooth gear)
60 mph (96,5 km/h)
Channel 12 - RRolSp
Channel 12 is used to measure the speed of the rear roll from a
magnetic pickup attached to a gear on the rear chassis dynamometer roll. This channel is scaled to produce a mph (km/h)
reading from the frequency received.
000.0
000.0
1680.7 Hz
(for 180 tooth gear)
60 mph (96.5 km/h)
Channel 13 - AirlnT
Channel 13 is used to measure the inlet air temperature to the
engine. This channel is set up for a type K thermocouple. The
maximum range is 2000F (1100C)
Channel 14 - TurbOt
Channel 14 is used to measure the turbocharger outlet temperature. This channel is set up for a type K thermocouple.
The maximum range is 2000F (1100C)
Channel 15 - ManT
Channel 15 is used to measure manifold air temperature. This
channel is set up for a type K thermocouple. The maximum
range is 2000F (1100C).
Channel 16 - ExhT
Channel 16 is used to measure exhaust temperature. This
range is 2000F (1100C).
Channel 17 - CoolIn
Channel 17 is used to measure engine coolant inlet temperature. This channel is set up for a type K thermocouple. The
maximum range is 2000F (1100C).
Channel 18 - CoolOt
Channel 18 is used to measure engine coolant outlet temperature. This channel is set up for a type K thermocouple. The
maximum range is 2000F (1100C).
Channel 19 - Oil In
Channel 19 is used to measure engine oil inlet temperature.
This channel is set up for a type K thermocouple. The maximum range is 2000F (1100C).
Section 9 - Page 4
E S C R I P T I O N
O F
T H E
Channel 20 - OilOut
Channel 20 is used to measure engine oil outlet temperature.
This channel is set up for a type K thermocouple. The maximum range is 2000F (1100C).
Channel 21 - Fuel T
Channel 21 is used to measure Diesel fuel temperature. This
range is 2000F (1100C).
Channels 22 through 26 - THERMOCOUPLE INPUTS 22 THROUGH 26
Channels 22 through 26 are for standard thermocouple inputs.
These may be renamed to fit specific functions by using the
Configuration Program. These channels are normally set up for
Type K thermocouples. No other type of thermocouple can be
used without a hardware modification. The maximum range is
2000oF (1100oC).
Channel 27 - Dynoln
Channel 27 is used to measure dynamometer water
inletemperature. This channel is set up for a type K thermocouple. The maximum range is 2000F (1100C).
Channel 28 - DynOut
Channel 28 is used to measure dynamometer water outlet
temperature. This channel is set up for a type K thermocouple.
The maximum range is 2000F (1100C).
Channel 29 through 41 - ECM data
Channels 29 through 41 are reserved for inputs from the
engine control module (ECM). The SF-602 accepts data sent
via J1587 and J1708 protocols. SAE J1939 will be supported
when required. All ECM data channels start with e. All
channels use the F (Fetch) command and an appropriate
scaling factor. These factors are determined by the protocol
and should not be changed.
Channel 30 - eCruse
Channel 30 is used for the cruise control speed setpoint.
Channel 31 - eAccl%
Channel 31 is used for the position of the accelerator pedal in
% of travel.
Channel 32 - eLoad%
Channel 32 is used for the % of load applied to the engine.
Channel 33 - eOilP
Channel 33 is used for the engine oil pressure.
Channel 34 - eBoost
Channel 34 is used for the turbocharger boost pressure.
Channel 35 - e AC T
Channel 35 is used for the aftercooler temperature.
Channel 36 - eCoolT
Channel 36 is used for the engine coolant temperature.
Channel 37 - eRetrd
Channel 37 is used for the retarder status.
Section 9 - Page 5
I L E
SF-602
M a n u a l
Channel 38 - eBattV
Channel 38 is used for the battery voltage.
Channel 39 - eFuelT
Channel 39 is used for the Diesel fuel temperature.
Channel 40 - eFuelV
Channel 40 is used for the volumetric fuel flow as calculated
by the ECM, based on the fuel injector timing and pressures.
Channel 41 - eEngSp
Channel 41 is used for engine speed.
Channel 62 - Rail P
Channel 62 is for measuring rail pressure. The transducer has
a range of zero to 300 psi (0-2068 kPa). It may be recalibrated if
required, through the calibration menu, or through changes in
the Configuration File.
0.000
0.0
3.636 volts
300.0 psi (2068 kPa)
Channel 63 - Fuel P
Channel 63 is used to measure the fuel pressure. The transducer has a range of 150 psi (1034 kPa)
0.000
0.000
3.636 volts
150 psi (1034 kPa)
Channel 64 - Man P
Channel 64 is used to measure manifold pressure in inches of
Mercury (kPa)
0.000
0.000
3.636 volts
407.20 In Hg (1379 kPa)
Channel 65 - FulScP
Channel 65 is used to measure Diesel fuel suction pressure in
psi (kPa)
0.000
0.000
3.636 volts
60 psi (413.7 kPa)
Channel 66 - CrankP
Channel 66 is used to measure the pressure in the crankcase
of the engine, in inches of water (kPa)
0.000
0.000
3.636 volts
138.40 in H2O (34.470 kPa)
Channel 67 - Cool P
Channel 67 is used to measure engine coolant pressure in psi
(kPa)
0.000
0.000
3.636 volts
300 psi (2068 kPa)
Channel 68 - Oil P
Channel 68 is used to measure engine oil presure in psi (kPa)
0.000
0.000
Section 9 - Page 6
3.636 volts
150 psi (1034 kPa)
E S C R I P T I O N
O F
T H E
Channel 69 - TurboP
Channel 69 is used to measure turbocharger boost pressure in
inches of Mercury (kPa)
0.000
0.000
3.636 volts
407.20 in Hg (1379 kPa)
Channel 70 - ArInDP
Channel 70 is used to measure the differential pressure across
the inlet air restriction (filter), in inches of water (kPa)
0.000
0.000
3.636 volts
276.80 in H2O (69 kPa)
Channel 71 - Exh BP
Channel 71 is used to measure exhaust system backpressure in
inches of water (kPa)
0.000
0.000
3.636 volts
276.80 in H2O (69 kPa)
Channel 72 - RolSpd C11 * 9.342

Channel 72 - RolSpd C11*9.342/1.609
Channel 72 is used to calculate roll speed in rpm from the roll
speed in mph (km/h) measured in channel 11.
Channel 73 - Opacity C4
Channel 73 is used to display opacity of the exhaust gas in %.
The default calculation uses channel 4 as is. If any calculations need to be performed on the measured opacity of channel 4, such as linearization or conversion to other units of
measurement, this channel should be used.
Channel 74 - Blowby C7
Channel 74 is used to display blowby volume in cfm (l/min).
The default calculation uses the frequency blowby input of
channel 7 as is. If an analog sensor is used, this channel
should call the value of channel 5. If any calculations need to
be performed on the measured blowby of channel 5 or 7, such
as linearization or conversion to other units, this channel
should be used.
Channel 75 - Rack
Channel 75 is used to measure the rack % from the electrical
rack point sensor installed on some Diesel engines.
0.000
0.000
4.095 volts
100 %
Channel 76 - Baro P
Channel 76 is used to measure the barometric pressure. The
barometric pressure transducer is located on the circuit board
installed in the sensor box. If you have an accurate mercury
barometer, it is recommended that you calibrate your barometric pressure sensor to exactly agree with the mercury barometer. If you do not have an accurate barometric pressure
measurement device, you should use the default calibration.
0.000
0.000
3.698 volts
29.920 in Hg (101,32 kPa)
Section 9 - Page 7
I L E
SF-602
9.2.
M a n u a l
Specifications
Channel 77 through 99 are constant channels, called Specifications. On some test systems, these are used to configure the
system for a specific vehicle or engine, by loading all the
parameters of that vehicle or engine into the system with one
specifications file. On SF-602 systems, the specifications are
mostly used to store certain parameters used for calculations
during automated tests.
Channel 77 - WhISIp Default Value 1.000
Channel 77 is used to store the wheel slip on the rolls. It is not
currently implemented.
Channel 84 - ActE/R
Default Value 1.000
Channel 84 is used to store the actual engine speed to roll
speed ratio under no Load conditions. This information can
be compared to channel 102, Measured E/R, to see the effects
of tire slippage under load and to correct for this.
Channel 85 - Rack10 Default Value 0
Channel 85 is used to store the engine rpm for a rack signal of
10%. This information will be combined with the information
in channel 86, Rack70, to calculate the Caterpillar Rack point
in channel 105.
Channel 86 - Rack70 Default Value 0
Channel 86 is used to store the engine rpm for a rack signal of
70%. This information will be combined with the information
in channel 85, Rack10, to calculate the Caterpillar Rack point
in channel 105.
Channel 87 - EngTac Default Value 113
Channel 87 is used to store the number of the teeth on the
engine flywheel and is combined with channel 10, EngFrq, to
produce the engine speed reading in channel 125, EngSpd.
Channel 88 - Set Pt
Default Value 0
Channel 88 is used to store and display the engine speed
setpoint used by automated tests. Not all tests use this feature.
9.3.
Calculations
Channel 100 - VehPwr
C72*C2/5252.113
Channel 100 - VehPwr
C72*C2/9549
Channel 100 is a calculated channel used to calculate the
power at the dynamometer rolls. This channel uses the roll
speed signal from channel 72; any wheel slip during the test is
not accounted for.
Channel 101 - CVehPw
C100*C103
Channel 101 is a calculated channel used to correct the
vehicle power from channel 100 for wheel slip to display
power at the wheels of the vehicle. It multiplies vehicle power
from channel 100 by the correction factor for wheel slip
calculated in channel 103.
Section 9 - Page 8
E S C R I P T I O N
O F
T H E
Channel 102 - MesE/R

C125/C72
Channel 102 is a calculated channel used to measure the ratio
between engine speed and roll speed during the test. The ratio
will vary as wheel slip due to load occurs, and the value will
be compared to the ratio at no load from channel 84 to result in
the correction factor for slip in channel 103.
Channel 103 CorFac
C102/C84
Channel 103 is a calculated channel which compares the
engine speed to roll speed ratio under load to the engine speed
to roll speed ratio at no load, resulting in a correction factor for
wheel slip. This correction factor is then used by channel 101
to correct measured vehicle power for wheel slip, and by
channel 104 to correct vehicle speed for wheel slip.
Channel 104 - CVehSp
C103*C11
Channel 104 is a calculated channel used to correct wheel speed
for slip appearing under load. It multiplies the measured roll
speed from channel 11 by the correction factor from channel 103.
Channel 105 - RackPt
(C85+C86)/2
Channel 105 is a calculated channel used to calculate the
Caterpillar Rack point as the average of the rpm for Rack 10%
and the rpm for Rack 70% from channels 85 and 86.
Channel 106 - V BSFC
C128/C100
Channel 106 - V BSFC
C128*1000/C100
Channel 106 is a calculated channel used to calculate Brake
Specific Fuel Consumption of the vehicle in lb/HPh (g/kWh). It
divides the fuel mass consumption from channel 128 by the
vehicle power from channel 100. The result is not corrected for
wheel slip.
Channel 107 - BSFC C
C128/C101
Channel 107 - BSFC C
C128*1000/C101
Channel 107 is a calculated channel used to calculate Corrected Brake Specific Fuel Consumption of the vehicle in
lb/HPh (g/kWh). It divides the fuel mass consumption from
channel 128 by the corrected vehicle power from channel 101.
The result is corrected for wheel slip.
Channel 110 - FulClT
C228
Channel 110 - FulClT
(C228-32)/9*5
Channel 110 is used to call the fuel coolant temperature value
of the gravimetric fuel consumption measurement system from
system channel 228 so it can be displayed. The temperature is
displayed in deg F (deg C)
Channel 111 - SpdDif
(C12-C11)abs
Channel 111 is a calculated channel used to measure a
difference in speed between the front and rear rolls of the
dynamometer. The absolute value is displayed so the difference will always be shown as a positive number. The difference in speed is displayed in mph (km/h).
Channel 120 - Fuel V
C229/C227/8.373
Channel 120 - Fuel V
C128/C227
Channel 120 is a calculated channel used to display fuel
consumption in gallons per hour (liters per hour) based on the
Section 9 - Page 9
I L E
SF-602
M a n u a l
mass fuel consumption from channel 229 (channel 128). The

mass consumption is divided by the density of the fuel to
obtain volumetric consumption.
Channel 121 - API
C226
Channel 121 is used to display the API value of the fuel as
determined by the gravimetric fuel consumption system.
Channel 121 calls this value from system channel 226.
Channel 123 - Fuel SG
C227
Channel 123 is used to display the specific gravity of the Diesel
fuel as determined by the gravimetric fuel consumption
measurement system. Channel 123 calls this value from
system channel 227.
Channel 125 - EngSpd
C10*60/C87
Channel 125 is a calculated channel used to determine engine
speed based on the frequency signal from the optical or
magnetic tachometer pick-up in channel 10 and the number of
pulses per revolution determined by channel 87.
Channel 128 - Fuel M
C229
Channel 128 - Fuel M
C229*0.454
Channel 128 is used to display the mass fuel consumption as
determined by the gravimetric fuel consumption measurement
system. Channel 128 calls this value in pounds/hr from system
channel 229. For metric units, the value is converted to
kilograms/hr by multiplying by 0.454.
Channel 129 - SpdDif
((C12-C11)/(((C11+C12)/2)+(C111/2)))*100
Channel 129 is a calculated channel used to calculate the speed
difference in % between the two rolls of the dynamometer.
9.4.
Interpolation Tables
Channel 130 through 139 are all interpolation tables. On some
systems they can be used to calculate non-linear functions
such as sensor calibration curves. Interpolation tables can have
up to 20 fixed or variable intervals and will return a value f(x)
for each value of x, by interpolating x and f(x) between known
values. The standard SF-602 configurations do not use interpolation tables.
9.5.
System Channels
Channel 226 through 229 are reserved system channels
allocated to the gravimetric fuel system. They can be called
but cannot be modified.
Channel 226 - Fuel system channel for API
Channel 226 returns the API value of the Diesel fuel as determined by the gravimetric fuel consumption measurement
system. It is called by channel 121.
Channel 227 - Fuel system channel for specific gravity of the fuel.
Channel 227 returns the specific gravity of the Diesel fuel as
determined by the gravimetric fuel consumption measurement
Section 9 - Page 10
E S C R I P T I O N
O F
T H E
system. It is called by channel 123

Channel 228 - Fuel system channel for cooling circuit temperature.
Channel 228 returns the temperature in deg F of the Diesel fuel
cooling circuit as measured by the gravimetric fuel consumption measurement system. It is called by channel 110.
Channel 229 - Fuel system channel for mass consumption.
Channel 229 returns the mass consumption in lbs/hr of Diesel
fuel as measured by the gravimetric fuel consumption measurement system. It is called by channel 128.
Section 9 - Page 11
I L E
10
WinDyn
Introduction
10. WinDyn Introduction

10.1
SuperFlows Software License Agreement ................................................ 3

10.1.1.
10.1.2.
10.1.3.
10.1.4.
Grant of License ........................................................................................... 3

Copyright ...................................................................................................... 3
Other Restrictions ......................................................................................... 3
Dual Media Software ..................................................................................... 4
10.2. Limited Warranty ........................................................................................ 4

10.2.1.
10.2.2.
10.2.3.
Customer Remedies ..................................................................................... 4

No other Warranties ....................................................................................... 5
No Liability for Consequential Damages. ....................................................... 5
10.3. WindynTM minimum Computer and Printer Requirements .......................... 6

10.3.1.
10.3.2.
WinDyn Minimum Computer Requirements .................................................. 6

WinDyn Suggested Printer Requirements .................................................... 6
10.4. WinDynTM Release Notes .......................................................................... 7

10.4.1. Introduction ................................................................................................... 7
10.4.2. How to install WinDyn ................................................................................... 7
10.4.3. Some New features for WinDyn Release 1.10 ............................................... 7
Other features for WinDyn Release 1.10 ...................................................................... 8
10.4.4. How to run WinDyn ....................................................................................... 9
10.4.5. How to remove (uninstall) WinDyn ................................................................. 9
10.4.6. How to run WinDyn in DEMO mode ............................................................ 10
10.5. WindynTM How To Notes for Windows95 users ....................................... 10

10.5.1.
10.5.2.
10.5.3.
10.5.4.
10.5.5.
10.5.6.
10.5.7.
10.5.8.
How to place a program into the startup group ............................................ 10

How to create a new folder .......................................................................... 10
How to place a folder or program on Win95 desktop .................................... 10
How to start a program in Win95 ................................................................. 11
How to explicitly run a program ................................................................... 11
How to add a program icon to a folder ......................................................... 11
How to use the print screen program ........................................................... 11
How to change the printer spool settings .................................................... 12
10.6. All New Features for WinDynTM Release 1.10 .......................................... 12

10.6.1. New Features ............................................................................................. 12
10.6.2. Current data display enhancements ............................................................ 13
10.6.3. Test data display & plotting enhancements ................................................. 13
10.6.3.1. New Plotting Features ........................................................................... 13
10.6.3.2. Other .................................................................................................... 13
10.6.4. General Windyn enhancements ................................................................ 13
10.1
I N
Y N
N T R O D U C T I O N
SuperFlows Software License Agreement

This is a legal agreement between you (either an individual or
an entity) the end user, and SuperFlow Corporation. If you do
not agree to the terms of this agreement, promptly return the
software package and accompanying items (including written
materials and binders or other containers) to the place you
obtained them for a full refund.
10.1.1.
Grant of License
This SuperFlow Corporation License Agreement (License)
permits you to use the copy of the current version of this
SuperFlow Corporation software (Software) on any single
computer, provided the Software is in use only one computer
at any one time. If you have multiple Licenses for the Software, then at any time you may have as many copies of the
Software in use as you have Licenses. The Software is in
use on a computer when it is loaded into the temporary
memory (i.e., RAM) or installed into the permanent memory
(e.g., hard-disk, CD ROM, or other storage device) of that
computer, except that a copy installed on a network server for
the sole purpose of distribution to other computers is not in
use. If the anticipated number of users of the Software will
exceed the number of applicable Licenses, then you must have
a reasonable mechanism or process in place to assure that the
number of persons using the Software does not exceed the
number of Licenses. If the Software is permanently installed
on the hard-disk or other device of a computer (other than a
network server) and one person uses that computer more than
80% of the time it is in use, then that person may also use the
Software on a portable or home computer.
10.1.2.
Copyright
The Software is owned by SuperFlow Corporation or its
suppliers and is protected by United States copyright laws and
international treaty provisions. Therefore, you must treat the
Software like any other copyrighted material (e.g., a book or
musical recording) except that you may either (a) make a copy
of the Software solely for back-up or archival purposes, or (b)
transfer the Software to a single hard-disk provided you keep
the original solely for back-up or archival purposes. You may
not copy the written materials accompanying the Software.
10.1.3.
Other Restrictions
This SuperFlow Corporation License Agreement is your proof
of license to exercise the rights granted herein and must be
retained by you. You may not rent or lease the Software, but
you may transfer your rights under this SuperFlow Corporation
Section 10 - page 3
SF-602
M a n u a l
License Agreement on a permanent basis provided you

transfer this License Agreement, the Software, and all accompanying written materials and retain no copies, and the
recipient agrees to this Agreement. You may not reverse
engineer, decompile, or disassemble the Software. Any transfer of the Software must include the most recent update and
all prior versions.
10.1.4.
Dual Media Software
If the Software package contains both 3.5-inch and 5.25-inch

disks, then you may use only the disks appropriate for your
single designated computer or network server. You may not
use the other disks on another computer or computer network,
or loan, rent, lease, or transfer them to another user except as
part of a transfer or other use as expressly permitted by this
SuperFlow Corporation Licensing Agreement.
10.2.
Limited Warranty
SuperFlow Corporation warrants that (a) the Software will
perform substantially in accordance with the accompanying
written materials for a period of ninety (90) days from the date of
receipt; and (b) any hardware accompanying the Software will
be free from defects in materials and workmanship under
normal use and service for a period of one (1) year from the date
of receipt. Any implied warranties on the Software and hardware are limited to ninety (90) days and one (1) year respectively. Some states do not allow limitations on duration of a
implied warranty, so the above limitation may not apply to you.
10.2.1.
Customer Remedies
SuperFlow Corporations entire liability and your exclusive
remedy shall be, at SuperFlow Corporations option, either (a)
return of the price paid or (b) repair or replacement of the
Software or hardware that does not meet SuperFlow
Corporations limited Warranty and that is returned to
SuperFlow Corporation with a copy of your receipt. This limited
Warranty is void if failure of the Software or hardware results
from accident, abuse, or misapplication. Any replacement
Software will be warranted for the remainder of the original
warranty period or thirty (30) days, whichever is longer.
Section 10 - Page 4
10.2.2.
I N
Y N
No other Warranties
SuperFlow Corporation disclaims all other warranties, either
expressed or implied, including but not limited to implied
warranties of merchantability and fitness for a particular
purpose, with respect to the Software, the accompanying
written materials, and any accompanying hardware. This
limited warranty gives you specific legal rights. You may have
others, which vary from state to state.
10.2.3.
No Liability for Consequential Damages.

In no event shall SuperFlow Corporation or its suppliers be
liable for any damages whatsoever ( including, without limitation, damages for loss of business profits, business information,
or pecuniary loss) arising from the use of or inability to use this
SuperFlow Corporation product, even if SuperFlow Corporation has been advised of the possibility of such damages.
Because some states do not allow the exclusion or liability for
consequential or incidental damages, the above limitation may
not apply to you.
For more information about SuperFlow Corporations licensing
policies call SuperFlow Corporation at (719) 471 1746 or write:
Customer Service Department
3512 North Tejon Street
Colorado Springs, CO 80907
or fax to (791) 578 1792
Section 10 - page 5
SF-602
10.3.
M a n u a l
WindynTM minimum Computer and Printer

Requirements
This document lists the Minimum Computer and Printer
Requirements for systems using SuperFlows WinDyn Data
Acquisition and Display Software Package.
10.3.1.
10.3.2.
WinDyn Minimum Computer Requirements
IBM PC compatible Computer
90 MHz Pentium Processor
Enhanced IDE controller, PCI bus
64 bit graphics, PCI bus
16 Megabyte RAM (32 Mb preferred)
256 Kb cache
2 ISA, 2 PCI slots
1.2 Gigabyte hard drive
1.44 Megabyte floppy disk drive (3.5)
2 serial ports and 1 parallel port
CD ROM (4x speed) (optional)
17 SVGA Color Monitor (1024768256 colors capable)

(preferred)
2 Megabyte Video memory, (4 Mb preferred)
Keyboard
Mouse (two or three button)
Operating System: Windows 3.1, Windows 3.11, or Windows 95(preferred) (Windows NT supported on some
SuperFlow systems).
WinDyn Suggested Printer Requirements

Any Microsoft Windows compatible, Parallel Port, Laser or
InkJet Graphics Page Printer (e.g., Hewlett-Packards HP660C
Color DeskJet)
Section 10 - Page 6
10.4.
WinDynTM Release Notes
10.4.1.
Introduction
I N
Y N
These Release notes are general for WinDyn. Be sure to also

read the "readme" notes specific to your system type (eg,
SF901, SF602, etc.). These system specific notes can be found
on Install Disk #1, and in the WinDyn program group (after
installation).
10.4.2.
How to install WinDyn

Insert the installation diskette #1 into drive A (or B) and run
A:setup.exe from the Windows Program Manager or File
Manager.
The Setup program will then prompt you all the way through
the WinDyn installation process.
Refer to Section 2 for complete installation information.
10.4.3.
Some New features for WinDyn Release 1.10

Many new features and enhancements have been added to
WinDyn for this release. You can view a list of the most
important new features by selecting the Version Info button in
the On-Line Help for WinDyn. From WinDyn, press F1 to
display the Help file, then click on the Version Info button at
the top of the Help file. The most important differences previous WinDyn users will notice right away are:
1. No need to run wcomlink first:
Just run WinDyn (the SuperFlow icon) and communication
with the dyno will be automatically established. If you currently have an icon for WCOMLINK in the Startup program
group, it is recommended that it be deleted.
2. Password security:
When you first run WinDyn, the new password security system
will be disabled. To enable the password system,select
"File|Configure User Access" from the WinDyn main menu,
then uncheck the "Disable password system" box.When
WinDyn starts from now on, you will be prompted to enter a
USER ID and a PASSWORD. The defaults are as follows:
USER ID: admin
PASSWORD: password
Entering the above USER ID and PASSWORD gives you administrator level access to WinDyn. With this access level, you can
proceed to tailor the security system to your needs (to configure, select "File|Configure User Access" from the WinDyn
main menu).
Section 10 - page 7
SF-602
M a n u a l
3. Specifications (constants):
Throughout WinDyn, "Constants" are now referred to as
"Specifications."
4. Datalib:
A new database front-end program called DATALIB has been
added to WinDyn. This program is provided to assist the user
in the management of WinDyn data files. Whenever a data file
is saved to disk, this program will be activated to prompt the
user to enter information about the test being saved. This
information can later be viewed/searched/printed using the
same DATALIB program.
Use of the WinDyn DATALIB database is optional. If you do not
want to use the DATALIB database, delete the executable file
DATALIB.EXE from the \WINDYN\PROGRAMS\ directory.
5. Configuration file utility:
A new utility named "Configuration Utility" has been added to
WinDyn in the Tools menu item. This tool reads all
SuperFlow configuration files (WinDyn & non-WinDyn). It can
show all calculated channels as a group, using channel names
instead of channel numbers example:(EngSpd*EngTrq/5252)
It can search for and display all calculated channels that
reference a particular channel. It can also search for any
undefined channels used in calculations (the current DEF
editor does not check this). Note that this utility will not run
under Windows 3.1 (Windows95/WindowsNT only).
Other features for WinDyn Release 1.10
Section 10 - Page 8
1.
The WinDyn install program automatically registers WinDyn

data files with your computer. This means you can easily view
WinDyn data files (*.SFD) by opening them from any program
that displays a list of files (such as Explorer or File Manager).
For example, from Explorer, simply double click on the data
file name of interest to quickly display the data.
2.
WinDyn data plots (graphs) can now be exported as OLE

Objects. This means you can cut and paste a WinDyn data plot
into an application like Microsoft Word or Microsoft Excel
and still view and modify the plot as if it was running under
WinDyn (e.g., zoom in on data). For instructions, press F1 from
WinDyn, click on the "Stored Data" button at the top of the help
window, and then click on the topic labeled "Export an OLE
Plot for use with other programs."
10.4.4.
I N
Y N
How to run WinDyn

NOTE
All programs are 'run' by double clicking on the appropriate icon in the
SuperFlow WinDyn program group).
1.
Run "WinDyn" (WinDyn.EXE)
2.
Load a WinDyn "Test Group". To load, select "File|Open Test

Group" from the WinDyn main menu (or simply press the F2
key). Next select a Test Group file (*.TGP) from the displayed
list and click OK.
3.
Refer to the Manual, Training Video, or On-Line Help, to learn

further WinDyn features necessary to run and analyze tests.
NOTE
The SUPERFLOW environment variable (written to the AUTOEXEC.BAT file) is

required by WinDyn to run the DOS based configuration editor. This editor is
accessed from the WinDyn main menu via "Design|System Configuration."
NOTE
WinDyn requires 30 Megabytes of free disk space in order to install, even when
installing a version upgrade. This ensures that the Install program has enough
working space during the install process, and it ensures there is a reasonable
amount of disk space available for the normal functioning of WinDyn itself.
10.4.5.
How to remove (uninstall) WinDyn
NOTE
This procedure will remove all the WinDyn files which were originally installed on
your computer. It will NOT erase any files you have created & saved since
installing WinDyn, including your data files. You should only run Uninstall WinDyn
if you wish to eliminate WinDyn from your computer permanently. You DO NOT
need to run Uninstall WinDyn when upgrading WinDyn to a newer version.
1.
Simply run the WinDyn "unInstall" program (the "trash can"

icon) located in the same program group as WinDyn. Note that
running this uninstall program will NOT delete any files you
have created OR modified since first installing WinDyn (including data files).
2.
Remove the superflow environment variable from autoexec.bat

(for example: "SET SUPERFLOW=C:\WINDYN\PROGRAMS").
3.
Delete the file SUPERFLO.INI located in your windows directory (for example: "del C:\WINDOWS\SUPERFLO.INI")
Section 10 - page 9
SF-602
10.4.6.
M a n u a l
How to run WinDyn in DEMO mode

WinDyn has a DEMO mode, which is especially useful if you
wish to load Test Groups and perform other WinDyn tasks that
require communication with a data acquisition system, but the
data acquisition system is not available, such as when working
at home. To run WinDyn in the DEMO mode, simply doubleclick on the "WinDyn Demo" icon located in the SuperFlow
Windyn program group.
NOTE
Note that to exit Demo mode, you must close both the WinDyn program AND the
WComDemo program.
10.5.
WindynTM How To Notes for Windows95 users
10.5.1.
How to place a program into the startup group

1. Right-click on the Start button
2. Left-click on Open
3. Double-click on Programs
4. Double-click on Startup folder
5. Double-click on folder which contains desired program
6. Drag desired program icon to Startup group to move it,
hold ctrl key to copy it
7. Close any open folder
10.5.2.
How to create a new folder

1. Right-click somewhere on desktop
2. Select New
3. Click on Folder
4. Click on the newly created folder
5. Select Properties
6. Change New Folder to the desired name
7. Left-click OK to dismiss the dialog box
10.5.3.
How to place a folder or program on Win95 desktop

1. Right-click on the Start button
2. Left-click on Open
Section 10 - Page 10
I N
Y N
3. Double-click on Programs
4. Drag program from Programs folder to Desktop to move it,
hold ctrl key to copy it
10.5.4.
How to start a program in Win95

A. If program/folder is on desktop - double-click on it
B. If program is not on desktop
1. Left-click on Start button
2. Move the mouse pointer over the desired folder
3. Click on the desired program
10.5.5.
How to explicitly run a program

A. From Run dialog
1. Left-click on Start button
2. Left-click on Run
3. Enter desired filename or browse for it
4. Select OK
B. From MS-DOS prompt
1. Start MS-DOS prompt (as in A. above)
2. Type path/filename as in conventional DOS practice.
10.5.6.
How to add a program icon to a folder

1. Double-click on the desired folder
2. Right-click somewhere in the folder
3. Select New|Shortcut
4. Enter the desired filename (or browse for it)
5. Select Open
6. Select Next
7. Enter the desired name
8. Left-click Finish
10.5.7.
How to use the print screen program

This program should first be installed as per the manufacturers
instructions. Once installed, the program icon can be placed
into the startup group to startup automatically each time the
computer is started.
Section 10 - page 11
SF-602
M a n u a l
To activate the print screen feature, press the Print Screen

button to print the entire screen. To print just the current
window, hold down the Alt key while pressing the Print
Screen button.
To configure the print screen program, start it and select
Options from the main menu. Place a check mark by Auto
Print to automatically send the image to the printer when the
Print Screen key is pressed. Other options can be selected
from this menu which will allow saving data to a file, printer
configuration, and stretching of the image to fit the display
window, among others. Consult the on-line help file for further
information.
If a computer running Windows 95 locks up when using the
print screen program, change the printer spool data format to
RAW as described in How to change the printer spool settings
below.
10.5.8.
How to change the printer spool settings

Some systems may lock-up when the print-screen program is
used. We have traced the problem to the print spooler settings. To correct this problem, do the following:
1. Double-click on My Computer
2. Double-click on the Printers folder
3. Right-click on desired printer
4. Left-click on Properties
5. Select Details tab
6. Left-click on Spool settings at bottom of page
7. From Spool data format select RAW
8. Select OK
9. Select OK again
10.6.
All New Features for WinDynTM Release 1.10
10.6.1.
New Features
System Password Security (Basic/Advanced/Administrator)
Searchable Database for all Test Information (DataLib)
Report Generator for Custom Data Printouts (DataLib)
Playback Saved Test Data Feature
Create Test Data Diskette Feature
10.6.2.
Y N
Ten (10) Current Data screens (was 5)
Background Picture (Bitmap) Displays
Improved Current Data Display Editing
Enhanced Options for Current Data Displays
Enhanced keyboard support for Editing Current Data Displays
Test data display & plotting enhancements
10.6.3.1.
New Plotting Features
10.6.4.
Current data display enhancements
10.6.3.
10.6.3.2.
I N
Ten (10) Data & Plot screens (was 6)
Ability to plot any combination of channels on each page
Selectable Line Colors
Independent Channel Scale Factors
Manual Plot Scaling (Horizontal & Vertical axes)
Line Color indicates Test or Channel
X-Axis data Sorted or Unsorted
Plot Legend Simple or Detailed
Data Column Averages/Maximums/Minimums
Page Name limit increased to 100 characters
OLE Support for WinDyn plots
Channel Order information saved with all test data
Option to delete the data files used to create averaged data
Plot print mode (portrait/landscape) settings saved
Other
General Windyn enhancements
Test Group Notes
New Specifications (i.e., Constants) Viewer/Editor (with

Specification Files)
Specification Files included in Test Groups
New options for Printing Test Data
User Customizable Tool Menu
Save & Print Test with single menu command (F9)
View & Plot Test with single menu command (F11)
SF-602
M a n u a l
Improved Channel Selection (sort by Name or Number)
Automatic remote communications (no need to run WComlink

manually).
Receive (Save) Calibration (*.CAL) files from remote to disk.
Configuration File Viewer Utility (DEFTOOL)
Updated On-line Help Documentation
11
WinDyn Tutorial
11. WinDyn Tutorial

11.1. Using the Current Data Screens ................................................................ 3
11.2. The WinDynTM Menu .................................................................................. 3
11.3. Designing Test Screens ............................................................................. 4
11.4. Screen Editing Mode Preferences ............................................................. 5
11.5. Resizing Objects ....................................................................................... 5
11.6. Selecting Objects for a Screen Design ...................................................... 6
11.7. Designing Panel Meters ............................................................................ 7
11.8. Designing Bar Graphs ............................................................................... 8
11.9. Designing X-T Graphs ............................................................................... 9
11.10. Designing Configurations ........................................................................ 11
11.11. Modifying a Configuration File ................................................................. 11
11.12. Types of Channels ................................................................................... 12
11.13. Measured Sensors Channels .................................................................. 12
11.14. Specifications Channels .......................................................................... 13
11.15. Calculated Channels ............................................................................... 14
11.16. Interpolation Tables .................................................................................. 15
11.17. Setting File Paths .................................................................................... 16
11.18. Determining the Channel Order ............................................................... 16
11.19. Running Tests .......................................................................................... 17
11.20. Selecting Other Test Features .................................................................. 18
11.1.
I N
Y N
U T O R I A L
Using the Current Data Screens

WinDyn allows you to design ten Current Data windows for
each particular screen setup. You can create as many setups
as desired. A common plan might be to create a basic setup for
many tests, and then to customize the basic setup for each
individual engine type and to resave each new screen design
under a new filename. It is quite feasible to have different
screen designs for each size of engine and for each type of
test. This allows you to scale all the screen graphs appropriately for the type of test and size of engine.
A Test Group consists of the desired screen designs, calibrations, specifications, limits, and automatic tests, if desired. You
can load a single Test Group for a given engine without having
to select each of the individual items. The loaded Test Group
files are displayed in the Status Bar at the bottom of the
WinDyn screen.
11.2.
The WinDynTM Menu

On the second line of the WinDyn display are ten operational
categories. These begin with File and end with Help. Click on
each of these menu choices in turn to see the drop-down
menu features.
Below the menu items is a Tool Bar. The Tool Bar provides a
number of commands you can perform directly without going
through the menus. Position the mouse arrow over each button
on the Tool Bar to display a short popup description of the
buttons function.
Click on the numbers 1 through 10, and the Current Data Screens
will change from the current screen to the number of the screen
selected. You can do this anytime during testing to present data
which is most appropriate for that portion of the test.
By clicking on the menu item titled Window, a drop-down
menu will provide a choice to turn the Status Bar and the Tool
Bar off and on. Click on each item. A check-mark to the left
means that item will be displayed automatically. When the
check-mark disappears, that item will no longer be shown on
your display window.
The Control Panel (F12) option presents on-screen buttons for
controlling the dynamometer. Click on all the buttons to see the
effect. Click on the button again to close any sub-screens.
Section 11 - page 3
SF-602
M a n u a l
To close the Control Panel, click on Window in the Tool Bar

and click on Control Panel or push F12. This will remove the
check-mark and turn off the Control Panel. You may call up
the Control Panel on top of any WinDyn windows at anytime
during a test.
There are four major activities when using WinDyn software.
These are Design, Calibrate, Test Group, and Analyze. First,
Design the System Configuration, Tests, Limits, and Switches (*
switches are used on some systems only). Next, Calibrate the
system as required. Then, group these items together in a Test
Group, and run a test. Last, you will Analyze the test data.
11.3.
Designing Test Screens

Click on Screens in the menu, then click on Edit Screen
Displays and then click on Existing Screens. Now you will see
a list of existing display files. Select a Display File and click
OK. A current data display window should now appear on the
screen. Notice that in the Tool Bar, most of the number buttons
are up, while one button is depressed. The depressed button is
for the screen you are viewing. Click on the other buttons to
view the additional screens.
Section 11 - Page 4
I N
Y N
U T O R I A L
Next, experiment with redesigning the screens. Click on

Screens | Edit Screen Displays | Save Screens As in the
Menu Bar. When the Save As menu appears, place the cursor
in the box below |FILE NAME| and move the cursor left from
the .CDF to clear a space for the new title. Now the asterisk
will be highlighted. Type in the name for a new screen design,
as in NAME.CDF. Next click on OK. Now you should see the
name of the new display file in the lower right corner of the
screen. You can now modify this file and save it without
affecting the original design. This is the same procedure you
will use to design special screens for each of the different
types of tests and engines.
11.4.
Screen Editing Mode Preferences

Click on Screens | Edit Screen Displays | Preferences in the
Main Menu. A menu now offers a selection for Show Edit
Grid, Snap Objects to Grid, and a Coarse, Medium, or Fine
Grid. You can also enable or disable a message to Confirm on
delete objects during screen designs. Click on Show Edit Grid,
Snap to Grid, and Fine Grid. Then on OK.
11.5.
Resizing Objects
Now experiment with resizing the existing objects on the
screen. Click on one of the panel meters in the corner, and
then drag the corner with the double-headed arrow to resize
the meter. You can drag it over other existing display items.
When you release the mouse button, the object should snap to
the nearest grid lines. The grid lines are used to make it easier
to line up all the objects. If you wish to overlap objects in an
unusual way, you can go back to the Editing Preferences and
turn off the Snap to grid command. If you later turn the snap to
grid back on, the object that you did not snap to the grid line
will not change unless you reselect it.
By sizing objects in this way, you can make any object any
size within the size of the entire screen. By clicking on the
center of an object, it will outline the object. Now you can drag
Section 11 - page 5
SF-602
M a n u a l
this object to any position on the screen. It is even possible to

position the object on top of another object. If you should
decide to do this, be careful with the sequence because the
object selected last will always be the one on top when the
screen is recalled for use. Always completely size and design
the object to be on the bottom before designing and positioning
the second object on top. If you should inadvertently move one
object behind the other, slide the overlaid object out of the
way, and then drag the object beneath it back onto the screen.
Then reposition the objects and continue.
11.6.
Selecting Objects for a Screen Design

Whether you begin with a new screen design or wish to add
objects to an existing screen design, you have a wide variety of
choices. There should now be a floating toolbar displayed on
your screen entitled Editing Control Buttons. On this floating
tool bar are a number of tool buttons for various display objects. Click on the button with the white box and the green bar.
This will create a new digital display item ( a Tabular object).
Use the mouse to move the floating tool bar out at the way if
necessary. Use the mouse to position the arrow on this new
object. Then push down the left mouse button to drag the
object to any place on the screen. Place the arrow at the corner
of the object and hold down the left mouse button to drag the
object to a larger or smaller size.
Next, position the arrow in the object and press the right
mouse button. A sub-menu will appear that allows you to
select the data for display in this object and to select color
ranges for the object as the display value changes. There is
also a choice for various horizontal and vertical styles.
NOTE
No changes will appear in the object until you push Apply or OK on the Tabular
Editor Screen.
First, click on the button in the Channel Select box. The

Select Channel Menu will appear. Use the scroll bar to page
through all the channels currently available for display objects.
These channels are determined by the configuration file for the
test system. You will learn about the Configuration File in
another part of the manual. The Configuration File contains all
of the sensor inputs, the specifications and the calculated
channels. Select one of the channels for your display object.
Place the cursor on the item and push the left mouse button to
select it. Now select the OK button. Next, click on the Ranges
tab and select for 1, 2, or 3 color ranges. For learning purposes,
we suggest you select 3. Now enter the lowest expected range
for this data item, usually zero, and the highest expected
value. Enter the lowest value on the left side of Line 1, and the
highest value in Line 3. Select the intermediate color change
points by entering them in the remaining two boxes.
Section 11 - Page 6
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Next, click the left mouse button in the color bar next to each
item. Now review the Color Menu for selections. Choose any of
the existing colors, or define custom colors for the particular
application. Click on Define Custom Colors to make a new
color a standard choice. Then click on OK to return to the
main design screen. Repeat the color choice for each of the
other two bars. When one range is selected, no value entry is
required or possible.
Next, click on the Style tab. Try selecting various style options
and click the Apply button to see the effect of each.
Finally, select OK to complete the design. Now you should
have the new display object on the screen with the correct title
and color changes. Resize the object and move it to any place
else on the screen as desired. To remove this object, just push
the Del button and it will disappear.
11.7.
NOTE
Be careful not to continue to push the Del button multiple times because
additional objects will be deleted from the screen.
Designing Panel Meters

On the Editing Control button floating tool bar, create the
semicircular panel button. Click on this Meter button. A new
panel meter will appear. Click on the corner of this panel
meter and drag the corner to increase the size. Place the
mouse pointer in the middle of the display, and click on the
right mouse button to redesign the display.
The Meter Editor Menu should appear. Click on the button in
the Channel Select box and choose a channel for your meter.
Click on OK. Move to the Ranges and select 3. Set the left
hand box for the beginning range of the meter. It does not have
to be zero. It can be any positive or negative number. Enter the
maximum range of the meter in the lower right box. When
choosing ranges, try to select numbers with even increments to
design an attractive and easy to read panel meter. It is much
better if increments are in jumps of 1, 2, 5, or 10. Meters with
increments of 3 1/3 or 2 1/2 are very difficult to read.
Next, select the points for color change. Enter the numbers in
the remaining two boxes. Finally, click on the right hand color
bars and select the appropriate colors for each range of the
meter. You may wish to use green for normal, yellow for
caution, and red for danger. You might also select blue for
cold, green for normal, and red for hot. Use other combinations
that might make sense for your testing purposes. After completing the colors, move to Annotation.
Annotation determines the positioning of the numbers and the
increments for the panel meter. Look at the total numeric
range you selected from the start point to the end point for the
meter. It is desirable to divide the tick marks in even increments between these points. For example, if the range is 1,000
Section 11 - page 7
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you may wish to have 51 to 101 tick marks. We generally

recommend choices between 41 to 81 tick marks for making
the most attractive meter. Use the lower number if the meter is
smaller. If the full scale range is 1,000, indicate 51 tick marks.
This choice will provide 50 increments plus zero.
For the label category, select a number that will give between
four and ten labels. For example, for 51 tick marks, select
Label Every Fifth Tick Mark, for eleven labels total.
Now click on OK to review the finished panel meter. Consider
if the increments make sense for the display. Also determine if
there are too few or too many numbers. Note the color
changes. Are they appropriate for the requirements?
In the space in-between the lower units and the meter, there
will be a digital display of the actual numeric value. You wont
be able to see this display until the meter is used. Note that
there is a red arrow either to the right or left of the meter. This
arrow is used to indicate that the current value is either below
or above the range of the display meter. Reposition and resize
this meter to fit into the display, or push Del to remove it. The
units and titles of these meters are determined by the configuration file. You must go to the Configuration File Editor if you
wish to change these. See the Configuration File section of the
manual.
11.8.
Designing Bar Graphs

Use the mouse to select the Editing Control Button with the
vertical bars. Click with the left mouse button, and a bar graph
display should appear on the screen. Grab the right corner of
the bar graph to resize the display. With the mouse arrow on
the bar graph, click the right mouse button to bring up the Bar
Graph Display editor.
First, select the number of bars desired in the display. For
example, you might select the same number as the number of
engine cylinders (for exhaust gas temperatures). Next, move to
the Bar Channels and click on the first button. The Select
Channel Menu will appear. Scroll up and down the channels
to select the first item to appear in the bar graph. Because all
the items in the bar graph will have the same scale, you will
normally only use the bar graph for channels which are
similar. The most common use would be for temperatures or
pressures.
Select each of the channels for the bar graph. Then click on
the Title tab and type in a title for the bargraph. Next, click on
the Ranges tab and select the beginning range and the ending
range for the bar graph. Either range can be any positive or
negative number. On the Ranges, select 1, 2, or 3 color
changes. Then enter the beginning range and the ending
range. Add the intermediate color change points. Next, click
on a color box and select the color for each range.
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Finally, click on the Style tab. Look at the beginning and

ending range to determine the total numeric range of the
meter. Enter a reasonable number of tick marks, which will
indicate specific values. Try to choose a size for data steps of
1, 2, 5, 10, 100, 500, 1000, etc. A typical number of display
increments is 41 to 81. Use the lower number for smaller
display items. Then choose to label tick marks in a common
increment. Use 4 to 8 labels for a given display. Choose a
number. You may wish to label every 5 to 10 tick marks. You
may also choose to draw tick lines across the graph to make it
easier to read the values. These can include lines only on the
major tick lines or on both the major and minor tick lines.
Click both to see how the graph may look. Now click Apply to
view the final design. If the design is not quite what you want,
modify the design as required. When you have achieved the
final design, click OK. Now resize and position the bar graph
anywhere on the screen. You can also delete the item by
pressing Del.
11.9.
Designing X-T Graphs

Click on the Editing Control Button with the single trace on a
graphical background. A message will indicate Strip Chart. A
strip chart display graph should appear on the screen. Strip
charts are designed to display a graphical history of a function
over time.
Click on the corner of the X-T graph display and expand it.
With the cursor on the graph, click the right mouse button to
bring up the Strip Chart Display editor.
Enter 4 for the Number of Channels. Click on the tabs located
at the bottom of the Setup box to edit the information for each
channel that will appear on the Strip chart. Select the channel,
color, and Display Range for each channel. In the Annotation
box, select the vertical scale increments. Select a vertical scale
which will be compatible with each of the channels, selected
in the channel setup. Some experimentation or calculations
may be required to determine a combination which will fit
multiple channels and still give even increments that are
useful for a readout. Select from 21 to 81 minor tick marks with
major increments typically every 5 to 10 tick marks. Click on
major tick lines and minor tick lines to add lines to the graph.
Move to Time Base and make similar choices.
Next, click on the Timebase tab and enter the time base range
in seconds, minutes, or hours. Last, select a Start Trigger and
Stop Trigger point to begin and end the graphing. Once the
graph has been triggered, it will continue to record data until it
reaches the stop trigger condition. If no stop trigger condition
is met, it will continue to graph data indefinitely, whether you
are running a test or not.
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You can start or stop the trigger based on any item contained in
the Configuration File. First, choose Event from the mode selection to trigger (select Continuous for the graph to run all the time).
To stop or start the graph, enter a value for the data or select a
channel. For example, power could be graphed on the chart
whenever the speed channel exceeds 60 mph. To make this
selection, click on the Trigger Parameters left button and select
EngSpd. Then click on the greater than (>) button, followed by
Entered Data, and enter 60 in the data box. Now the graph will
trigger whenever speed exceeds 60 mph and will continue until
it receives a stop command. Next click on the Stop Trigger tab
(click on Event, select EngSpd again, and enter greater than (>)
160. You have set the graph to begin recording when speed first
exceeds 60 mph and to continue to record until the speed
exceeds 160 mph. Click on OK.
This completes the X-T graph design. Now resize and reposition the graph as desired. To make additional changes, simply
position the mouse arrow on the graph and click on the right
button to return to the design menu.
Note there are selection buttons for Options and Start/Stop in
the upper left and right corner of the X-T Graph. These buttons
are not functional during the design phase, but you can use
them during testing. By going to the Options Menu, you can
change the channels graphed, the scaling, and the trigger
points. Use the Stop/Start button to manually start and stop the
graph. To permanently save changes from the Options menu,
press Ctrl-S.
You can trigger the graph for a test, and then stop it manually.
Use the Print Screen utility provided with WinDynTM to print
the graph, even if you have not stored the data. For additional
information on display design, see the section in the manual.
To exit the Screen Design menu, click on Screens|Edit Screen
Displays|Save Screens in the main menu bar or press Ctrl-S.
From the WinDynTM menu, select Screens|Edit Screen
Displays|Save Screens... to save your changes. The select
Screens|Edit Screen Displays| Close Screens... to exit the
screen design mode.
11.10.
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Designing Configurations
WinDyn software has been designed so you can create your
own instrumentation system. You can select the units for data
display, the calculations, the specifications used for calculations, and the resolution of the read-outs. All these functions
are accomplished using the Configuration Design feature. Note
that when Designing Configurations, Specifications are also
known as Constants.
Position the mouse arrow over Design in the menu, then click on
System Configuration. The configuration editor will appear on
the screen. Use the mouse to select the Get Configuration from
Disk command. A list of available configuration files will appear.
Use the mouse to select a file. Before proceeding further, use the
mouse to select Keep Configuration on Disk. Now replace the old
file configuration name with your name for the trial design. Press
the Enter key to create a new file with your name. Now there is
a copy of the old configuration file stored with your name. Your
name should appear in the upper right corner of the screen with
a .CFD following it. CFD stands for configuration data. You can
design as many configuration files as you desire. Because you
may wish to change the scale or the utilization of the fuel and air
channels for each size engine, you may wish to make special
configuration files for each type of test or size of engine in your
program. Engine, vehicle, and test set-up data is usually stored in
Specification Channels 77-99. Specification channels can be
modified or installed from Calibrate|Specifications in the
WinDyn main menu.
11.11.
Modifying a Configuration File

In most cases, it is easiest to start with an existing configuration file and modify it. To change a configuration file, use the
mouse and click on G GET (open) config from Disk. Select a
configuration file. Then click on Edit Channel Specifications.
Now you should see a screen for selecting any particular data
or information channel, which you may then edit to suit your
needs. To see a list of all the available channels, hold down
the Ctrl key and press Z on the keyboard. A list of the defined
channels will appear.
Each channel has a number. Enter these numbers for the
calculation and other features of the program. Whenever you
forget the number or the name, press Ctrl-Z and this information will appear.
Press Ctrl-Z again and a second menu will appear that shows
the special data channels with various timers and the controller setpoint information. Pressing Ctrl-Z again will return you
to first listing of channels. To exit these listings, press any key.
SF-602
11.12.
M a n u a l
Types of Channels
There are five general types of channels in the WinDyn
system. These are listed below.
Measured Sensors
Calculated Channels
Entered Constants
Timers
A few additional special channels are included with some

systems.
11.13.
Measured Sensors Channels

Measured sensors channels are for displaying the inputs from
the various sensors, such as torque, speed, temperatures, pressures, etc. You are limited to the number of sensors supplied
with your system. There may be optional channels available
for your system which appear on the screen, but that are not
supported by your particular hardware. You can delete these
channels from the configuration files you use, or simply do not
put the extra channels on the screens or print-outs.
A typical sensor input is a strain-gage for measuring torque. Use
Ctrl-Z to locate the channel for engine torque. On a CycleDyn it
will usually be Channel 2. Place the mouse arrow over the
number on the screen, and press the left mouse button to select
that channel and enter it into the Edit Menu. With Channel 2
displayed on the Edit Menu, press the Enter key on the
keyboard to get into the Channel Edit Screen. Information on
the type of channel is displayed here. The input is for analog
voltage from a strain gage on your dynamometer power absorption unit. Six characters are allowed for the name of the channel
and six characters for the units. Neither the name or the units
have any effect on the calculations.
You must enter the correct scaling for calibration to get the
correct answer. The channel name characters are limited to
six, so the names will fit onto the various screen displays and
print-outs. If longer names were used, it would be very difficult
to generalize the design of these items.
You may edit the channel name. For example, change the
name from EngTrq to Torque. Use the Enter key to move to
the channel units and modify them if you wish. Now use the
Enter key to the data format line. This line allows you to
choose the resolution of the data. You must only enter the first
one or two letters of the word for the program to recognize
your choice.
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Press the Enter key again for the choice of calibrating by

entry, full scale, or special formula. For torque, calibrate by
entry. Some of the other devices require you enter the full
scale reading, and special formula allows you to change the
channel to a channel that is based only on calculations using
data from other channels. A torque channel would always be
done by entry. With entry selected, press the Enter key to
see the Calibration Entry Screen.
The strain gage operates on a zero to ten volt signal for full
scale for existing SF-901 dynamometers, and the calibration is
pre-scaled from the SF-901 console.
For other dynamometer systems, the torque is scaled for 4.096
VDC for full scale.
On many pressure transducer and flow channels, you can
enter the actual calibration units from the sensor. Use the
Enter key to step through the choices. After the last choice,
it will move you to the AutoZero line. Select No and press the
Enter key. On data filtration, select None, and press Enter
key again. The minimum value and maximum value units do
not need to be filled in. For the line that reads, Is all the above
data what you want ? Select Yes and press the Enter key. For
Print a copy, select Yes or No, and press the Enter key. Now
you are back to the initial menu.
11.14.
Specifications Channels
Use Ctrl-Z to bring up the current defined channel list and
select Channel 77. Place the cursor over the 77 and click with
the left mouse button. This channel has been designated for
Wheel Slip. Use the Enter key to step through the choices.
You will see a default specification value. These values may
be changed from the computer operating screen during any
test or saved as a Specification group (Channels 77-99) and
installed at any time. By entering the appropriate group of
specifications, the computer can calculate all the other important information about the engine or vehicle, including its
displacement, piston speed, volumetric efficiency, BMEP, etc.
It is important to check the specifications before running each
engine test to make sure they agree with the engine being
tested. Channels 77 to 99 are for Specifications. If you wish to
use different specifications, select a channel and change it to
another value.
NOTE
Note that you DO NOT need to create multiple configuration files simply to set
different specification values. Use WinDyns Specification Files for this purpose.
SF-602
11.15.
M a n u a l
Calculated Channels
The calculated channels are one of the most powerful features
of the WinDyn software. You can use inputs from any sensor,
any constant channel, and any interpolation table, and combine them into any kind of mathematical calculations to
produce real time data that will be displayed and recorded
along with the rest of the test results. A common use for a
calculated channel would be to determine power from the
speed and torque, or for correcting power and torque to
atmospheric conditions. Use Ctrl-Z to view the current defined
channels. Calculated channels begin at 100 and continue to
Channel 129. Additional calculated channels may be added
between Channel 44 and 76. If any of these channels are not
utilized, you may add a calculated channel at that location
and make it part of your data file.
Move the mouse arrow to the number 100 next to Power and
click the left mouse button and then press Enter . You should
see Channel Definition Screen for Power, Channel 100. Use
the Enter key to step through the screen to view the calculation formula.
Below the calculation formula is a list of the mathematical
operations that can be performed in an equation. The equation
must fit within the green box, so it can only use that many
characters. For an extremely complex formula, use two
calculation channels so that the first channel is called by the
second channel.
It is very important to use the parentheses ( ) symbols to
designate the order of precedence in the calculations. Any
calculations inside the parentheses will be done before any of
the calculations outside the parentheses. Use multiple levels of
nested parentheses if required. The exponential function uses
the ^ symbol followed by a number. Use any power required.
For example, a square root would require a ^ followed by 0.5.
It is necessary to always proceed a decimal point with a
numeral or a zero when entering it into a formula. For trigonometric functions, the angle must be entered in degrees and
fractions of a degree.
One special feature is the ability to call an interpolation table.
These tables are located in Channels 130 through 139. They
are discussed in the next section.
Use the Enter key to step through the menu. Select additional calculated formulas to see how the operations are
performed.
11.16.
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NOTE
The following example is only used in gasoline engine dynamometer systems.

The SF-602 configuration files do not use interpolation tables as standard.
The Interpolation Tables are located in Channels 130 through

139. Use Ctrl-Z to call up the menu and place the mouse arrow
over the number 130. Press the Enter key to open the Interpolation Table. You will see this channel is for SpFTrq (Spark
Friction Torque). A menu will appear for a choice between fixed
interval and variable interval numbers. Leave it on fixed variable and press the Enter key. The interval displayed is 500.
Press the Enter key twice to view the entire chart.
With the chart displayed, you can see the general principle
involved in an interpolation table. The upper line is for the
input data. This is the data that arrives from a calculated or
sensor channel. The lower line is the output data. This is the
data output by this channel as a result of the input. The
advantage of this concept is that it allows you to put in data for
non-linear sensors or numeric information. Put in all the data
points that are available, and the table will then calculate the
appropriate points that would fall in-between. This feature is
used to linearize a sensor, or simply to perform calculations
from a set of arbitrary data.
In this example, a chart is generated based on the piston speed of
the engine. The piston speed is the input running from zero to
10,000 in feet per minute. The output is the typical friction-torque
per cubic inch of engine displacement at that piston speed. This
data has been obtained from tests of hundreds of engines of all
different sizes. Almost all of the engines will fall within + 10% of
these values. It is much easier to use a standard friction torque
value for calculations than it is to develop devices to measure the
actual friction losses in the engine. The friction torque table has
proved to be very accurate and improves the accuracy of corrected power calculations substantially.
To build an Interpolation Table, select the intervals for the
input values. It is limited to 21 entries. If you select fixed, it
will make even increments. If you select variable, you may
type in the values for each of your increments, whether they
are evenly spaced or not. Then type in the output values that
correspond with the input values. A typical example might be
to enter the flow rate in gallons per minute for a turbine on the
lower line while entering frequency for the input on the upper
line. Then write a calculation formula that uses the frequency
from the sensor channel and calls the interpolation table
number to obtain gallons per minute. The output from the
calculated channel would then be gallons per minute.
To see how this is written, look at the Calculated Channel 107
for SpFTrq. It calls this Interpolation Table 130 to return the
torque per cubic inch as a function of piston speed. Press the
Enter key to exit this screen. Enter Channel 107 to view the
SF-602
M a n u a l
Calculated Channel that utilizes Channel 130. This operation

returns the value for torque per cubic inch at each piston
speed, which is multiplied by Channel 126, the cubic inch
displacement of the engine. The result is the friction torque in
lb-ft at that piston speed. By using this process, it is possible to
linearize sensors, and to otherwise utilize data that is in a nonlinear format. This is very powerful tool for improving the
accuracy of the test system.
To exit the Configuration Screen, first press the Esc key to
return to the basic menu. Then press K to Keep the Configuration on Disk. Save the configuration under your name, not the
old title name. After saving it, select QUIT, and return to
WinDyn. Now you should be back to the standard WinDyn
Operating System.
11.17.
Setting File Paths

From the main WinDyn Menu, select Design | System Setup
| File Paths. The Set Paths menu shows the data path for each
of the various program features in the system. When each of
these program features looks for file data or configuration files,
this is the location it checks. It is also where WinDyn will
store any files saved during the operation of the system. It is
very important that these be correct for your computer. You
can leave all these files in the main WinDyn directory, or you
can create sub-directories. You may find an advantage for
storing your test data in various sub-files that are related to the
engine type or the engine owner. To do this, you must access
this window before storing the files. Test data will be stored in
the first category: Data Path.
If you enter a path that does not exist, WinDynTM will create it
for you.
Click on Cancel to exit this window if you have not made any
changes. If you made changes, click on OK.
11.18.
NOTE
WinDynTM Version 1.10 DOES NOT support WinDows 95 style Long

Filenames. All directory paths and filenames must be 8 characters or less with
no space
Determining the Channel Order

You can determine the display order for your channels for
Saved Tests, Data Analysis, and Print-Outs. For example, you
might wish to have Speed in Column 1, Torque in Column 2,
Power in Column 3, and so on. You can specify up to ten
pages of column designs.
To design the Channel Order, click on Test Group, Design Test
Group, and Edit Existing Test Group. Select a file, click on
OK, and then click on the Channel Order Edit button. Now
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the Channel Order Design Screen will appear. In the upper left
of this screen is the Page Select. Choose a page and fill in the
blanks for the channels to be displayed on that page. You can
also name the page, and this name will appear at the top of the
display. On the left side of the screen, select the number of items
to be displayed. On the right side, select whether or not the items
are plotted, the plot scale, and the plot color for each item.
To select the channels to display, click on each at the channel
buttons. Use the slide bar to scroll through the various choices,
and enter the choice for the desired channel. The First Channel will always be the X-axis, (the axis across the bottom), on
the graphs. Upon completing your channel design, click on OK
or cancel. If you choose OK, your design choices will be saved
under the existing Test Group name.
The Channel Order is always dependent upon a Configuration
File. If you change the configuration file, the same changes
will appear in the channel order. For example, if speed
became an air flow channel, air flow would now appear in the
first position of all your channel order pages where speed had
been located.
There can be many Channel Order Designs for each Configuration File. For example, you can have one Channel Order
Design for Power Tests and a second one for Endurance Tests.
A third one might be used for Engine Break-In Cycles. Just
give each one an appropriate name, and load it when you
wish to begin your tests.
Channel Order is specifically assigned to Test Groups. By
utilizing this function, you can load a single Test Group for a
particular type of test. It will automatically install the configuration file, calibration file, channel order, specifications, and
screen displays for that test combination.
To use the same Channel Order with a new Test Group, open
the existing Test Group and modify it and then save it as a
new Test Group.
11.19.
Running Tests
From the main menu bar, select Test Group. Use the Open
Test Group menu for beginning any test program. For this
menu to function properly, there must be previously generated
Configuration Designs and Screen Designs. Test Group can
only access files that have been previously designed using the
design functions. Select a test group. It will load, and the
Status windows at the bottom of the screen will display the
new items.
Select Test Group in the main WinDyn menu bar. You will
notice a line that says Autoload Test Group. Click on Autoload
Test Group to see the selection. Select this command and a
Test Group will be automatically loaded in your system on
computer boot-up.
SF-602
M a n u a l
Click on Test Group in the main WinDyn menu. Now you

should see the Design Test Group menu. Click on Design Test
Group, and New Test Group. Enter a name for the new Test
Group, and click OK.
First, you must select a Configuration. Click on the file choice
for Configuration and you will see all the various configuration
files available. Click on a file name, then click on OK. There is
also a choice for Channel Order. Click on Channel Order and
design the data order and names for each of the print-out
pages and graphs for the new Test Group. Click on OK when
the Channel Order is complete. (If the Channel Order was
previously designed in another Test Group, it will save time to
Load the Channel Order from that Test Group and modify it.
Then save it under a new Test Group or Channel Order name).
The Display button determines which items will appear on the
computer screens. The Tool Bar is the bar across the top of the
screen that has each of the screen keys and various logos for
loading and unloading programs. The Status Bar is the information which appears across the bottom of the screen showing
which files are active for Test Group, Configuration, Test,
Limits, and Display. The Control Window is the communication with the dynamometer control system. Activate it manually from the Test Group menu, or check the item in the
Window menu so that the Control window will automatically
appear on top of the displays.
The various Load buttons select the Screen, Test, Specifications, Limits, and Calibration for the Test Group. You do not
have to select anything except the Display file and the Configuration file. The others are optional. Click on the desired button,
and it will show the choices currently available. If nothing is
available, return to the Design Menu to design a particular set
to be used for the Test Group.
You cannot design any items other than the Channel Order
from this menu. You can only select files that have already
been created.
11.20.
Selecting Other Test Features

The easiest way to perform a test is to select an existing Test
Group from the File menu, which assigns all the files, required
for Configuration, Screens, Specifications, Tests, Limits, and
Calibration.
If you do not select a Test Group, you can achieve the same
results by selecting each of the other items on the Test Group
menu, except for the Channel Order. On some systems, you
can also change the Control System and Selected Switches.
Once a Test Group has been selected, or a group of individual
selections have been made, the dynamometer may be operated
for testing.
12
WinDyn
Reference Guide
12. WinDyn Reference Guide

12.1. WinDyn Terms .......................................................................................... 5
12.2. Design Test Group ..................................................................................... 5
12.2.1.
Dialog Box Options ....................................................................................... 6
12.3. Channel Order ........................................................................................... 7

12.3.1.
12.3.2.
Overview ...................................................................................................... 7
Using ............................................................................................................ 7
12.4. Autoload Test Group .................................................................................. 8

12.4.1.
12.4.2.
Overview ...................................................................................................... 8
Using ............................................................................................................ 9
12.5. Edit Stored Data Headings ........................................................................ 9

12.6. Auto-Incrementing Data Filenames ......................................................... 10
12.6.1.
12.6.2.
12.6.3.
Name Format .............................................................................................. 10

Manual Increment Filename ........................................................................ 10
Auto-Increment Filename ............................................................................ 11
12.7. Playback Data ......................................................................................... 11

12.7.1.
12.7.2.
12.7.3.
12.7.4.
12.7.5.
12.7.6.
Overview .................................................................................................... 11
Playback Data Menu .................................................................................. 11
Playback Data Menu - Load Saved Test ...................................................... 12
Playback Data Menu - Playback Functions ................................................ 12
Playback Data Menu - Repeat Play ............................................................ 14
Playback Data Menu - Exit Playback Mode ................................................ 14
12.8. Selecting Channels ................................................................................. 14

12.8.1.
Dialog box options ...................................................................................... 15
12.9. Editing Specifications Channels .............................................................. 15

12.9.1.
12.9.2.
Overview .................................................................................................... 15
Editing Specifications ................................................................................. 16
12.10. Channel Calibration and Autozero .......................................................... 18

12.10.1. To calibrate a channel, follow these steps ................................................... 18
12.10.2. To zero a channel, follow these steps ......................................................... 18
12.11. Password Protected WinDyn Features .................................................. 19

12.11.1. Overview .................................................................................................... 19
12.11.2. File Menu - Login ........................................................................................ 19
12.11.3. File Menu - Logoff ....................................................................................... 19
12.11.4. File Menu - Change Password..................................................................... 19
12.11.5. File Menu - Configure Password System .................................................... 20
12.11.5.1.Disabling the Password Protection system .......................................... 20
12.11.5.2.Selecting the WinDyn default access ................................................. 20
12.11.5.3.Adding a user ...................................................................................... 21

12.11.5.4.Update an existing user ....................................................................... 21
12.11.5.5.Deleting a user ..................................................................................... 21
12.11.6. WinDyn User Configuration ........................................................................ 21
12.11.7. Individual WinDyn Access Features .......................................................... 22
12.12.
Custom Tools .................................................................................... 23

12.12.1. Overview .................................................................................................... 23
12.13.
Bargraph Display Configuration .......................................................... 24

12.13.1.
12.13.2.
12.13.3.
12.13.4.
12.13.5.
12.13.6.
12.14.
Tabular Display Configuration ............................................................. 28

12.14.1.
12.14.2.
12.14.3.
12.14.4.
12.14.5.
12.15.
Meter Display ............................................................................................. 32

Meter Display Dialog Box ........................................................................... 32
Meter Dialog Box - Channel Select ............................................................. 33
Meter Dialog Box - Meter Style ................................................................... 34
Meter Dialog Box - Color Ranges ................................................................ 34
Meter Dialog Box - Annotation .................................................................... 35
Stripchart Display Configuration ......................................................... 36

12.16.1.
12.16.2.
12.16.3.
12.16.4.
12.16.5.
12.16.6.
12.16.7.
12.17.
Tabular Display ........................................................................................... 28

Tabular Display Dialog Box ......................................................................... 29
Tabular Dialog Box - Channel Select ........................................................... 30
Tabular Dialog Box - Style .......................................................................... 30
Tabular Dialog Box - Color Ranges .............................................................. 31
Meter Display Configuration ................................................................ 32

12.15.1.
12.15.2.
12.15.3.
12.15.4.
12.15.5.
12.15.6.
12.16.
Bargraph Display ........................................................................................ 24

Bargraph Display Dialog Box ...................................................................... 24
Bargraph Dialog Box - Channels ................................................................. 25
Bargraph Dialog Box - Ranges ................................................................... 26
Bargraph Dialog Box - Style ........................................................................ 26
Bargraph Dialog Box - Title ......................................................................... 28
StripChart Display ...................................................................................... 36

StripChart Display Dialog Box..................................................................... 36
Stripchart Dialog Box - Y Channels ............................................................. 37
Stripchart Dialog Box - Timebase ............................................................... 37
Stripchart Dialog Box - Start Trigger ............................................................ 38
Stripchart Dialog Box - Stop Trigger ............................................................ 38
Stripchart Dialog Box - Title ........................................................................ 38
XY Display Configuration .................................................................... 38

12.17.1.
12.17.2.
12.17.3.
12.17.4.
12.17.5.
XY Display ................................................................................................. 38
XY Display - Options .................................................................................. 39
XY Display - Stop (Start) ............................................................................ 39
XY Display Dialog Box ............................................................................... 39
XY Dialog Box - Y Channels ....................................................................... 40
12.17.6.
12.17.7.
12.17.8.
12.17.9.
12.18.
XY Dialog Box - X Channel ......................................................................... 41

XY Dialog Box - Start Trigger ...................................................................... 42
XY Dialog Box - Stop Trigger ....................................................................... 44
XY Dialog Box - Title .................................................................................. 44
Panel Indicator Configuration ............................................................. 45

12.18.1. Panel Indicator Display ............................................................................... 45
12.18.2. Panel Indicator Display Dialog Box ............................................................. 45
12.19.
Push Switch Configuration ................................................................. 46

12.19.1. Push Switch Display ................................................................................... 46
12.19.2. Push Switch Display Dialog Box ................................................................. 46
12.20.
Push Switch with Indicator Configuration ........................................... 48

12.20.1.
12.20.2.
12.20.3.
12.20.4.
12.21.
Push Switch with Indicator Display ............................................................. 48

Push Switch with Indicator Display Dialog Box ........................................... 48
Panel Indicators with Push Switches - Panel Indicator ................................ 49
Panel Indicators with Push Switches - Push Switch .................................... 49
Video Display Configuration ............................................................... 50

12.21.1. Video Display ............................................................................................. 50
12.21.2. Video Display Dialog Box ........................................................................... 51
12.21.3. Video Dialog Box - Video Setup .................................................................. 51
12.22.
Remote Status Display Configuration ................................................ 52

12.22.1. Remote Status Display ............................................................................... 52
12.22.2. Remote Status Display Dialog Box ............................................................. 52
12.23.
Background Bitmap Configuration ..................................................... 53

12.23.1. Background Bitmap Display ........................................................................ 53
12.23.2. Background Bitmap Display Dialog Box ...................................................... 54
12.23.3. Background Bitmap - Style ......................................................................... 54
12.24.
XY-Reference Plots ............................................................................ 55

12.24.1. Adding Reference Plots .............................................................................. 56
12.24.2. Removing Reference Plots ......................................................................... 56
12.24.3. Reference File Info ..................................................................................... 56
12.1.
I N
Y N
E F E R E N C E
WinDyn Terms
The following WinDyn terms are important to understand in
order to achieve maximum software performance during all
phases of testing.
Configuration Files
Master file which determines how WinDyn will collect and
calculate data.
Test Groups
Powerful feature which quickly and completely configures
your data acquisition system for testing.
12.2.
Design Test Group

This dialog box, accessed from the WinDyn main menu via
Test Group|Design Test Group|Edit Existing Test Group (or
New Test Group), allows you to design a test group. Test
Groups may be used to quickly and automatically configure
the dynamometer system for testing.
Section 12 - page 5
U I D E
SF-602
12.2.1.
M a n u a l
Dialog Box Options

Configuration
The configuration file may be selected by left-clicking on the
button configuration. A file selection dialog box will be displayed prompting you to select a configuration file. The
selected configuration file name will be displayed on the
button. To automatically load this configuration file each time
the Test Group is loaded, place a check mark in the Load
check box.
Load Boxes
The load boxes have buttons for selecting the Display, Autotest,
Limits, Calibration, Control, or Switch files to be included in
the Test Group. To choose any of these files, left-click on the
associated button and select a file from the list of those displayed in the file selection dialog. Click OK to dismiss the file
selection dialog. To automatically load the selected file each
time the Test Group is loaded, place a check mark in its corresponding check box. If the load box itself is grayed out
(disabled), then the system you are using does not utilize this
file type.
Channel Order
Left-clicking this button will cause the Channel Order dialog
box to be displayed. This dialog box will allow you to select
which channels will be displayed, printed and plotted when
viewing test data.
Display
This group of check-boxes allows you to select several runtime preferences that will be active when the Test Group is
loaded. To display the Control Window when the test group is
loaded, place a check mark in its associated check-box. To
display the Tool Bar at the top of the main window, place a
check mark in its associated check-box. To display the Status
Bar at the bottom of the main window, place a check mark in
its associated check-box. The recommended default selections
are made for you.
OK
When you are finished designing your test group, select this
button and you will be prompted for a new file name to use for
this test group. To use an existing Test Group as a model for
others, open that Test Group, make changes, then save it using
a different name.
Install, Save, & Exit
This button will load the test group into the dynamometer
system, save it to disk, and exit the dialog box.
Section 12 - Page 6
12.3.
Channel Order
12.3.1.
Overview
I N
Y N
E F E R E N C E
This dialog box is accessed from the WinDyn main menu via
Test Group|Design Test Group| Edit Existing Test Group (or
New Test Group), and then selecting the Edit button next to
the label Channel Order. This allows you to select which
channels will be displayed and plotted when viewing
WinDyn data.
12.3.2.
Using
To modify a stored data page, select the desired page using the
Page Select drop-down list box. You can enter a Page Name for
the currently selected page. This name will appear on the
headings of the WinDyn STORED DATA and PLOT screens,
and on your data and plot prints.
Section 12 - page 7
U I D E
SF-602
M a n u a l
Select the number of data channels that will be displayed on

the page by using the up-down arrows on the left-side of the
dialog box. For each channel on the page, select the channel
to display by clicking on the desired channel button.
To plot a particular channel, place a check-mark in the associated check-box.
The Save button will permanently save any Channel Order
changes to the data file you are currently viewing (or to the
currently active Test Group if you are viewing the data currently recorded in the remote). The Load button allows you to
get a saved channel order from a Data File (*.SFD) or a Test
Group (*.TGP), so that you dont have to enter all the Channel
Order information manually.
NOTE
The first data channel will always be used for the X-axis (horizontal plot axis).
12.4.
Autoload Test Group
12.4.1.
Overview
This dialog box allows you to specify a Test Group that will be
loaded automatically when WinDyn is started. From the
WinDyn main menu, click on Test GroupAutoload Test Group
to display this dialog.
Section 12 - Page 8
12.4.2.
I N
Y N
E F E R E N C E
Using
To select a test group, left-click on the button in the current
selection box. A list of all Test Groups that are located in the
Configuration path will be displayed. Select the desired Test
Group and then click OK. The selected Test Group will be
displayed on the button. To automatically load this test group
each time WinDyn is started, check the Load on startup
check box. Left-click on OK to save the new selection and
dismiss the dialog box. Install, Save, & Exit will load the test
group into the dynamometer system, save any changes to disk,
and exit the dialog box.
12.5.
Edit Stored Data Headings

This dialog box allows you to edit the customer heading
banner that will be displayed on your stored test data
printouts and Reports. From the WinDyn main menu, select
DesignSystem SetupReport Headings..to display this dialog.
Up to five (5) lines of text may be entered. The text is saved in

the SUPERFLO.INI file located in the Windows subdirectory of
your hard disk.
Section 12 - page 9
U I D E
SF-602
12.6.
M a n u a l
Auto-Incrementing Data Filenames

This dialog allows you to specify the default file names for
storing test data. To display this dialog, select Design|System
Setup|File Names... from the WinDyn main menu.
12.6.1.
Name Format
These file names (maximum 8 characters) have a special
format as follows:
First four characters can be any letter or number combination.
|
DATAxxxx
|
Last four characters must be numbers.
For example, if you enter a filename such as TST1, each
time data is saved the name you entered will automatically
increment from TST1 to TST2 all the way to TST9999.
After TST9999, the filename will automatically wrap around
to TST0001. To prevent accidental loss of data, you will be
prompted before saving if a data file with the same name
already exists.
12.6.2.
Manual Increment Filename

This file name is for data that is saved manually with the
Analyze|Save Current Test... menu command. The file name
entered will be automatically incremented for each successive
save. For example, if a data file name of DATA0004 is chosen,
data will be stored in DATA0004.SFD for the first run,
DATA0005.SFD for the second run, and so forth.
12.6.3.
I N
Y N
E F E R E N C E
Auto-Increment Filename
This filename is for data produced by autotests (Terminal Tests
for SF901/SF7100 users). The file name entered will be automatically incremented for each successive save. For example,
if a data file name of TEST0001 is chosen, data will be stored
in TEST0001.SFD for the first run, TEST0002.SFD for the
second run, and so forth.
12.7.
Playback Data
12.7.1.
Overview
The Playback entry on the WinDyn main menu allows you to
play back a stored test. This allows you to review a previously
run test with any display file, and also to show a customer how
their engine or vehicle performed on the dynamometer. During
Playback, data will be displayed as nearly as possible to that of
the actual test. How close the playback data represents the live
test depends on how frequently the live test data was recorded
and how the live test data varied between recordings. You can
also vary the rate at which the data is played from 1/8 up to 8
times the original speed.
12.7.2.
Playback Data Menu
The playback menu contains four menu items and a sub-menu

for the Playback Functions. The Load Saved Test menu item is
available in all modes except Edit mode. The Playback Functions and its sub-menu are only available in playback mode.
Playback mode is active after Load Saved Test has been
performed. Repeat Play is available in all modes. Exit Playback
Mode is only available during Playback mode.
U I D E
SF-602
12.7.3.
M a n u a l
Playback Data Menu - Load Saved Test

This menu command displays a dialog box that will let you
choose the saved test to load for playback. Once a test has
been loaded, a floating toolbar appears with VCR like
buttons used for controlling the data playback.
If WinDyn is currently in Run mode, the Playback operations
will be performed with the currently active displays, otherwise, a dialog box will appear allowing you to choose the
display to be used for playback.
12.7.4.
NOTE
The Load Saved Test menu item can be used to compare data from different
saved tests. For X-Y plots, the data does not get erased unless Erase Real-time
Plot is selected. After playing back a test, data from another test can be loaded
using this menu item and then played back over the existing X-Y plot. Using the
Reference Plot Display or Plot Test Data function of the stored data viewer are
other methods for comparing saved tests.
Playback Data Menu - Playback Functions
The Playback functions contain the operations that can be

performed on the data file. Once a saved test has been loaded
for playback, the floating toolbar with the playback operations
appears. This toolbar contains VCR like buttons that are a
shortcut to using the WinDyn menu system. In addition,
informational text appears that indicates the status of Repeat
Play and Playback Speed. The following describe each function of the playback floating toolbar.
Rewind
This operation performs several functions depending on what
the playback system is currently performing. The following
table indicates the functions of the Rewind operation:
Current State
Action
Stopped
Paused
Play - Reverse, any speed
Play - Forward, Speed x 1/8
Play - Forward, Speed x 1/4 or more
Instantly rewinds to beginning of data

Play - Reverse, Speed x 1
Doubles reverse speed up to 8X
Play - Reverse, Speed x 1/8
Halves forward speed
I N
Y N
E F E R E N C E
Reverse
This operation will always set the system to play in reverse at
normal(x1) speed. Play will continue from the end of the data
(if just loaded, rewound, or fast forwarded) or from the current
position(if just stopped, paused, or if playing in any direction
and speed).
Stop
This operation will always stop the data from playing. The
current data position is not altered.
Play
This operation will always set the system to play forward at
normal(x 1) speed. Play will continue from the beginning of the
data (if just loaded, rewound, or fast forwarded) or from the
current position (if just stopped, paused, or if playing in any
direction and speed).
Fast Forward
This operation performs several functions depending on what
the playback system is currently performing. The following
table indicates the functions of the Fast Forward operation:
Current State
Stopped
Paused
Play - Forward, any Speed
Play - Reverse, Speed x 1/8
Play - Reverse, Speed x 1/4 or more
Action
Instantly fast forwards to end of data
Play - Forward, Speed x 1
Doubles forward speed up to 8X
Play - Forward, Speed x 1/8
Halves reverse speed
Pause
This operation will always pause the system. The current data
position is not altered. This operation is ignored if the playback
system is stopped.
Exit
Exits the playback mode and returns the system to Run mode.
The playback floating toolbar is removed.
Repeat Play
Selecting this operation will toggle the current status of the
repeat play mode. If the repeat play mode is on, the playback
of data will continue to repeat every time the end of the data
has been reached. If the repeat play mode is off, the data file
will be played back once and then stop. Text next to the
Repeat Play button indicates the current status of this operation. A check mark will appear next to this menu item if
Repeat Play is on.
Playback Speed
This text indicates the current rate at which the data is being
displayed. The rate at which the data can be displayed is from
1/8 to 8. For example, if the data file contains 80 seconds of
data, playing the data at 8X will cause the data to be played
back in only 10 seconds. Use the Fast Forward or Rewind
operations to change the playback speeds.
U I D E
SF-602
12.7.5.
M a n u a l
Playback Data Menu - Repeat Play

Selecting this operation will toggle the current status of the
repeat play mode. If the repeat play mode is on, the playback
of data will continue to repeat every time the end of the data
has been reached. If the repeat play mode is off, the data file
will be played back once and then stop. Text next to the
Repeat Play button indicates the current status of this operation. A check mark will appear next to this menu item if
Repeat Play is on.
12.7.6.
Playback Data Menu - Exit Playback Mode

Exits the playback mode and returns the system to Run mode.
The playback floating toolbar is removed.
12.8.
Selecting Channels
This dialog box is used to select a channel from a list of those
as defined by the currently loaded configuration file. This
dialog box is accessed from numerous points in WinDyn
(anytime you are required to select a channel).
Only channels that are defined are displayed in the channel

list. The channel list can be sorted alphabetically or numerically. The channel list can contain either the channel or digital
data types. The channel list can also be filtered so that only a
specific channel type is listed. The number in the [brackets] is
the channel number. Any channels labeled Sys are predefined system channels that cannot be changed regardless of
the configuration file loaded.
HINT
NOTE
12.8.1.
I N
Y N
E F E R E N C E
You can quickly scroll the channel list to a specific block of channels as follows:
1.
Click the mouse inside the box which has the current channel selected.
This box will be blank if no channel is selected.
2.
Using the keyboard, press the first letter of the channel name you are
interested in (for example, E for EngSpd). The channel list will then
scroll directly to all the channels that begin with E. If you continue
typing, the channel list will continue scrolling for each letter typed. For
example, the channel named Speed will be highlighted as in the
above illustration if you had typed Spe.
Clicking on a channel from the list of channels will automatically fill in the
channel selected box with the channel clicked.
Dialog box options

This dialog box also contains options that allow you to control
what channels will be listed.
Data Type
Select Channel to list the channel data type. Select Digital to
list the digital and relay channels. This option is normally
disabled with Channel automatically selected. This option
becomes available when selecting the channel to trigger from.
Sort By
This option allows you to select the order for which the
channels are listed. Select Channel Name to list alphabetically.
Select Channel Number to list numerically.
Channel Type
This option allows you to filter the channel list so that only
channels of the selected type are listed. Select one of the
channel types to only list those channels or select All to list all
channels.
12.9.
Editing Specifications Channels
12.9.1.
Overview
This window allows you to enter the Specifications (Constants)
Channel Values which will be in effect during testing. From
this window, you may install a specification file (*.CST),
thereby setting all the active constant values simultaneously.
Select File|Save As to create new specification files from the
displayed list. Click on the column headings (Name, Value,
etc...) to sort the display according to that column.
U I D E
SF-602
12.9.2.
M a n u a l
Editing Specifications
Active Specifications
A gray background indicates you are viewing the currently
active set of specifications. Use the arrow keys (or single click
the left mouse) to position the highlight cursor. To edit the
highlighted channel, press Enter (or double-click the left
mouse). Type in the desired value and click Done.
Note that active specifications cannot be changed individually
from WinDyn on NGE test systems such as SF-602 and
CycleDyn. Change the specifications using the handheld
controller, or install a specification file from this window or
Test Group.
I N
Y N
E F E R E N C E
Specifications file
To open a specifications file, select File|Open|Saved Specifications from the menu (or simply press F2). A default specifications file is provided with WinDyn for your particular
system. Select the desired specifications file and click OK. The
background color changes indicating you are now editing a
specifications file (not the active specifications). The window
title lists the name of the file you are editing. Use the arrow
keys (or single click the left mouse) to position the highlight
cursor. To edit the highlighted channel, press Enter (or
double-click the left mouse). Type in the desired value and
click Done.To install these specifications in the system so that
they are active during your test, select File|Install Specifications (or simply press F5). Note that the background color
changes to indicate you are now viewing the active specifications which will be used during your test.
NOTE
All specifications (constant) channels are reset to their configuration default

values each time a configuration file is loaded into the test system.
U I D E
SF-602
12.10.
M a n u a l
Channel Calibration and Autozero

This dialog box allows you to both calibrate and zero measured
data channels.
12.10.1.
12.10.2.
To calibrate a channel, follow these steps

1.
Select (highlight) a channel from the list of available channels.

The Current value for the selected channel will be displayed.
2.
Click on the Calibrate button. A new dialog box will appear

which will prompt you to enter the new channel value in an
edit box. Click OK to activate the new calibration value.
3.
When you have finished calibrating one or more channels,

click the Done button to dismiss the dialog box.
To zero a channel, follow these steps
1.
Select (highlight) a channel from the list of available channels.

The Current Value for the selected channel will be displayed.
2.
Click on the Zero button. A new dialog box will appear which
will prompt you to confirm the zero action. Click Yes; the
channel value is now zero.
3.
When you have finished zeroing one or more channels, click

the Done button to dismiss the dialog box. On some dynamometer systems, measured channels cannot be zeroed while the
engine is running.
12.11.
12.11.1.
I N
Y N
E F E R E N C E
Password Protected WinDyn Features
Overview
The WinDyn program is a highly configurable software
application. This allows a great degree of flexibility in customizing your system.You may want to limit access to the
configurability features and other program functions for
specific individuals. The administrator(s) for WinDyn can
limit the access of individuals to specific WinDyn features.
The software has been equipped to allow individuals with the
Configure user access privilege to enter user accounts which
contain the users name, login identification, password, and
access privileges.
When the WinDyn program is started, all access privileges
are disabled and the login dialog box appears. To gain the
appropriate access privileges, the user must login. Once
logged in, WinDyn will enable the appropriate features. If the
administrator(s) for WinDyn selected the default WinDyn
access to be Basic User, then, as a minimum, the Basic User
privileges will be enabled to all times. The operator will only
need to login to gain other privileges.
12.11.2.
NOTE
The administrator(s) for WinDyn can easily disable the password protection
system. When the WinDyn program is started with the password protection
system disabled, access to all features will be enabled
File Menu - Login

Selecting this menu item allows the operator to Login and gain
the appropriate access privileges. The program will automatically Logoff the prior user, if still logged in, and then modify
the access privileges appropriate for the new user. When
logging in, the user must enter their login identification and
password.
12.11.3.
File Menu - Logoff

Selecting this menu item allows the operator to Logoff the
system. When a user has logged off, access to WinDyn
features will be set to the WinDyn default access.
12.11.4.
File Menu - Change Password

Selecting this menu item allows the operator currently logged
in to change his or her own password. A dialog box will
appear containing two editable text fields labeled New Password and Verify Password. The new password must be
entered into both of the password fields and must be the same.
U I D E
SF-602
12.11.5.
M a n u a l
File Menu - Configure Password System

Selecting this menu item allows the operator to enable or
disable the password system, select the WinDyn default
access, and to manage user accounts. A user account contains the user name, login identification, password, and access
privileges. The following is a sample of the Configure Password System dialog box.
The list box contains a list of all the login accounts indicated
by user name. The dialog box has the three buttons: Done,
Cancel, and Help. Clicking the Done button will apply the
changes made and exit the dialog box. Clicking Cancel will
cancel all changes made and exits the dialog box. Clicking on
Help will bring up the help documentation and automatically
proceed to this page.
12.11.5.1. Disabling the Password Protection system
Clicking on the check box labeled Disable Password System
will disable the password protection system. Once disabled,
the WinDyn program will operate as if the password protection system does not exist with access to all features enabled.
12.11.5.2. Selecting the WinDyn default access
If the password system is enabled, the administrator(s) can
determine the default access level that WinDyn will enable.
Select the access of None to disable all access privileges. This
will force all users to login to gain their appropriate access
privileges. Selecting Basic User access will cause WinDyn to
enable the Basic User access privileges when no user is logged
in. Users need to login to gain additional access privileges
beyond the Basic level.
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12.11.5.3. Adding a user

To add an existing user, click on the Add button. A dialog box
will appear containing the user name and ID, a password
button, and the features that the user can access. The user
name, ID, and password will be blank. The user access level
will be set to Basic User. Enter the users information as
desired and click the OK button when completed. Details for
this dialog box are described below.
12.11.5.4. Update an existing user
To update an existing user, highlight the appropriate user from
the list and click on the Edit button. A dialog box will appear
containing the user name and ID, a password button, and the
features that the user can access. Modify the user name, ID,
password, and access level as desired and click the OK button
when completed. Details for this dialog box are described
below.
12.11.5.5. Deleting a user
To delete an existing user, first highlight the appropriate user
from the list box. Next, click on the Delete button. The selected
user will be deleted from the list box. Click the Done button to
save all changes. Other users can be added, deleted, or updated prior to clicking the Done button. Clicking Cancel will
cancel all changes made to all users and exits the dialog box.
12.11.6.
WinDyn User Configuration

The WinDyn User Configuration dialog box contains all the
information for an individual user and can be updated as
desired. The two editable text boxes contain the user name
and identification. The user name should contain the more
descriptive form of identifying the user. The ID is an abbreviated form of identifying the user and is used for logging into
WinDyn. To update the users password, the Password
button must be selected. A dialog box will appear containing
two editable text fields. The new password must be entered
into both of the password fields and must be the same.
The lower part of the dialog box contains the information for
the access features available to the user. The left side of the
dialog box contains four default user access level selections.
Selecting one of these access levels will set up the access
features according to the default WinDyn settings. Select one
of the access levels and/or customize the access features you
want available for this user by clicking on the desired access
feature checkboxes. Click off the checkbox for each access
feature you want to disable for this user.
U I D E
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12.11.7.
M a n u a l
Individual WinDyn Access Features

The WinDyn menu items and other functions have been
grouped into categories called the Individual WinDyn Access
Features. These grouped features can contain from one to
several related WinDyn operations. The following is a
detailed list of the available WinDyn menu items and other
functions for each of the Individual WinDyn Access Features
groups.
Protected Feature
WinDyn Menu Name/Access
Test cell(s) and network config
Configure (On Comlink Menu)

Reset|Dyno Clocks (On 901/7100 Comlink Menu)
Design|System Setup|File Paths
File|Configure Password System
Test Group|Design Test Group
Test Group|Autoload Test Group
Test Group|Install Configuration
Test Group|Install Control System
Test Group|Install Switches
Design|System Configuration
Design|Test
Design|Limits
Design|Control System
Design|Switches
Design|System Setup|Report Headings
Calibrate|Channel (F7)
Calibrate|Input Data (F8) (901 and 7100 only)
Calibrate|SF901 Sensors (901 only)
Calibrate|SF7100 Sensors (7100 only)
File|Open Test Group (F2)
Configure password system

Test System Configuration
Operator Test Functions
Test Group|Open Test Group (F2)

Test Group|Install|Screens (F3)
Test Group|Receive|Calibration
Screens|Install Screens Displays(F3)
Screens|Edit Screen Displays|Close Screens (Ctrl-X)
Design|Test Description (F10)
Design|System Setup|File Names
Design|System Setup|File Paths, data file path only
Calibrate|Specifications (F6)
Calibrate|Channel (F7), Calibrate button is disabled.
Window|Database
Configure Screens
Screens|Toggle Screen Mode (Ctrl-V)

Screens|Edit Screen Displays|New Screens
Screens|Edit Screen Displays|Existing Screens (Alt-F3)
Screens|Edit Screen Displays|Save Screens (Ctrl-S)
Screens|Edit Screen Displays|Save Screens As
Screens|Edit Screen Displays|Preferences
Screens|Edit Screen Displays|Assign Configuration
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Screens|Screen Display Windows

Screens|Screen Display Objects
Test file management/use
Test Group|Install Test (F4)
Limits file management/use
Test Group|Install Limits (F5)
Specifications file management/use Test Group|Install Specifications
Calibration file management/use
Test Group|Install Calibration
Data Analysis
File|Create Test Data Diskette
Analyze|Save Current Test
Analyze|Print Current Test
Analyze|Save and Print Current Test (F9)
Window|Test Data
Analyze|Excel Spreadsheet
Playback
Tools|Configure
Excel
Data Playback
Tools Configuration
12.12.
12.12.1.
Custom Tools
Overview
The Tools entry on the WinDyn main menu allows you to add
menu entries for your own programs to WinDyn. To display
the tool configuration dialog shown below, select
Tools|Configure from the WinDyn main menu.
U I D E
SF-602
12.12.2.
12.13.
12.13.1.
M a n u a l
Dialog box options

Add
Adds a new program name to the WinDyn

main menu (under Tools).
Edit
Changes a program name on the WinDyn

Remove
Deletes a program name from the WinDyn

Test
Runs the currently selected program (for example,

Calculator). Testing here ensures the program you
are adding or editing will run as expected when
called from the WinDyn main menu.
Done
Closes the above dialog box.
Bargraph Display Configuration
Bargraph Display
Each WinDyn Bargraph Display object allows you to graphically
monitor the value of up to eight separate channels during testing.
12.13.2.
Bargraph Display Dialog Box

This dialog box is accessed by clicking the Right Mouse Button
over a Bargraph Display Object during Edit mode. This dialog
box allows you to edit the bargraph objects run-time characteristics. There are 4 tabbed pages containing the display features
that can be accessed.
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Each tabbed page has the four buttons; OK, Cancel, Apply, and
Help. Clicking the OK button will apply the changes made to
the bargraph and exit the bargraph display dialog box. Clicking
Cancel exits the dialog box without applying changes made.
Clicking the Apply button will immediately apply the changes
made to the bargraph, but keeps the dialog box open. This
allows you to see the effects of your changes without leaving the
bargraph display dialog box. Clicking on Help will bring up the
help documentation and automatically proceed to this page.
12.13.3.
NOTE
Clicking the Cancel button will not remove changes that have been applied with
the Apply button.
Bargraph Dialog Box - Channels

The tabbed page labeled Channel contains the Number of bars
and Bar Channels options. This is the first page that appears
when clicking the Right Mouse Button over a Bargraph Display
Object during Edit mode as shown in the illustration above.
Number of bars
Select the number of channels to be displayed on the bar
graph from the available radio buttons.
Bar Channels
To choose the channels that will be displayed on the bar
graph, left-click the corresponding button to display the Select
Channel dialog box. The selected channel name will be
displayed on the face of the button.
U I D E
SF-602
12.13.4.
M a n u a l
Bargraph Dialog Box - Ranges
The tabbed page labeled Ranges contains the Color Ranges

option. Select the number of color ranges desired by clicking
on the appropriate radio button (One, Two, or Three). For the
first range, you will need to enter both a starting and ending
value. For the second and third ranges (if desired), you need
only enter an ending value. For each range, you can select a
color by clicking on the colored rectangle to the right of each
range. Note that the start range value must be less than the
end range value, but the range values can be negative.
12.13.5.
Bargraph Dialog Box - Style
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The tabbed page labeled Style contains the Label Orientation,

Vertical Label Type, and Annotation options. The bargraph has
different sizing limitations unique for the label orientations,
types, and annotation chosen. Choose the options that best fit
your requirements
Label Orientation
This option allows you to choose between displaying the labels
for the channel names in the horizontal or vertical directions.
See examples below.
Vertical Label Type
This option allows you to choose the type of vertical label
displayed for the channel names. The Labels Below Graph
selection will have the channel names displayed from top to
bottom starting below the graphing area. The Labels in Graph
selection will have the channel names displayed from bottom
to top starting in the lower portion of the graphing area. This
option is only available if Vertical Labels was chosen for the
Label Orientation. See following examples.
Annotation
Allows you to select how many tick marks are displayed
vertically on the bargraph, and which of those will be labeled.
The actual label values will depend on the minimum and
maximum range values entered in Color Ranges.
For example, assume that you want to create a bargraph to
display water temperature from 0 to 300 degrees, a label every
50 degrees, and have a tick mark for each 10 degrees. Determine how many tick marks are needed using the following
formula:
Number of tick marks = ((Max range - Min range) /interval) + 1
In this case, ((300 degrees - 0 degrees)/10 degrees) + 1 = 31 tick
marks. Now divide the label interval by the tick mark interval
to determine which tick marks should be labeled. In the
example case, 50/10 = 5. Therefore, enter 31 for the number of
tick marks, and label every 5th tick.
U I D E
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M a n u a l
By selecting the Major tick lines check box you can add grid
lines on the bargraph which correspond to the labeled tick
marks. Selecting the Minor tick lines check box will add grid
lines to the bargraph which correspond to the unlabeled tick
marks. In the examples above, both the Major tick lines and
the Minor tick lines check boxes were selected.
12.13.6.
Bargraph Dialog Box - Title

The tabbed page labeled Title contains the Window Title
option. In this dialog box enter any text you would like to give
the bargraph a title.
12.14.
12.14.1.
Tabular Display Configuration
Tabular Display
Each WinDyn Tabular Display object allows you to monitor
the digital value of a single channel during testing.
12.14.2.
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Tabular Display Dialog Box

The tabular display dialog box is accessed by clicking the
Right Mouse Button over a Tabular Display Object during Edit
mode. This dialog box allows you to edit the Tabular Display
Objects run-time characteristics. There are 3 tabbed pages
containing the display features that can be accessed.
the tabular display and exit the tabular display dialog box.
Clicking Cancel exits the dialog box without applying changes
made. Clicking the Apply button will immediately apply the
changes made to the tabular display, but keeps the dialog box
open. This allows you to see the effects of your changes
without leaving the tabular display dialog box. Clicking on
Help will bring up the help documentation and automatically
proceed to this page.
NOTE
the Apply button.
U I D E
SF-602
12.14.3.
M a n u a l
Tabular Dialog Box - Channel Select

The tabbed page labeled Channel contains the Channel Select
option. This is the first page that appears when clicking the
Right Mouse Button over a Tabular Display Object during Edit
mode as shown in the illustration above. The button label
indicates the data channel which will be displayed by the
meter. To select a different data channel, press the button and
select the desired channel from the Select Channel dialog box.
12.14.4.
Tabular Dialog Box - Style
The tabbed page labeled Style contains the Style, Orientation,

and Options groups.
Style
Select the Horizontal radio button to display the heading, data,
and units from left to right.Select the Vertical radio button to
display the heading, units, and data from top to bottom depending on orientation. See examples below.
Orientation
For the vertical style only, there are two orientations available.
Select the Data On Top radio button to display the data value
positioned over the channel name and units. Select the Data
On Bottom radio button to display the data value positioned
below the channel name and units. See examples below.
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Options
For all styles and orientations, the displaying of the heading
and/or units is optional. Click the Heading and/or Units check
boxes to display these items. If a check mark (x on some
systems) is in the check box, that item will be displayed.
Examples
12.14.5.
Tabular Dialog Box - Color Ranges
U I D E
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M a n u a l

12.15.
12.15.1.
NOTE
If One is chosen for the number of ranges, the range values are not editable as
shown in the above illustration.
Meter Display Configuration
Meter Display
The WinDyn Meter Display object allows you to monitor the
value of a channel on an analog meter. Two different meter
styles are available.
Compact meter style
12.15.2.
Panel meter style
Meter Display Dialog Box

The meter display dialog box is accessed by clicking the Right
Mouse Button over a Meter Display Object during Edit mode.
This dialog box allows you to edit the meter objects run-time
characteristics. There are 4 tabbed pages containing the
display features that can be accessed.
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the meter and exit the meter display dialog box. Clicking
made to the meter, but keeps the dialog box open. This allows
you to see the affects of your changes without leaving the
meter display dialog box. Clicking on Help will bring up the
12.15.3.
NOTE
the Apply button.
Meter Dialog Box - Channel Select

The tabbed page labeled Channel contains the Channel Select
option. This is the first page that appears when clicking the
Right Mouse Button over a Meter Display Object during Edit
mode as shown in the illustration above. The button label
indicates the data channel which will be displayed by the
meter. To select a different data channel, press the button and
select the desired channel from the Select Channel dialog box.
U I D E
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12.15.4.
M a n u a l
Meter Dialog Box - Meter Style
The tabbed page labeled Style contains the Style options.

There are two meter styles to choose from, compact meter and
panel meter. Choose one of the styles by clicking on the
appropriate radio button and click the Apply button to see the
differences in the styles. Examples of these styles are shown in
Meter Display.
12.15.5.
Meter Dialog Box - Color Ranges
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12.15.6.
Meter Dialog Box - Annotation

The tabbed page labeled Annotation contains the Annotation
option. This option allows you to select how many tick marks
are displayed on the meter, and which of those will be labeled.
The actual label values will depend on the minimum and
maximum range values entered in Color Ranges.
For example, assume that you want to create a meter to

display engine speed from 0 to 8,000 rpm, label every 1,000
rpm, and have a tick mark for each 250 rpm. Determine how
many tick marks are needed using the following formula
In this case, ((8,000 rpm - 0 rpm)/250 rpm) + 1 = 33 tick marks.
Now divide the label interval by the tick mark interval to
determine which tick marks should be labeled. In the example
case, 1,000/250 = 4. Therefore, enter 33 for the number of tick
marks, and label every 4th tick.
U I D E
SF-602
12.16.
12.16.1.
M a n u a l
Stripchart Display Configuration
StripChart Display
The WinDyn StripChart Display object allows you to plot the
value of up to four (4) channels during testing. The x-axis of
the plot is always Time (in hours, minutes, or seconds).
12.16.2.
StripChart Display Dialog Box

The stripchart display dialog box is accessed by clicking the
Right Mouse Button over a Stripchart Display Object during
Edit mode or by clicking the Options button during Run mode.
This dialog box allows you to edit the stripchart objects runtime characteristics. There are 5 tabbed pages containing the
display features that can be accessed. These tabbed pages are
identical with those of the XY Display configuration with the
exception that the stripchart has the tabbed page Timebase
instead of X Channel.
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the stripchart and exit the stripchart display dialog box. Clicking
made to the stripchart, but keeps the dialog box open. This
allows you to see the affects of your changes without leaving the
stripchart display dialog box. Clicking on Help will bring up the
12.16.3.
NOTE
the Apply button.
Stripchart Dialog Box - Y Channels

See XY Display Configuration
12.16.4.
Stripchart Dialog Box - Timebase

The tabbed page labeled Timebase contains the Range and
Annotation options as shown in the illustration above
Range
Enter the desired time width of the stripchart window to be
displayed in the edit box and the time resolution from the
available radio buttons.
U I D E
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M a n u a l
NOTE
Range items can only be changed while in Edit mode
Annotation
Allows you to select how many tick marks are displayed on
the X axis (time axis), and which of those will be labeled. The
actual label values will depend on the Range.
For example, assume that you want to create a stripchart to
display 5 minutes of data, label every minute, and have a tick
mark every 10 seconds. Determine how many tick marks are
needed using the following formula:
Number of tick marks = (range / interval) + 1
In this case, ((5 min * 60 sec/min)/10 sec) + 1 = 31 tick marks.
Now divide the label interval by the tick mark interval to
determine which tick marks should be labeled. In the example
case, 60 sec/10 sec = 6. Therefore, enter 31 for the number of
tick marks, and label every 6th tick.
lines on the plot which correspond to the labeled tick marks on
the X axis. Selecting the Minor tick lines check box will add grid
lines to the plot which correspond to the unlabeled tick marks.
12.16.5.
Stripchart Dialog Box - Start Trigger

See XY Display configuration.
12.16.6.
Stripchart Dialog Box - Stop Trigger

See XY Display configuration.
12.16.7.
Stripchart Dialog Box - Title

the stripchart a title.
12.17.
12.17.1.
XY Display Configuration
XY Display
The WinDyn XY Display object allows you to plot the value of
up to four (4) channels during testing. The x-axis of the plot may
be any channel you choose, such as Engine Speed or Time.
12.17.2.
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XY Display - Options
Clicking the Options button will bring up a menu containing
Setup, three Reference Plot functions and Erase Real-time Plot.
Setup
Selecting Setup will bring up the XY Display Configuration
dialog box.
Reference Plot
See Reference Plot Display for details of the reference plot
functions.
Erase Real-time Plot
Selecting Erase Real-time Plot will erase all the real-time data
plotted. Reference Plots will not be erased by this operation.
12.17.3.
XY Display - Stop (Start)

The XY Display has an additional button labeled Stop (or
Start). Selecting this button when it is labeled Stop will stop
the XY display from plotting any additional data. Selecting this
button when it is labeled Start will cause the XY Display to
return to the plotting of data if trigger conditions are met. See
also the Start Trigger and Stop Trigger sections of XY Display
Configuration.
12.17.4.
XY Display Dialog Box

The XY display dialog box is accessed by clicking the Right
Mouse Button over a XY Display Object during Edit mode or by
clicking the Options button during Run mode and selecting
Setup from the Options menu. This dialog box allows you to
edit the XY objects run-time characteristics. There are 5
tabbed pages containing the display features that can be
accessed. These tabbed pages are identical with those of the
Stripchart Display Configuration with the exception that the
stripchart has the tabbed page Timebase instead of X Channel.
U I D E
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M a n u a l
the XY-Plot and exit the XY display dialog box. Clicking Cancel
exits the dialog box without applying changes made. Clicking
the Apply button will immediately apply the changes made to
the XY-Plot, but keeps the dialog box open. This allows you to
see the affects of your changes without leaving the XY display
dialog box. Clicking on Help will bring up the help documentation and automatically proceed to this page.
12.17.5.
NOTE
the Apply button.
XY Dialog Box - Y Channels

The tabbed page labeled Y Channels contains the Setup and
Annotation options as shown in the illustration above.
Setup
The setup option allows you to setup the number of channels,
channel names, the color for plotting, and the scale to be used
for each channel on the Y-axis. Enter the number of channels
from 1 to 4 to be plotted. Select the channel name, color and
range for each channel. Use the lower tabs to switch between
channels. The Select Channel dialog box will appear when
clicking on the channel button.
NOTE
The number of channels, channel name, and channel color items can only be
changed while in Edit mode.
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Annotation
the Y axis, and which of those will be labeled. The actual label
values will depend on the minimum and maximum range
values entered in the Setup group.
For example, assume that you want to display torque from 0 to
500, label every 100 ft-lbs, and have a tick mark every 20 ft-lbs.
Determine how many tick marks are needed using the following formula:
In this case, ((500 - 0) / 20) + 1 = 26 tick marks. Now divide the
label interval by the tick mark interval to determine which tick
marks should be labeled. In the example case, 100 / 20 = 5.
Therefore, enter 26 for the number of tick marks, and label
every 5th tick.
the Y axis. Selecting the Minor tick lines check box will add grid
12.17.6.
NOTE
Since there can be up to 4 channels being plotted, the annotation used may
look fine for some channels, but not necessarily all. For example, using the
annotation of 26 tick marks and label every 5th tick from the Annotation
example above, suppose one of the other channels was coolant temperature
with a range from 50 to 260 deg. F. In this case, values of 92, 134, 176, and 218
deg. F would appear on the Y axis. A simple way to change these value such
that they are divisible by 10 would be to change the lower range from 50 to 60
deg F. In this case , Y axis values of 100, 140, 180, and 200 would appear.
XY Dialog Box - X Channel
U I D E
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M a n u a l
The tabbed page labeled X Channel contains the Setup and

Annotation options as shown in the illustration above.
Setup
The button labeled Channel: can be used to select the channel to be used for the X-axis. The Select Channel dialog box
will appear when clicking on the channel button. Enter the
range starting and ending values into the edit boxes labeled
start at and end at, respectively.
Annotation
the X axis, and which of those will be labeled. The actual label
values will depend on the start at and end at values entered in
the Setup group.
For example, assume that you want to create a graph to
display engine speed from 2000 to 8000 rpm, label every 1000
rpm, and have a tick mark for each 100 rpm. Determine how
many tick marks are needed using the following formula:
In this case, ((8000 rpm - 2000 rpm)/100 rpm) + 1 = 61 tick
marks. Now divide the label interval by the tick mark interval
to determine which tick marks should be labeled. In the
example case, 1000/100 = 10. Therefore, enter 61 for the
number of tick marks, and label every 10th tick.
the X axis. Selecting the Minor tick lines check box will add grid
12.17.7.
XY Dialog Box - Start Trigger
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The tabbed page labeled Start Trigger contains the Mode and
Trigger Parameters options as shown in the illustration above.
This tabbed page allows for the definition of the conditions that
will cause the plot window to start plotting.
Mode
Selecting the Continuous radio button will cause the plot to be
free-running, with no starting trigger. Selecting the Event radio
button will allow the entry of conditions that must be met
before the plot window will start plotting.
Trigger Parameters
Select the channel to use for the source of the trigger. The
Select Channel dialog box will appear when clicking on the
channel button. Select one of the four comparators, <, <=, >=,
or >. The selected channel may be compared to an entered
data value or another data channel. To compare to a data
value, select the Entered Data radio button and enter the data
value in the accompanying edit box. To compare to another
data channel, select the Channel radio button and click the
accompanying channel button to get the Select Channel dialog
box to appear. Note that the channel button will disappear and
the edit box appear when the Entered Data radio button id
selected while the opposite occurs if the Channel radio button
is selected.
If a digital channel was chosen for the source of the trigger,
only an entered data value can be compared to it, therefore,
the Entered Data and Channel radio buttons are grayed. Enter
the value for the digital channel to be compared to into the edit
box above the Entered Data radio button. Only values of 1 or 0
are to be used for digital comparisons. These digital values
may be set by an autotest or external condition depending on
your system
For example, the above illustration has the start trigger set up
such that data will begin plotting when the Speed channel is
greater than or equal to 2500 RPM.
U I D E
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12.17.8.
M a n u a l
XY Dialog Box - Stop Trigger
The tabbed page labeled Stop Trigger contains the Mode and
Trigger Parameters options as shown in the illustration above.
This tabbed page allows for the definition of the conditions that
will cause the plot window to stop plotting.
Mode
Selecting the Never radio button will cause the plot to be freerunning, with no stop trigger. Selecting the Event radio button
will allow the entry of conditions that must be met before the
plot window will stop plotting.
Trigger Parameters
The stop trigger parameters are setup the same way as the
start trigger parameters. See the details of the Trigger Parameters option for the Start Trigger tabbed page above.
An example for setting up a stop trigger can be seen in the
above illustration. This illustration has the stop trigger set up
such that data will stop plotting when the Speed channel is
greater than 7500 RPM.
12.17.9.
XY Dialog Box - Title

the X-Y plot a title.
12.18.
12.18.1.
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Panel Indicator Configuration
Panel Indicator Display

Each WinDyn Tabular Display object allows you to monitor
the ON/OFF status of a system parameter during testing.
12.18.2.
Panel Indicator Display Dialog Box

This dialog box allows you to configure the run-time characteristics for digital panel indicator displays. Digital panels are
typically used to display various system status conditions (ON/
OFF).
U I D E
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12.18.3.
M a n u a l
Dialog box options

On Text
Enter the text that will be displayed when the digital input or
relay is set to 1, the on state.
On Color
Left-click inside the accompanying rectangle to select a color
which will be displayed when the digital input or relay is set
to 1, the on state.
Off Text
relay is set to 0, the off state.
Off Color
that will be displayed when the digital input or relay is set to
0, the off state.
Input Source
If this panel indicator is to display the state of a digital input,
select the Digital input radio button. If this panel indicator is to
display the state of a digital relay, select the Digital relay radio
button.
Input Number
Enter the number of the digital input or relay to be associated
with this panel indicator.
12.19.
Push Switch Configuration
12.19.1.
Push Switch Display
12.19.2.
Push Switch Display Dialog Box

This dialog box allows you to configure the run-time characteristics for digital relay switches. Digital relay switches are
typically used to turn ON/OFF various system functions.
12.19.3.
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Dialog box options

On Text
Enter the text that will be displayed when the digital relay is
set to 1, the on state. The button will appear depressed in the
on state.
Off Text
Enter the text that will be displayed when the digital relay is
set to 0, the off state. The button will appear raised in the off
state.
Switch Type
If the switch is to turn a relay on only while it is depressed
(such as a starter switch), select the Momentary radio button. If
the switch is to turn a relay and leave it on once it is depressed (such as an ignition switch), select the Push on/push
off radio button.
Output Relay Number
Enter the number of the relay which will be associated with
this switch.
U I D E
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12.20.
M a n u a l
Push Switch with Indicator Configuration
12.20.1.
Push Switch with Indicator Display
12.20.2.
Push Switch with Indicator Display Dialog Box

The Push Switch with Indicator display dialog box is accessed
by clicking the Right Mouse Button over a Push Switch with
Indicator Display Object during Edit mode. This dialog box
allows you to configure the run-time characteristics for combination digital panel indicators with push switches. Digital
panels are typically used to display various system status
conditions (ON/OFF). Digital relay switches are typically used
to turn ON/OFF various system functions. There are 2 tabbed
pages containing the display features that can be accessed.
These tabbed pages are identical with those of the panel
indicators with push switches.
12.20.3.
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Panel Indicators with Push Switches - Panel Indicator

The tabbed page labeled Panel Indicator contains the Panel
Indicator options as shown in the illustration above.
On text
relay is set to 1, the on state.
On color
1, the on state.
Off text
relay is set to 0, the off state.
Off color
0, the off state.
Input source
If this panel indicator is to display the state of a digital input,
select the Digital input radio button. If this panel indicator is to
display the state of a digital relay, select the Digital relay radio
button.
Input number
Enter the number of the digital input or relay to be associated
with the panel indicator.
12.20.4.
Panel Indicators with Push Switches - Push Switch
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On text
Enter the text that will be displayed when the digital relay is set to
1, the on state. The button will appear depressed in the on state.
Off text
Enter the text that will be displayed when the digital relay is set
to 0, the off state. The button will appear raised in the off state.
Switch type
If the switch is to turn a relay on only while it is depressed
(such as a starter switch), select the Momentary radio button. If
the switch is to turn a relay and leave it on once it is depressed (such as an ignition switch), select the Push on/push
off radio button.
Output relay number
Enter the number of the relay which will be associated with
the switch.
12.21.
12.21.1.
Video Display Configuration
Video Display
The WinDyn Video Display object allows you to view live
video from either a Video Camera or a VCR directly on your
computer monitor. This live video can be viewed at the same
time you view test data as a test is running.
NOTE
1.
2.
This display object works only in conjunction with additional hardware.

It has only been tested with the Videologic DVA-4000 overlay card.
Only one (1) video display may be active at a time.
12.21.2.
I N
Y N
E F E R E N C E
Video Display Dialog Box

over a Video Display Object during Edit mode. This dialog box
allows you to edit the Video Display Objects run-time characteristics.
12.21.3.
Video Dialog Box - Video Setup

Video Source
If the video source is a camera or VCR without RS232 tape
transport control, select the Video camera radio button. If the
video source is a VCR with RS232 tape transport control (such
as the Panasonic AG5700), select VCR. This will cause the
tape transport buttons to be displayed.
Dual VGA Card
If WinDyn is to be run on a dual-screen Colorgraphics
system, checking this box will cause the video window display
coordinates to be adjusted for better alignment.
Acquisition Source
Only the Videologic DVA-4000 overlay card has been used with
this system, so capture card is disabled. Capture card ability
may be added in future releases.
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12.22.
12.22.1.
M a n u a l
Remote Status Display Configuration
Remote Status Display

The WinDyn Remote Status Display object allows you to
monitor the status of a remote hardware device during testing.
12.22.2.
NOTE
This display is only used on systems that have serial communication with a
remote device such as an Engine Control Module (ECM) or emissions reading
device.
Remote Status Display Dialog Box

over a Remote Status Display Object during Edit mode. This
dialog box allows you to edit the Remote Status Display
Objects run-time characteristics.
12.22.3.
I N
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E F E R E N C E
Dialog box options

Window Title
In this dialog box enter any text you would like to give the
status display a title.
Background Color
Left-click inside the accompanying box to choose a color that will
serve as a background color for the text region of the display.
12.23.
12.23.1.
Background Bitmap Configuration
Background Bitmap Display

The WinDyn Background Bitmap Display object allows you to
have any BMP file used as a background for a screen. More than
one bitmap can be used per screen. Overlapping other display
objects with a background bitmap will always result in the
display object being on top of the bitmap. The following illustration uses several tabular display objects over the bitmap.
U I D E
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12.23.2.
M a n u a l
NOTE
Bitmap files can be directly read into the paint program provided by Windows.
The paint program, and other graphics programs, can be used to enhance
existing bitmaps or create new bitmaps.
Background Bitmap Display Dialog Box

Bitmap files with many colors (photos) display much better in
the higher color modes. If your high color bitmap displays
have bands and/or incorrect color representations, try changing the color palette display properties of Windows to High or
True color mode. If the color palette is set to 256 colors,
Windows will use the first 256 colors that it finds in the image
and then try to match the rest of the colors to those 256 colors.
This will cause color banding and mismatches in the high
color displays.
This dialog box allows you to configure the run-time characteristics for the background bitmap.
12.23.3.
Background Bitmap - Style

Select Keep aspect ratio to keep the image height to width
ratio intact. Select Stretch to fit window area to have the
bitmap stretched to fit into the current window. The following
illustrates these styles:
12.24.
I N
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E F E R E N C E
XY-Reference Plots
The Reference Plots feature, available for WinDyn XY-Real

Time plots, allows you to display up to two (2) reference plots
(that is, previous tests) on the same display that shows your
current test as it is running.
Reference plots are useful for quick, visual test comparisons
and for displaying Min/Max tolerance conditions. For example,
in the illustration below, the data plotted has a noticeable dip
in the torque and power from about 3950 to 4050 RPM when
compared to the reference plot.
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13
WinDyn
Stored Data Viewer
13. WinDyn Stored Data Viewer

13.1.
What is the Stored Data Viewer? .......................................................... 3
13.2.
View Test Data (File Commands) .......................................................... 4
13.3.
Printing Test Data .................................................................................. 4
13.4.
Plotting Test Data .................................................................................. 5

13.4.1.
13.4.2.
13.4.3.
Overview ...................................................................................................... 5
Plot Window Main Menu... ............................................................................ 5
Using the Data Cursor ................................................................................... 6
13.5. View Data as Recorded (Auto-Refresh) .................................................... 8

13.5.1.
13.5.2.
Auto data refresh .......................................................................................... 8

Refresh Current Data .................................................................................... 8
13.6. Export Data (*.CSV) .................................................................................. 8

13.7. Exporting OLE Plots .................................................................................. 9
13.7.1.
13.7.2.
Overview ...................................................................................................... 9
Example ....................................................................................................... 9
13.8.
Convert (*.DDF) file to (*.SFD) ............................................................ 10
13.9.
Viewing WinDyn Current Data ........................................................ 10

13.9.1.
13.9.2.
13.10.
Leave data viewer running .......................................................................... 10

Terminate Stored Data Viewer ..................................................................... 10
Column Averages, Minimums, Maximums ......................................... 11
13.11. Averaging Test Data ................................................................................. 11

13.11.1. Overview .................................................................................................... 11
13.11.2. Sequence ................................................................................................... 12
13.11.2.1.Selecting Data Files To Average ........................................................... 12
13.11.2.2.Selecting the Average Reference Channel (Non-NGE systems only) ... 12
13.11.2.3.Saving the Averaged Data ................................................................... 13
13.11.2.4.Deleting the Source Files ..................................................................... 14
13.11.2.5.Displaying the Averaged Data .............................................................. 14
13.11.2.6.Adding the Averaged Data to the Database .......................................... 15
13.11.3. Test Description ......................................................................................... 15
13.11.3.1.
Average Engineering Details ....................................................... 16
13.12. Post Processing Data .............................................................................. 17

13.12.1. Overview .................................................................................................... 17
13.12.2. Filter Measured Data Channel(s)... .............................................................. 18
13.12.3. Update Specification Values ....................................................................... 20
13.13. Plot Preferences ...................................................................................... 21

13.13.1. Overview .................................................................................................... 21
13.13.2. Display Tab ................................................................................................. 22
13.13.2.1.Y-Axis .................................................................................................. 22
13.13.2.2.Legend ................................................................................................. 22
13.13.2.3.Line Color ............................................................................................ 23
13.13.2.4.Annotation Position (X-Axis) ................................................................ 23
13.13.3. X-Axis Tab .................................................................................................. 24
13.13.3.2.Display ................................................................................................ 24
13.13.3.3.Draw Order .......................................................................................... 24
13.13.4. Left Y-Axis Tab ............................................................................................ 25
13.13.4.2.Mode ................................................................................................... 25
13.13.4.3.Minor Grid ............................................................................................ 25
13.13.5. Right Y-Axis Tab .......................................................................................... 26
13.13.5.2.Mode ................................................................................................... 26
13.13.5.3.Major/Minor Grid .................................................................................. 26
13.13.6. Grid Style Tab ............................................................................................. 27
13.13.7. Custom Title Tab ......................................................................................... 27
13.13.8. Printing Tab ................................................................................................. 28
13.14. Description of the Stored Program Terminology ....................................... 28
13.1.
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A T A
I E W E R
What is the Stored Data Viewer?
The WinDyn Stored Data Viewer allows you to view and plot
both Recorded and Disk test data. You may print both the
numeric data and the graphical plot.
The Stored Data Viewer will allow you to Column Average a
single test over a specific range (for example, 4500 - 5500 rpm).
You may also choose to view the Minimum or Maximum data
values for that range.
To display the following Pop-Up menu,
Place the mouse cursor over the data area and single-click the
right mouse button (or simply press the Q key). This Pop-Up
menu gives you quick access to many of the Stored options
available to you, such as print, average, plot, and help.
Using the Auto data refresh option, the Stored Data Viewer
will allow you to view test data on the computer as it is being
recorded in the dyno.
The Edit Test Description option allows you to enter the
custom test notes (i.e., comments) that will be saved along
with test data each time you save data to disk.
The Export option allows you to convert a SuperFlow data file
(*.SFD) to a Comma Separated Variable (*.CSV) data file,
which may be easily imported into most spread sheet
programs (e.g., Excel) for analysis.
The OLE Export Plot option allows WinDyn data plots (graphs)
to be exported as OLE (Object Linking and Embedded) Objects.
This means you can cut and paste a WinDyn data plot into an
application like Microsoft Word or Microsoft Excel and still
view and modify the plot as if it was running under WinDyn.
The remaining topics in this help file explain in detail the
various options and capabilities of the WinDyn Stored Data
Viewer.
Section 13- Page 3
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13.2.
View Test Data (File Commands)
The File commands offer the typical controls one expects

when using a file based program. The options under File are
as follows:
Saved Test...
Open
Displays a test data file which is saved on the computers hard

drive disk.
Current Test...
Displays the test data which is currently saved in the Dynos
memory.
Save
Saves to computer disk the test data which is currently saved
in the Dynos memory. This command is only enabled when
you are viewing the data saved in the Dynos memory.
Save As...
Allows you to rename an existing test data file. This command
is only enabled when you are viewing a data file saved on the
computer disk.
Close
Clears the display of any test data which may be showing.
Exit
Exits the WinDyn Stored Data Viewer.
13.3.
Printing Test Data
To print the displayed data, select File|Print... from the stored

main menu (or click on the Print
icon in WinDyn ,). If
Prompt Before Print is checked, then this dialog box will pop
up allowing you to select what data will print. Otherwise,
printing will begin immediately based on the settings last
used.
Section 13 - Page 4
13.4.
13.4.1.
NOTE
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A T A
I E W E R
To print a graphical plot, first display the plot window via Window|Plot, and then
simply select File|Print Plot... from the plot window main menu.
Plotting Test Data
Overview
To plot the displayed data, simply select Window|Plot... from
the stored main menu (or click on the Plot
icon). A plot
window will appear and the data channel(s) selected in the
active Channel Order will be automatically plotted. To easily
change which channels are plotted, select Edit|Channel
Order from the stored main menu, select the new channels to
plot using the checkbox on the right, and then press the Apply,
OK, or Save button. To edit the plot preferences, select
Options|Preferencesfrom the plot window main menu.
13.4.2.
Plot Window Main Menu...

Overlays
To overlay multiple tests, select File|Open Overlay Plot.
Highlight the file(s) you want to overlay, and press OK. Up to
nine (9) overlay files are allowed (for a total of ten (10) files
plotted in the window at one time). You may select more than
Section 13 - page 5
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one overlay file name at a time by dragging the mouse with the
left button down, or holding the Ctrl key and selecting the file
names with the left mouse button. To remove one or all overlay
file(s), select File|Close Overlay Plot.
Printing
To print the current plot, simply select File|Print Plot...If the
grid does not print properly, modify it (make it darker or use a
different grid style) using the Options|Preferences... Grid tab.
To select whether the plot is printed in Portrait or Landscape
mode, use the Options|Preferences Printing tab.
Zooming
To zoom in on a specific area of the plot, hold down the Left
Mouse button and drag the mouse. Position the rubber-band
box (which appears when dragging) over the area of interest
and let up on the mouse. The plot will zoom in to the area you
selected with the box. Once you have zoomed in, you may
toggle the zoom in and out using the View|Zoom command (or
press Alt+Z). If a plot is currently in a zoom view, the word
(Zoomed) will appear in the title bar at the very top of the
plot window.
13.4.3.
NOTE
Each of the available plot pages maintains its own zoom view.
Using the Data Cursor

The plot window has a single data cursor which you can use to
identify the test, channel, and value of any data point on the plot.
Section 13 - Page 6
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A T A
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To mark the actual data points, display the plot window popup menu by clicking the right-mouse-button over the plot area,
and then select mark data points. Now activate the data
cursor by clicking the left-mouse-button once on a data point;
this positions the data cursor cross-hairs on that point. There
are two cursor position indicators. The upper left hand
corner shows the data points (x, y) value (that is, both horizontal & vertical plot values); the upper right hand corner identifies the test and channel. The keyboard left-right arrow keys
move the cursor from point to point; the up-down arrow keys
move the cursor from channel to channel. Also, you may
double-click (click twice in rapid succession) the left-mousebutton on any point in the plot area to see the value for that
point displayed next to the point. To hide the data cursor,
select ViewCursor from the plot window main menu.
Pop-Up Menu
To display the Pop-Up menu, place the mouse cursor over the
plot area and single-click the right mouse button (or simply
press the Q key). This Pop-Up menu gives you quick access
to many of the plot configuration options available to you, such
as colors, plot styles, and fonts.
Specifications
To select which specification channels are displayed at the top
of the plot window, select Edit|Plot Specifications...
NOTE
You may select different specifications channels to display on each of the Plot/
Data pages.
Section 13 - page 7
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Tile Windows
To quickly view both the test data and the test plot, select
Window|Tile Vertical which will arrange the 2 windows on
the screen for you. Also, the F12 key may be used to both
display the plot window and tile the 2 windows all with one
keystroke
13.5.
View Data as Recorded (Auto-Refresh)
13.5.1.
Auto data refresh

The Auto-Refresh option allows you to view test data on the
computer as it is being recorded in the dyno. To turn Auto-refresh
on, simply select Options|Auto data refresh from the Stored
main menu. To turn it off, re-select the same menu option.
13.5.2.
Refresh Current Data

Re-displays the test data which is currently saved in the
Dynos memory. Use this command, if needed, to force a
refresh of the data the dyno may have recorded since you
initially viewed the current test data.
13.6.
NOTE
Auto Data Refresh works most efficiently when there is NO WinDyn current
data display screen active. WinDyn will prompt you if this is the case.
Export Data (*.CSV)

The Export option allows you to convert a SuperFlow data file
(*.SFD) to a Comma Separated Variable (*.CSV) data file,
which may be easily imported into most spread-sheet
programs (for example, Microsoft Excel ) for analysis.
To Export a SuperFlow data file, first load the file you wish to
convert into stored as follows: select File|Open|Saved Test...
from the data window main menu, select the desired file to
convert, and click OK. Now convert the file just loaded to the
*.CSV format as follows: Select File|Export... from the data
window main menu, enter the desired name of the resultant
*.CSV file, and click OK. The *.CSV file is then created and
saved on disk.
NOTE
Section 13 - Page 8
You cannot view *.CSV files with the WinDyn Stored Data Viewer.
13.7.
Exporting OLE Plots
13.7.1.
Overview
I N
Y N
T O R E D
A T A
I E W E R
WinDyn data plots (graphs) can be exported as OLE (Object

Linking and Embedded) Objects. This means you can cut and
paste a WinDyn data plot into an application like Microsoft
Word or Microsoft Excel and still view and modify the plot as
if it was running under WinDyn.
13.7.2.
Example
The following example demonstrates step-by-step how to
export a WinDyn plot as an OLE object into a Microsoft Word
document.
1.
Display the WinDyn plot you wish to export (from the

WinDyn main menu, select Analyze|View Saved Test, select
the desired test, then press F12 to plot it).
2.
From the plot window main menu, select File|Export Plot. An

export dialog (like the one pictured below) will appear. In the
export group at the top of the box, select Embedded Object.
Then click the Export button at the bottom right of the box.
3.
Now switch to Microsoft Word, open the document you wish

to paste the plot OLE object into, and position the cursor in the
location you wish the plot to appear.
Section 13 - page 9
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13.8.
4.
From the Microsoft Word main menu, select Edit|Paste

Special which will display a Paste Special dialog. In the
Paste Special dialog, select PE OLE-Mini Server Object (not
Picture), and then click OK.
5.
The OLE plot now appears in your document. You can now
resize it or double-click the left mouse button on it to edit its
properties.
Convert (*.DDF) file to (*.SFD)
The Convert option allows you to convert old Stored data files
(*.DDF), which were created before WinDyn, to a form which
the Stored Data Viewer can use (*.SFD). To convert a file,
select File|Convert DDF file to SFD... from the Stored main
menu. Next select the *.DDF file you wish to convert and click
on OK
NOTE
1.
2.
13.9.
This conversion utility only works on data files created using the
SuperFlow 74x(xx) series of dynamometers (not SF901 or SF7100).
The configuration (*.CFA) file which was in effect when the *.DDF file
was created must be in the configuration path as the *.DDF file you
wish to convert.
Viewing WinDyn Current Data
The following explains how to switch back to viewing

WinDyn Current Data.
13.9.1.
Leave data viewer running

Select Window | Current Data from the main menu OR
Use Alt-Tab or Ctrl-Esc to access other running applications,
including WinDyn.
13.9.2.
Terminate Stored Data Viewer

Select File | Exit from the main menu.
13.10.
I N
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T O R E D
A T A
I E W E R
Column Averages, Minimums, Maximums
Anytime while viewing test data, you may press the F5 function key to view the Column Data window.
This window shows the column Averages, Minimums, and

Maximums for a particular data range. The information shown
is for the currently displayed page of test data; switch to any of
the available test data pages to view the Column Data information for that particular page. Printing the column data can be
enabled from the Print Setup dialog box (select File|Print
Setup from the stored data window main menu).
NOTE
For instructions on how to average multiple tests together into a single test, see
the Averaging Test Data topic.
13.11. Averaging Test Data
13.11.1.
Overview
WinDyn allows you to mathematically average the data from
multiple tests into a single data file. You may then display,
plot, and print the averaged data just as you would any other
data file. For instructions on how to average the column data
from a single test, see the Column Averages, Minimums,
Maximums topic.
SF-602
13.11.2.
M a n u a l
Sequence
13.11.2.1. Selecting Data Files To Average

To average test data, select File|Average|Tests from the data
window main menu. Highlight the files you want to average,
and press OK. Up to ten (10) files may be averaged together.
You highlight more than one file at a time by dragging the

mouse with the left button down (or holding down the Ctrl Key
and selecting the file names with the left mouse button).
13.11.2.2. Selecting the Average Reference Channel (Non-NGE systems only)
WinDyn data must be averaged with respect to a reference
channel. Requiring a reference channel allows WinDyn to
automatically adjust for un-aligned data files. An example of
un-aligned data is shown below, where the EngSpd column is
off by 100 rpm between the two data sets:
For the above example, if EngSpd is selected as the average

reference channel, WinDyn will automatically align the data
and average the common range from 3100 rpm to 4000 rpm.
The average reference channel is selected from the box below.
If WinDyn cannot use the currently selected average referSection 13 - Page 12
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ence channel, the OK button will be disabled until a new valid

reference channel is selected.
NOTE
The channel LineNo (Ch. #231) is always a valid average reference channel,
and can be reliably used if the data files are already aligned.
NOTE
SuperFlow NGE systems (those that communicate on a network) do not use a

reference channel when averaging tests. Data files must be already aligned
before averaging.
13.11.2.3. Saving the Averaged Data

Once you select a valid reference channel and click OK, the
data will be quickly averaged. A box appears prompting you to
enter a file name for the averaged data.
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A default name is provided, so simply click OK to save the

averaged data to disk (you may save the data under a different
name if you wish).
13.11.2.4. Deleting the Source Files
Next, a dialog box similar to the one below appears giving you
the option to delete the original data files used to create the
resulting averaged data file. The files which will be deleted
are listed. Click on No if you DO NOT wish to delete any files.
This dialog box can be set to NEVER display (and no files will
be deleted) by unchecking the box labeled Always display
this dialog box., or by selecting File|Average|Prompt to
delete files from the Stored Data Viewer main menu so that it
is unchecked.
If you know you will never use the original data files, and you
wish to PERMANENTLY remove them from your computer
disk, click on Yes (Delete) and the listed data files will automatically be deleted.
13.11.2.5. Displaying the Averaged Data
Next, a dialog box appears asking if you wish to display the
newly averaged data. Click Yes to display the averaged data.
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13.11.2.6. Adding the Averaged Data to the Database

Finally, a dialog box appears asking if you wish to add the
newly created averaged data file to the WinDyn database.
Click Yes to add to the database.
13.11.3.
Test Description
Information on the Averaged Data File (including the files from
which the averaged file was created) is listed in the Test
Description Notes of the averaged file. To view the Test Description Notes, select Edit|Test Description from the data
window main menu (or simply press F10). To edit the notes,
simply type in the desired text and click OK to save them.
# Restrictions
1. Files to be averaged must share a common configuration
(*.CFA).
2. The average reference channel must have exact even
increments between data lines (Note that LineNo, Channel
#231, will always work as a reference channel).
3. File Averaging is NOT supported for data files which
contain comment lines.
SF-602
13.11.3.1.
M a n u a l
Average Engineering Details

All SuperFlow SFD files are based on the 74x(xx) Data Record
format. When averaging SFD files, not all of the channels in a
74x(xx) Data Record are averaged. The following documents
which channels of a 74x(xx) Data Record are actually averaged:
1.
All measured channels from #1 through #76, including the

74x(xx) frequency channels #7 through #12.
2.
Runtime system channel #205 (RnTime).
3.
Fuel Mass (Gravimetric) system channel #206 (Fuel-M) .
4.
Specific Gravity system channels #209 through #210 (SpcGrv1,

& SpcGrv2).
5.
All Specification (Constant) channels #77 through #99.
6.
All Memory System Channels #220 through #230 (NGE systems

only).
7.
By default, all Calculated Channels whose values are derived

from the above channels will be automatically averaged.
All other 74x(xx) Data Record channels, including Time-of-Day
channels, Setpoints, Autotest Timers, and Interpolation tables
ARE NOT AVERAGED. The value resident in these unaveraged
channels will be identical to the values from the first data file
named in the list of source data files to be averaged.
An example averaged data plot is shown below:
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13.12. Post Processing Data
13.12.1.
Overview
WinDyn allows you to perform a limited number of Post
Process operations on your Data Files (such as filtering measured channels to reduce noise). The Post Process feature
creates a new Data File identical to the original Data File
except for the options you select. The new Data File is an
actual .SFD file, which means you can display and plot the
data, overlay the data on a plot, average the data, or perform
any other operation allowed on SuperFlow Data Files.
The example plot below shows a Post Processed Data File
overlaid on the original Data File, where the original Torque
channel has been filtered.
SF-602
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The remainder of this topic explains each of the available Post

Process operations.
13.12.2.
Filter Measured Data Channel(s)...

The Filter operation allows you to smooth any measured data
channel. The actual filter used is a moving window average.
The filter order (the amount of smoothing) is selectable.
To filter data, first open<+> the data file you wish to filter.
Next, select File | Post Process from the Stored Data Viewer
main menu. This will display the Post Process dialog box as
shown below.
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A T A
I E W E R
Save As:
Type in the name for the new data file. A default name is
provided. Click the browse button if you wish to select a
directory other than the default, or if you wish to select (and
overwrite) an existing .SFD file.
Filter Order:
Use the Up/Down arrows to select a filter order (a higher
number means more smoothing). Click the Suggest button to
let the software determine the best filter order for this data.
Note that the filter order maximum range is dependent upon
the data.
Channels to Filter:
Select (highlight) the measured channels you wish to smooth.
You can select more than one channel at a time by dragging
the mouse with the left button down (or by holding down the
Ctrl key and then selecting the file names with the left
mouse button). Click the Select All button if you wish to
smooth all measured channels. Click the Sort by Name check
box to display the available channels in a different order.
Test Description
Click on the Test Description tab if you wish to type in some
notes about the new data file you are creating.
OK Button
Once you have selected the name, filter order, and channels to
filter, click the OK button to create the new data file. The new
data file will be displayed automatically. The original data file
still exists and is not modified in any way.
SF-602
13.12.3.
M a n u a l
NOTE
Only measured channels can be filtered. Since each calculated channel may
reference several measured channels, the noise you wish to filter may be the
result of more than one channel. For example, if the system under test
calculates Engine Power (EngPwr) using the standard formula
EngPwr=EngSpd*EngTrq/5252, then the Engine Speed (EngSpd) and Engine
Torque (EngTrq) measured channels will each contribute some noise to the
resultant Engine Power. Since Engine Power in this example is a calculated
channel (it is not directly measured), you cannot filter it directly. Therefore, to
effectively filter Engine Power, you may need to filter both Engine Speed and
Engine Torque. Also note that if you filter Engine Speed and you are using
Engine Speed as the horizontal x-axis for your plots (a common scenario), the
plot appearance may change dramatically.
Update Specification Values

The Specifications (Bore, Stroke, etc.) that were in effect
during a test are stored as part of the test data file. These
Specifications are used to calculate various important values
(such as Corrected Power, Displacement, etc.). Once a data
file is saved, you cannot change the Specification values
stored in the data file. Using this Post Process feature, however, you can create a new data file (based on the original) that
has new Specification values.
You may wish to enter new Specification values for a couple of
reasons. For example, if you run a series of tests with incorrect
Specification value(s), you can fix the error and get the true
data without re-running the tests. Also, changing specification
values allows you to see the effect on your data using various
correction factors.
To update the value for any Specification channel(s), first
select File | Post Process from the Stored Data Viewer main
menu, then click on the Specifications tab. This will display
the Post Process dialog box as shown below.
I N
Y N
T O R E D
A T A
I E W E R
The value for each Specification channel is displayed (these

are the values that were in effect when you ran the test). You
may type in a new value for any Specification. Click on the
Load from File button if you wish to update all the displayed
Specification values with the Specification values stored in a
previously created Specification file (.CST file).
Test Description
Click on the Test Description tab if you wish to type in some
notes about the new data file you are creating.
OK Button
Once you have modified any desired Specifications, click the OK
button to create the new data file. The new data file will be
displayed automatically. Any changes you made to the displayed
Specification values are now entered in the new data file. The
original data file still exists and is not modified in any way.
13.13.
13.13.1.
Plot Preferences
Overview
From the plot window main menu, select
Options|Preferences to display the Plot Preferences dialog.
Each tabbed page on the Plot Preferences dialog allows you to
configure a different aspect of your WinDyn plots.
SF-602
13.13.2.
M a n u a l
Display Tab
13.13.2.1. Y-Axis
To use a second Y-Axis, select the Left and Right button and
press OK. When plotting data using both a Left and Right YAxis, channels are assigned to either the Left or Right Y-Axis
in the following manner: Think of the Channel Order Dialog
Plot-Checkboxes as being ordered from the top to the bottom.
The first half of the channels checked for this page will be
plotted with respect to the Left Y-Axis, and the remaining half
checked will be plotted with respect to the Right Y-Axis. If an
odd number of channels are checked, the greater number will
always appear on the Left Y-Axis.
Using a Left and Right Axis has two primary purposes:
1. Allows you to graphically compare channels which have
very different values (differ by some order of magnitude).
2. Using the Comparison plot style option, you may plot
data against the Left Y-Axis using one particular plot style
(such as Best Curve Fit), and then plot the same data
against the Right Y-Axis using a different plot style (such
as Cubic Spline). To modify the comparison plot styles,
select Options|Customize Plot..., then select the Plot
Style tab. The Plot Style box is for the Left Y-Axis, and
the Comparison Plot Style box is for the Right Y-Axis.
13.13.2.2. Legend
Configures how the channel description legends, which
display at the top of the plot window, will appear.
I N
Y N
T O R E D
A T A
I E W E R
Detailed (the default): Implies that every channel displayed on

the plot will have a complete legend entry to include the test
name, channel name, and channel units (example:
DEMO0001: EngPwr - hp). Also displayed is the line color (or
style) indicator applicable to each channel plotted.
Simple: When plotting several channels, the legend can get
crowded and hard to read. Use the simple option to display
only the test name and line color (or style) indicator.
13.13.2.3. Line Color
Configures how the plot uses line color (and line style) to
distinguish between different channels and different tests
(overlays).
Indicates Channel: Line color is the same for each channel
(e.g., all EngTrqs are red), and line style (e.g., solid, dashed,
dot) indicates the test (overlay).
Indicates Test (Overlay): Line style is the same for each
channel (e.g. all EngTrgs are dashed), and line color (e.g., red,
blue) indicates the test (overlay).
13.13.2.4. Annotation Position (X-Axis)
Selects where the channel names (annotations) will be displayed on the plot. When annotations are on (click rightmouse-button over plot to display popup menu and turn
annotation on or off), the channel names (e.g., EngTrq,
EngPwr) are displayed near the plot line(s) for that channel.
Try this option if some of the annotations dont display correctly in the currently selected mode.
Min/Max data points: For channels plotted against the Left YAxis, each channel name is displayed next to the Minimum
data point plotted for that channel. For channels plotted
against the Right Y-Axis, each channel name is displayed next
to the Maximum data point plotted for that channel.
First/Last data points: For channels plotted against the Left YAxis, each channel name is displayed next to the First data
point plotted for that channel. For channels plotted against the
Right Y-Axis, each channel name is displayed next to the Last
data point plotted for that channel.
SF-602
13.13.3.
M a n u a l
X-Axis Tab
13.13.3.1. Scaling and Range

Together, these determine how the plot is scaled for this axis.
Automatic: Plot is automatically scaled, fitting the plot window
to the channel with the greatest range for this axis. The
manual range values (Minimum and Maximum) are disabled.
Manual: Allows you to enter a specific Minimum and Maximum range for this axis.
13.13.3.2. Display
Bottom only: A single X-Axis is displayed at the bottom of the
plot.
Top and Bottom: In addition to the bottom X-Axis, a duplicate
X-Axis is displayed at the top of the plot.
13.13.3.3. Draw Order
This option controls what order the plot lines will be drawn
from data-point to data-point (i.e., connect the dots).
Unsorted (as recorded): Line is drawn from point to point in
the order the data was recorded.
Sorted: Line is drawn from point to point in order from the
minimum X-Axis data value to the maximum X-Axis data value.
NOTE
For large data sets (>= 200 data lines), the plotting time increases significantly
when the data is sorted.
13.13.4.
I N
Y N
T O R E D
A T A
I E W E R
Left Y-Axis Tab

13.13.4.2. Mode
Controls the scaling mode used for this Y-Axis. Default is
Linear. Logarithmic may be useful for data sets with a very
large Y-Axis range.
13.13.4.3. Minor Grid
Controls the minor grid markings for the Left Y-Axis. Tick
marks displays small ticks along the edge of the Y-Axis.
Gridlines displays lines across the entire plot.
NOTE
Grid Lines must be enabled for this option to take effect. To enable Grid Lines,
click the right-mouse-button over plot to display the popup menu, and then
select Grid Lines|Both Y and X Axis.
SF-602
13.13.5.
M a n u a l
Right Y-Axis Tab

13.13.5.2. Mode
Controls the scaling mode used for this Y-Axis. Default is
Linear. Logarithmic may be useful for data sets with a very
large Y-Axis range.
13.13.5.3. Major/Minor Grid
Controls both the major and minor grid markings for the Right
Y-Axis. Tick marks displays small ticks along the edge of the YAxis. Grid Lines displays lines across the entire plot
NOTE
Grid Lines must be enabled for this option to take effect. To enable Grid Lines,
click the right-mouse-button over plot to display the popup menu, and then
select Grid Lines|Both Y and X Axis.
13.13.6.
I N
Y N
T O R E D
A T A
I E W E R
Grid Style Tab

The page allows you to select how the plot grid will appear on
all plots. This is useful if the grid does not appear properly on
your plot printouts.
13.13.7.
Custom Title Tab

Enter a Title or any other information here that you desire (for
example, your company name). The information entered here
will be displayed at the bottom of each WinDyn plot.
SF-602
13.13.8.
M a n u a l
Printing Tab
Select the desired Plot Print orientation, then click the Print
button to send the currently displayed plot to the printer. The
selected orientation will be saved until you change it.
13.14.
Description of the Stored Program

Terminology
Apply
Saves displayed dialog box settings for future printing and
closes the dialog box (does NOT print any data).
Cancel
Ignore all dialog box changes and close dialog box
Change
Sets the Current value of the highlighted constant channel to
the value specified in the New value box.
Colors
Left-click mouse in color box to select a new color.
Done
Closes this dialog box (does NOT modify any data).
Help
References the help topic for this dialog box.
Print
Prints the data and number of pages currently selected in this
dialog box.
Printer Options...
Allows you to choose a specific printer and/or change the
options for printing.
Zero
Forces to zero (0.0) the value of the selected (highlighted)
channel.
Zero All
Forces to zero (0.0) the value of ALL channels in the displayed list.
14
WinDyn
DataLib Program
14. WinDyn DataLib Program

14.1. Description ................................................................................................ 3
14.2. Test Sequence ........................................................................................... 3
14.3. Add existing record to database ................................................................ 4
14.3.1.
14.3.2.
14.3.3.
14.3.4.
14.3.5.
14.3.6.
Add existing record to database .................................................................... 4

Automatic feature ......................................................................................... 4
Modifying a database record ......................................................................... 4
Adding a picture to a database record. .......................................................... 4
Deleting a picture from a database record ..................................................... 5
Delete record from database ......................................................................... 5
14.4. Database Navigation ................................................................................. 5

14.4.1. Using the database cursor ............................................................................ 5
14.4.2. Viewing data associated with a database record ........................................... 6
14.4.3. Using the database edit control ..................................................................... 6
14.4.3.1.Database edit control ............................................................................... 6
14.4.3.2.Database edit buttons .............................................................................. 6
14.5. Database Reporting .................................................................................. 6

14.5.1.
14.5.2.
Concise Reports ........................................................................................... 6

Column reports ............................................................................................. 7
14.6. Searching the Database ............................................................................ 7

14.7. Sorting the Database ................................................................................. 8
14.8. Database Field Description ....................................................................... 8
14.8.1
14.8.2.
14.8.3.
14.8.4.
14.8.5.
14.8.6.
14.8.7.
Owner Tab ..................................................................................................... 8

Test Device Tab ............................................................................................ 9
Miscellaneous Tab ...................................................................................... 10
Comments Tab ............................................................................................ 10
Test Information Tab .................................................................................... 11
Picture Tab .................................................................................................. 11
Grid Tab ...................................................................................................... 12
14.9. Return to WinDynTM current data screens ................................................. 12

14.10. Return to WinDynTM stored data viewer .................................................... 12
14.1.
I N
Y N
A T A
I B
R O G R A M
Description
The WinDyn DataLib program is an application designed to assist
the user in the management and archiving of stored data files.
Whenever test data is stored to disk, information about the test
can be stored in a database table. The user can then review all
test records which have been saved, and even search for
specific records based on such things as owners name, device
id number, work order, etc.
The DataLib program works in concert with the WinDyn and
Stored programs.
14.2.
Test Sequence
The typical testing process involves the following steps:
1.
Record data about the unit under test and the test conditions.
2.
Select test to perform
3.
Run the test
4.
Archive the test results
5.
Analyze the test results
6.
Print the test results

The DataLib program is designed to assist the user in accomplishing steps 1 and 4 of this test sequence.
Section 14 - page 3
SF-602
M a n u a l
14.3.
Add existing record to database
14.3.1.
Add existing record to database

To add an existing file to the database,
14.3.2.
1.
Select File|Add data file from the main menu.
2.
Select the desired file from the displayed dialog box.
3.
Update any information into the edit fields as re quired.
4.
When all changes have been made, save the record by

clicking onthe Save edit button or select Edit|Save
record from the main menu.
Automatic feature
Every time a data file is saved to disk, a new record will be added
to the database. This makes it convenient to quickly make
multiple runs and add them to the database automatically.
Before saving test data, make sure that the information displayed in the DataLib program is current. This information can
be edited later, if changes need to be made.
14.3.3.
Modifying a database record

To change the data in one of the database records:
14.3.4.
1.
Select it as the current record.
2.
Press the Edit button or select Edit|Edit Record from

the main menu.
3.
Make any changes desired.
4.
Click on the Save button, or select Edit|Save Record

from the main menu.
Adding a picture to a database record.

Virtually any standard Windows format (.BMP) bitmap format
files may be added to a record:
Section 14 - Page 4
1.
2.

the main menu.
3.
Select the Picture tab.
4.
Select the Browse button, or enter the name of the

bitmap file name.
5.
Click on the Save button, or select Edit|Save record

from the main menu.
14.3.5.
I N
Y N
A T A
I B
R O G R A M
Deleting a picture from a database record

To delete a picture from the test record:
14.3.6.
1.
Select the desired record.
2.

the main menu.
3.
4.
Select the Delete Image button.
5.

from the main menu.
Delete record from database

To delete a record from the database:
14.4.
14.4.1.
1.
Select the record to delete.
2.
Select Edit|Delete Record from the main menu or

switch to the grid page and press the Delete button.
3.
Answer Yes to delete the current record.
4.
You will be prompted to delete the corresponding data

file. Answer Yes or No.
Database Navigation
Using the database cursor

The database maintains a cursor (pointer) to a record in the
database table. This is the current record. This cursor can be
moved by using the First / Previous / Next/ Last buttons of the
Navigator control.
In addition, on the Grid page the cursor can be moved by
using the Page Up / Page Down / Up Arrow / Down Arrow
keyboard buttons. The current record will be highlighted.
Navigator Control
Navigator Buttons
Moves database cursor to first record.
Moves database cursor to previous record.
Moves database cursor to next record.
Moves database cursor to last record.
Section 14 - page 5
SF-602
14.4.2.
M a n u a l
Viewing data associated with a database record

To view the test data associated with a particular database record,
click on the Test Data button, or select View|Test data from the
main menu. The Stored data viewer program will be activated and
the data file will be automatically loaded for display.
14.4.3.
Using the database edit control

In addition to the edit main menu items, the database edit
control provides a convenient way to edit the database fields.
14.4.3.1.
Database edit control
14.4.3.2.
Database edit buttons

Edit button, press this button to make changes to the current
record.
Save changes button, pressing this button will save any
changes made to the current record
Cancel changes button, pressing this button will abandon any
changes made to the current record.
14.5.
Database Reporting
The DataLib program can create and print Concise and Columnar reports.
14.5.1.
Concise Reports
A concise report is a short two page report containing information from the Owner tab, as well as any information from the
other tabbed pages selected by the user. You can also select
which page of test data to include with the report.
To configure a concise report
1. Select FileReport to display the Reports dialog box.
2. Select the Concise radio button.
3. Select Setup to display the Concise Report Setup dialog box.
4. Place a check mark in each check box that corresponds to
the data you want to include in the report.
Section 14 - Page 6
I N
Y N
A T A
I B
R O G R A M
5. The button to the right of the Data check box displays the
name of the Channel Order page that will be included in
the report. To change the Channel Order page, click on
this button. A new, Channel Order Selection dialog box
will be displayed. Check the desired data page and click
on the OK button to dismiss the dialog box.
6. Click on the OK button to dismiss the Concise Report
Setup dialog box. The report is now configured and ready
to view or print. Press the Preview button to see what the
report will look like before printing it, or press the Print
button to print the report immediately. You can also print
the report from the preview window.
7. When you are done printing, pres the Cancel button to
dismiss the Reports dialog box.
14.5.2.
Column reports
A column report is a summary report that contains a record for
each record in the database. Each record contains ownership
and contact information as well as the serial number and test
name.
To generate a column report:
14.6.
1.
Select FileReport to Display the Reports dialog box
2.
Select the Database summary radio button
3.
The report is now ready to view or print. Press the

Preview button to see what the report will look like
before printing it, or press the Print button to print the
report immediately. You can also print the report from
the preview window.
4.
When you are done printing, press the Cancel button

to dismiss the Reports dialog box.
Searching the Database

To help find a particular record, the DataLib program includes
a search function. You can search the database for a particular
record based on the owners last name, repair order number,
engine make, engine serial number, vehicle make, vehicle
model, and vehicle id number.
NOTE
Note theat on the tabbed pages some field headings are colored red. These are
the fields which can be searched.
Section 14 - page 7
SF-602
M a n u a l
To search the database for a record:
14.7.
1.
Select Search from the main menu
2.
Select the criteria to search for from the Select search

index drop-down list box.
3.
Enter the information to search the database for the

database for in the Enter value to search for edit box.
4.
Press the Search button. A dialog box will be displayed

informing you that an exact match has been found, or
that an exact match does not exist, and the currently
displayed record is the closest match found in the
database. If your exact match was not found, you can
use the navigator buttons to move through the database
to find the record of interest.
5.
When you are done searching the database, press the

Done button to dismiss the dialog box.
Sorting the Database

The database records can be sorted based on the same fields
used for searching the database. To sort the records in the
database, follow the instructions for searching the database.
Using the Grid page to view the sorted records makes it easy to
find the desired record.
14.8.
14.8.1
Database Field Description
Owner Tab
This page contains information about the owner of the unit
under test.
Last Name
The owners last name, this field is searchable, example Smith
First Name
The owners first name, example John
Address 1
First address line, example: 123 Maple Street
Address 2
Second address line, example: Suite 1A
City
City where owner lives, example: Colorado Springs
State
State where owner lives, example: CO for Colorado
Country
Country where owner lives, example: USA
Postal Code
Postal code for owners address, example: 80907
Telephone
Owners telephone number, example: (123) 456-7890
Contact
If the owner is a business, then this field could be used to

contain the name of the customer contact for this business,
example: Frank Doe
Searchable fields:
Section 14 - Page 8
Last Name
14.8.2.
I N
Y N
A T A
I B
R O G R A M
Test Device Tab

This page contains information about the system under test.
The unit may be only an engine, engine/transmission, or an
entire vehicle. Enter information into all applicable fields. Any
fields, which are not pertinent to the unit under test, can be
left blank, or filled with N/A for Not applicable.
Vehicle
Veh Make
Vehicle manufacturer, this field is searchable, example: Ford
Veh Model
Vehicle model, this field is searchable, example: F-150
Year
Year of vehicle manufacture, example: 1993
VIN
Vehicle identification number, this field is searchable,

example: ZGUVDAVFB2DM100162
ID no
Owners vehicle identification number, example: Unit12
Weight
Vehicle weight, example: 2 300 lbs
Mileage
Vehicle mileage, example: 89,456
Engine
Eng Make
Engine manufacturer, this field is searchable, example: Ford
Eng Model
Engine model, this field is searchable, example: 460
Type
Engine type, example: V-8
Eng Ser no
Engine serial number, example: DZ3879S47
Perf Spec
Performance specification number, example: 0T-1234
Transmission
Make
Transmission manufacturer, example: Ford
Model
Transmission model, example: C-6
Trns Type
Transmission type, example: 3-spd Auto
Drive Train
Axle Ratio
These entries typically would be used for chassis dynamometers

Drive axle ratio, example for 4.11 to 1: 4.11
Axles
Number of drive axles, example: 1
Tire Type
Type of tire on drive rolls, example for radial tires: RAD
Tire Size
Size of tire on drive rolls, example: P150x14
Tire Tread
Type of tire tread on drive rolls, example for mud & snow: M+S
Searchable fields: Veh Make, Veh Model, VIN, Eng Make, Eng
Model, Eng Ser no
Section 14 - page 9
SF-602
14.8.3.
M a n u a l
Miscellaneous Tab
This page contains fields for miscellaneous data about the unit
under test. Complete any fields as required. Any fields, which
are not pertinent to the under test, can be left blank, or filled
with N/A for Not applicable.
Accessories
Number of driven accessories, such as water pump,

alternator, etc. Example: 2
Combustion System
Type of combustion, e.g. direct or indirect injection,

Example: DI
Intake System
Intake system type, e.g. Turbocharged, Naturally

Aspirated, etc. Example: Turbo
Air Filter
Type of air filter, Example: Fram CA360
Governor
Governor Id for diesel engines, Example: Woodward
Fuel Type
Type of fuel used during test, Example: Exxon 97
Fuel Supply
Fuel supply type, e.g. Carb, Electronic Fuel Inj,

Throttle body fuel inj, Example: EFI
ECU ID
Control module identification, Example: Ford
Eprom ID
Control module eprom ID number, Example: 050696
Spark Plug ID
Type of spark plug used during test, Example:

CHAMP N11Y
Catalytic Converter
Indicates if test system has a catalytic converter,

Example: Yes
O2 Sensor
Type of Oxygen sensor, Example: Bosch LMS11
O2 Location
Location of Oxygen sensor, Example: Exh Manifold
Exhaust Description
Type of exhaust system, Example: Dual, Headers
Thermostat
Type of thermostat installed, Example: 180 degF
Coolant Type
of coolant used, Example: Zerex 50/50
Lubricant Type
of oil used, Example: Mobil 1
Oil Cooler
Indicate use of oil cooler, Example: Yes

Searchable fields
14.8.4.
No fields on this page are searchable.
Comments Tab
This page can be used to enter any comments that may be
applicable to this test. Up to 5280 characters may be entered.
In edit mode, the white region can be used as a simple text
editor.
Searchable fields
14.8.5.
I N
Y N
A T A
I B
R O G R A M
Test Information Tab

This page contains information about this particular test. The
following fields are underlined on the screen and will be filled
in automatically: Date, Time, Data Name, Data Filename,
Serial number, Cfa Filename, and Test Filename (obtained
from the currently loaded test group).
Repair Order
Number of customers repair order, example: RO56789
Date
The date the record is added to the database
Dyno Location
Location of dyno, Example: Dyno Cell #3
Dyno Operator
Name of dyno operator, Example: John Smith
System ID
Type of dyno system, Example: SuperFlow SF901
Cfa Filename
Name of system configuration file, Example: SF901A
Data Name
Name of saved data file without path information,

Example: Test0001
Time
The time the record is added to the database, Example: 13:04
Test Description
A short test description, Example: Slow acceleration
Test Type
The type of test used to record data, Example: 100rpm ramp
Test Serial No
Serial number of test in database, Example: 25
Test Filename
Name of test file used to perform system test, Example:

Ramp01
Data Filename
Name of data file including system path, Example:

c:\windyn\sf901\data
Searchable fields
Repair Order
Data Name
14.8.6.
Picture Tab
This page can be used to include a picture with the test
record. Use the Image Options radio buttons to display the
image as actual size or scale it to fit the display window.
Check the Show picture check box to display images in the
display window. If you use many large bitmap images with
your database records, the process of scrolling through the
database records may become slow. Unchecking this check
box will speed up the process.
To delete a picture from the test record:
1.
2.
Press the Edit button or select Edit|Edit record from

the main menu.
3.
4.
Select the Delete Image button.
5.

from the main menu.
SF-602
M a n u a l
Fit Window
Selecting this will cause the picture to be resized to fit the

display window.
Actual Size
Selecting this will cause the picture to be displayed using its

original size.
Show picture
Placing a check mark here will cause the picture to be dis

played automatically. (If your database has many pictures in
it, this can slow down the cursor movement through the
records of the database).
Delete Image
In edit mode, selecting this button will cause the image to be

deleted from the database record. See Deleting a picture from
a database record.
Browse
In edit mode, selecting this button will display a dialog box

that will allow you to select a bitmap file to be included with
the database record.
Picture filename
This is the path and file name of the bitmap file in the
database record.
Searchable fields:
14.8.7.
Grid Tab
This page provides a comprehensive view of the records in the
database. This can be a convenient way to look for a specific
record. Once the desired record is found, you can click on any
of the other tabbed pages to view the data for the current record.
Searchable fields:
14.9.
Return to WinDynTM current data screens
To view current data, press the
button on the tool bar or
select Window|Current Data from the main menu. This will

bring the current data screen to the top of the desktop and
make it the active window.
14.10.
Return to WinDynTM stored data viewer
To view stored data, press the
button on the tool bar or
select Window|Test Data from the main menu. This will bring
the test data viewer to the top of the desktop and make it the
active window.
15
WinDyn Test Editor
15. Test Editor

15.1. Overview ................................................................................................... 3
15.2. Test Profile Structure.................................................................................. 3
15.3. Test Profile Functions ................................................................................ 4
15.3.1.
15.3.2.
15.3.3.
15.3.4.
What does a test profile do? ......................................................................... 4

Device Control .............................................................................................. 4
Flow Control .................................................................................................. 4
Command Language ..................................................................................... 5
15.4. System Definition Considerations ............................................................. 6

15.4.1. Data Channel Assignment ............................................................................ 7
15.4.1.1. Sensors .................................................................................................. 7
15.4.1.2. Channels To Limit ................................................................................... 7
15.4.2. Operator Interaction in Test Profiles .............................................................. 8
15.4.3. Pause / Stop ................................................................................................. 8
15.5. Operator Data Input ................................................................................... 9

15.6. Data Management in Test Profiles ............................................................. 9
15.6.1.
15.6.2.
15.6.3.
Acquiring Data / Disk Space ......................................................................... 9

Printing ......................................................................................................... 9
Data Displays: WinDyn, PC, Handheld Controller ....................................... 9
15.7. Developing Test Profiles .......................................................................... 10

15.7.1. Writing the Test Profile ................................................................................ 10
15.7.1.1. Editor Interface ..................................................................................... 10
15.7.1.2. Opening the test profile editor ............................................................... 10
15.7.2. Test Profile Editor Display Screen ............................................................... 11
15.7.2.1. Test Profile Editor Key Functions .......................................................... 11
15.7.2.2. Test Description and Control Configurations .......................................... 11
15.7.2.3. Test profile command entry / editing ...................................................... 12
15.7.3. Saving the test profile ................................................................................. 13
15.8. Test Profile Commands Reference .......................................................... 13

15.8.1. RAMP Commands ...................................................................................... 13
15.8.1.1. Normal Ramp ........................................................................................ 14
15.8.1.2. Mode Change Ramp<R> ....................................................................... 15
15.8.1.3. Custom Ramp ....................................................................................... 15
15.8.2. SET Commands ......................................................................................... 17
15.8.2.1. Set Data Screen ................................................................................... 17
15.8.2.2. Set Data Filter ...................................................................................... 18
15.8.2.3. Set Timer .............................................................................................. 18
15.8.2.4. Set Counter .......................................................................................... 18
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15.8.2.5. Set Constant (Specification) ................................................................. 18

15.8.2.6. Set Setpoint .......................................................................................... 19
15.8.2.7. Set Limits On (Not Yet Implemented) .................................................... 20
13.8.3. BRANCH .................................................................................................... 20
13.8.3.1. GOTO ................................................................................................... 20
13.8.3.2. CALL .................................................................................................... 20
13.8.3.3. Repeat .................................................................................................. 21
13.8.3.4. Return ................................................................................................... 21
13.8.3.5. Wait ....................................................................................................... 21
13.8.3.6. Stop ...................................................................................................... 21
13.8.3.7. Input wait .............................................................................................. 21
15.8.4. ACTION ...................................................................................................... 22
15.8.4.1. Display ................................................................................................. 22
15.8.4.2. Display-Define Soft Key Labels ............................................................. 23
15.8.4.3. Print ...................................................................................................... 23
15.8.4.4. Alert ..................................................................................................... 25
15.8.4.5. Pause Test ............................................................................................ 25
15.8.4.6. Inc Counter ........................................................................................... 25
15.8.4.7. Dec Counter .......................................................................................... 25
15.8.4.8. Erase Memory ...................................................................................... 26
15.8.4.9. Roll Messages ...................................................................................... 26
15.8.4.10. Clr Messages ...................................................................................... 26
15.8.4.11. Keep Data ........................................................................................... 26
15.8.4.12. Exit Screen ......................................................................................... 27
15.8.4.13. Clear When Queue .............................................................................. 27
15.8.4.14. Config Cmd Line ................................................................................. 28
15.8.4.15. Graphics Function ............................................................................... 28
15.8.4.16. Load Limits File .................................................................................. 28
15.8.5. IF/WHEN .................................................................................................... 29
15.8.5.1. Overview of IF and WHEN commands .................................................. 29
15.8.5.2. If Data Channel ..................................................................................... 29
15.8.5.3. If Timer ................................................................................................. 30
15.8.5.4. IF counter ............................................................................................. 30
15.8.5.5. If data lines ........................................................................................... 31
15.8.5.6. When Data Channel .............................................................................. 32
15.8.5.7. When Limit Flag .................................................................................... 32
15.8.5.8. When Soft Key ...................................................................................... 33
15.8.6. RECORD .................................................................................................... 33
15.8.6.1. Record data line (Manual) ..................................................................... 33
15.8.6.2. No Automatic Recording ....................................................................... 34
15.8.6.3. Time Interval Recording ........................................................................ 34
15.8.6.4. Data Interval Recording ......................................................................... 34
15.8.6.5. Record a Comment Line ....................................................................... 34
15.9. Examples ................................................................................................. 34
Section 15 - Page 2
15.1.
E S T
D I T O R
Overview
This section covers five topics fundamental to understanding
Test Profiles:
15.2.
Test Profile Structure.
Test Profile Functions.
System Definition Considerations.
Operator Interaction in Test Profiles.
Data Management in Test Profiles.
Test Profile Structure

A Test Profile is a user-defined series of commands which
automatically perform test system functions. The Test Profile is
written in the test profile editor contained in the WinDyn
program on the PC. In some cases, the Test Profile automates
functions which an operator could perform in WinDyn, such
as recording data or command load and throttle. In other cases,
the Test Profile performs functions which an operator cannot do,
such as simultaneously comparing multiple data and calculated
channels against limits tables, and taking appropriate actions
should a limit or limits be exceeded.
The Test Profile itself is a file stored on the PC computer hard
disk. Multiple Test Profiles can be created and stored for use
as required. To use a Test Profile, the operator loads the Test
Profile from the PC Computer into WinDyn memory. Once
the Test Profile is resident in WinDyn memory, the operator
executes the Test Profile. WinDyn reads the Test Profile
and carries out the commands it contains.
Internally, Test Profiles perform many functions similar to
advanced programming languages. The Test Profile language
can command program flow control, data, temporary data,
variable data and memories, timer functions, variable statements, and counter functions. These functions are discussed
more thoroughly in the section, Writing the Test Profile and
the Test Profile Command Reference.
Section 15 - page 3
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15.3.
Test Profile Functions
15.3.1.
What does a test profile do?

In general, Test Profiles perform four types of actions: device
control, data control, display control and program branching.
The Test Profile can combine these functions in order to
control data values by means of device control or control a
device with information from a data channel. These functions
are implemented through the commands in the test profile
command language. This section provides a description of
autotest functions in the areas of device control and data
control and outlines the command structure of the advanced
test profile language.
15.3.2.
Device Control
The Test Profile can control many types of devices. Examples
of devices a Test Profile can control are throttle actuators,
water brake servo valves, eddy current controllers, solenoid
valves, fuel systems, HVAC systems, and relay functions (on /
off type functions, e.g. lights, fans).
Depending on the device, the Test Profile can control in either
open or closed loop modes. Open loop mode is essentially a
position mode. For example, a throttle actuator controlled in
open loop mode would be controlled to a position, i.e., 50% of
full travel. A throttle controller in closed loop mode could
employ a throttle position sensor to feed back information to
WinDyn on the actual throttle plate position. In this case, the
desired 50% setting would correspond to the actual measured
throttle plate position, not simply actuator travel. The actuator
would be controlled based on the information fed back to
WinDyn from the throttle position sensor. In this way, the
loop between throttle control signal, actual resulting throttle
position, and subsequent adjustment is closed. Not all devices
can or should be controlled in closed loop mode.
15.3.3.
Flow Control
In addition to devices, the Test Profile can control the flow and
the function of the test itself. Examples of flow control are:
event counters, event timers, data recording / management
functions, if/when conditional program branching, display /
messaging / alert functions, interactive limits and limit action
functions.
Flow control can be as simple as automatically recording a
temperature reading every 15 seconds. Advanced data control
functions can combine both data control and device control.
An example of an advanced data and device control function
Section 15 - Page 4
E S T
D I T O R
could be to use a counter to record the number of times a

value reaches a certain limit within a specific period of time
and taking a responsive action, such as engine shutdown.
Another example is controlling a measured or calculated
variable such as power or brake specific fuel consumption to a
specific value by employing device control functions to manipulate throttle or load. A third example could be incrementing
a calculated data value such as power in 40 hp steps of the
throttle every 10 seconds. In this case, WinDyn samples a
timer, torque, and speed data, calculates power, and modulates the throttle actuator to achieve the 40 hp step. Each of the
above mentioned groups of functions has many sub-types.
Many functions can be combined into a single Test Profile.
Flow control and device control functions often work interactively in the test profile.
15.3.4.
Command Language
The functions outlined above are implemented by the commands in the advanced test profile language. The advanced
test profile language is not unlike simple computer programming languages such as Basic. All forms of automated device
control and data control in the WinDyn system are implemented by means of the test profile commands. The Advanced
Test Profile commands are divided into six categories which
are briefly discussed below. A complete functional and syntactic reference to all advanced test profile commands is available in the Advanced Test Profile Command Reference. The
six test profile command categories are: Ramp, Set, Branch,
Action, If/When and Record.
Ramp commands are used to change an engine from one setpoint, say a speed or a torque value, to another. Set commands
control a variety of data and control functions including limits,
setpoints, data screens, constant values, timer reset, display
functions, and data filtering. Branch commands control
program flow. Branching commands are often used with If/
When commands to initiate conditional subroutine functions.
Action commands perform a variety of functions including
data display, operator alerts, pausing tests, and managing
event counters. If/When commands operate in tandem with all
other test profile commands to initiate conditional functions.
Record commands save data in the WinDyn memory. The
use of the command language is completely discussed in
Writing an Advanced Test Profile.
Section 15 - page 5
SF-602
15.4.
M a n u a l
System Definition Considerations

The autotest language was intended to cover a wide variety of
testing conditions. No one test would use all the features of the
test profile. In fact, one of the most significant limitations on
the test profile is the Configuration of the system. Before an
autotest is created, the programmer must have a clear understanding of the configuration of the system which the test
profile will control. It is possible to write a test which is incompatible or exceeds the capabilities of the system it is to
control. The following table lists the system definition considerations that should be made prior to writing a Test Profile and
their general impact on the test profile. These considerations,
unlike the others that follow, directly affect the primary tasks
the operator is trying to achieve: device control and data
acquisition. Having the information resulting from the considerations that follow will aid in planning a well organized test
profile. The table is intended as a general reference. Following
the table is a more detailed discussion of each item.
System Definition Considerations For Developing Test Profiles

System Definition Item
General Test Profile Implications
Data Channel Assignment
Auto test manipulates information by channel #. All

defined channel numbers which the test profile might
manipulate should be available. The test profile cannot
manipulate an undefined channel. See the discussion
below for more information.
Sensors
Type of sensors and sensor capabilities should be known.

The programmer must account for range and output capabilities. See the discussion below for more information.
Channels to Limit
Limit channels often perform important warning functions

for low oil pressure, low fuel, excess temperatures, inadequate voltages or frequencies. Such functions can be used
to trip limit action independent of the test profile or used to
trigger events in the test profile. See the discussion below
for more information.
Controlled Devices /
Device Control Mode
The devices controlled in the profile and the way they are
controlled have a great impact on the structure and function
of the test profile. The test profile must command a specific
device in a specific way. Throttle actuators and eddy
current controllers can be controlled in open or closed loop
mode. Any device controlled in closed loop mode can
control different closed loop values. For example: A throttle
controller could control torque or speed closed loop. A
significant number of combinations exist depending on
devices being controlled. See the discussion below for more
information.
Section 15 - Page 6
15.4.1.
E S T
D I T O R
Data Channel Assignment

One of the most important system considerations for developing the test profile are the existing channel assignments. Most
data functions performed by the test profile reference the
Channel Number to identify data. Data Channel Numbers must
be available to develop the test.
15.4.1.1.
Sensors
Sensors affect the type and nature of actions a test profile can
perform. In most cases, the technical issues of compatibility
and electrical characteristics are handled in the Configuration
(DEF). A small number of considerations remain for test profile
development. Of particular concern is sensor resolution. A
sensor with a wide range will have less resolution than a
sensor with a narrow range. Test Profile Commands and Limit
Action Levels can easily exceed the resolution of a wide range
sensor. In most cases, this is not a safety problem, but a data
reliability question. For example: a wide range temperature
sensor tasked with triggering an action that is specified at oneone hundredth of a degree Fo will trigger at approximately the
nearest whole degree number, but there is no guarantee that
the action triggered at the one-one hundredth degree increment specified. The same type of problem can be encountered
with controlled devices. The Test Profile can command far
greater resolution than a control valve or a throttle actuator is
cable of delivering. For example, a 0.1% step in throttle or
valve control might not be precisely repeatable, but a 5% step
would produce repeatable results.
15.4.1.2.
Channels To Limit
The Limits Program* permits the operator to set flags or limit
levels on data channels which, when tripped, can activate limit
actions or trigger events within a Test Profile. A limit can be a
high limit, a low limit, or both. Functions performed by limits
are called Limit Actions. Limit actions range from operator
alerts to full system shutdown. Limit actions can function
independently or trigger test profile actions. Limit triggered test
profile actions can activate any valid test profile functions.
*Limits are not currently available on SF-602 system.
Limits actions are tasked with triggering three types of actions:
safety actions, data recording actions, and system functions.
Limits actions are most often used in safety functions to alert
the operator and or shut off the system before a catastrophic
failure. Examples of limits functions in engine dynamometer
applications are: low dyno water pressure, low engine oil
pressure, high engine and or dyno water temperature, or
engine rpm. The above limits functions can be configured to
trigger limit actions and / or limit triggered Test Profile Events,
depending on the type of action desired.
A second type of limit function is triggered data recording.
When used in conjunction with a test profile, limits can trigger
Section 15 - page 7
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M a n u a l
data recording of events which exceed or fall below a window. To implement this function, a when limit flag and
goto or call function must be set up in the Test Profile.
The limit action itself cannot perform these functions. The
limit action sets a flag for the Test Profile to read. (For more
information, see the Test Profile Command Functions Reference, If/When statements section). An example of this function
is using a high and low limit to define acceptable engine oil
temperature and recording data such as power, torque, oil
pressure, and any other when the oil temperature falls below
the low limit or rises above the high limit. This function is
useful to identify concurrent events surrounding the oil temperature changes.
15.4.2.
Operator Interaction in Test Profiles

Once the programmer has determined the system configuration and its limits on the Test Profile, the nature and degree of
operator interaction must be determined. Many actions in the
Test Profile and Limits Functions can be performed with or
without operator interaction. In addition to interaction issues,
the programmer should consider what information in the Test
Profile should be displayed, how it will be displayed and on
what device it will be shown. Many test functions are designed
with user definable constant channels for acceleration ramp
times or ramp start and stop points. The operator can enter the
values as required from the Handheld Controller. In general,
four areas of operator interaction are available:
Test flow control functions
Pause / Stop functions
Operator data input
Flow Control
Test Profiles can contain branching commands which may be

operator controlled. In many circumstances, a condition
encountered during testing may require one of several actions.
For example, when an engine is being tested against a set of
specifications, and the engine fails to meet one specification
during the test, a branching routine could prompt the operator
to stop the test or continue further testing. Operator flow
control can be initiated directly by a branching command or
indirectly by a Limit Flag in the Test Profile that calls a branch
subroutine. This is effectively a conditional operator controlled
branch. For more information on branching, see the discussion
of flow control in the Test Profile Writing Section and the
BRANCH command in the Test Profile Command Reference
Section.
15.4.3.
Pause / Stop
Pause / Stop interaction is similar to branch action. The pause
or stop function is used to temporarily halt or to stop the
execution of the test profile.
Section 15 - Page 8
15.5.
E S T
D I T O R
Operator Data Input

The Test Profile can accept data input by the operator. Most
often, data input is used to provide test background data in an
automated fashion. Data can also be input numerically into
Constant Channels (also called Specifications) either by the set
const command of the handheld controller or by the input data
command under the Display sub-menu of the Action Test
Profile commands.
15.6.
Data Management in Test Profiles
15.6.1.
Acquiring Data / Disk Space

A minimum of one (1) MB should be available on the hard disk
before testing begins. If less than one megabyte is available,
the system could run out of disk space before all recorded data
is saved. This could result in a loss of data and or a lock-up of
the WinDyn system.
The rate of data acquisition should also be considered. If data
is taken at a very high rate, WinDyn can fill the available
RAM very quickly. In this condition, data must be written to
the hard disk and will slow the system and potentially cause
data loss if the system cannot keep up with the data recording
rate. The rate of data acquisition should be the minimum
necessary for your testing needs. This minimizes burden on
the system, offers the greatest guarantee of data integrity, and
uses the minimum amount of disk space.
15.6.2.
Printing
In many cases, it is not necessary or desirable to save all
recorded data to disk. In such cases, disk space can be conserved by printing data during the test.
15.6.3.
, PC, Handheld Controller

Data Displays: WinDyn
Data Display is the most common type of operator interaction.
Two devices are available for data display: The PC monitor
and the Handheld Controller. These devices can be used to
display any of the 10 current data screens (on the PC only), the
9 data screens (on the Handheld Controller), operator alerts,
custom messages, and, in the case of the PC monitor, graphic
displays.
Section 15 - page 9
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15.7.
Developing Test Profiles
15.7.1.
Writing the Test Profile

A Test Profile is a list of commands assembled in the Test
Profile Editor and saved to a file on the PC hard disk. Writing a
Test Profile is similar in method but less complex than writing
a program in C or Basic. Individuals who are familiar with
computer programming will find the methods presented here
familiar. The Test Profile Editor features pull down menus
which contain all the Test Profile commands. This eases the
learning process by limiting the need to memorize a command
language. In almost all cases, commands are entered into the
Test Profile script by the computer after the programmer selects
from a menu. This minimizes the chance of syntax errors.
It is important to remember, when planning Test Profiles, that
the Test Profile language was developed to account for the
wide variety of test equipment and conditions encountered by
a wide variety of SuperFlow customers. The potential functions of the Test Profile can easily exceed the function of your
hardware or testing requirements. It is important to clarify your
testing requirements. Test Profile development is complex and
a thorough understanding of the control and data requirements
and the system capabilities as well as the Test Profile language
are required. The sections that follow discuss these considerations in detail.
15.7.1.1.
Editor Interface
The Test Profile editor interface is the Test Profile programming environment. The editor interface is a module of the
WinDyn program on the PC computer. All writing and
editing of Test Profiles is done within this environment. All
programming tools, functions and information are available in
this environment.
15.7.1.2.
Opening the test profile editor

Select Design | Test from the WinDyn main menu to load
the WinDyn Advanced Test Profile editor. The Test Profile
editor main screen is displays. Select S - Select Configuration
file. Select a Configuration file to be used for your Test Profile
design. Press Enter. Or select G to get a previous test design
from disk to modify and save as a new test. If you select an
existing test to modify, immediately use the KEEP function to
save the test under a new name.
NOTE
If you do not take this step, the loaded test may be overwritten and the data
LOST! If you wish to simply edit the loaded test, you do not need to save it to a
separate file name.
E S T
D I T O R
Test profile Editor Menu

MAIN MENU OPTIONS
G- GET a Test File from Disk
CURRENT TEST FILE: UNNAMED .TPF

CFA Configuration File unnamed .CFA
NOTE: Type ESC to return to a previous name. ESC
(now)will return you to WinDyn
K - KEEP Current Test on Disk

C - CLEAR Test from Memory
From any of these Auto Test Development Options,

ESC will RETURN you to this Menu
E - ERASE Test from Disk

M - MODIFY the test in Memory
S - SELECT configuration file.
Q - QUIT and return to WinDyn
Choose an Option
Select M-Modify the test in memory to access the editor.

Once the Test Profile editor is active, the test can be modified.
15.7.2.
Test Profile Editor Display Screen

The Test Profile Editor display screen is divided in three
sections. The top of the screen displays information about the
current test. The name of the test, channel configuration file,
current number of steps in the test, control configuration and
test description are all shown in the top area of the screen.
The large central section of the screen displays the test script,
(or commands). The lower menu bar displays options to
modify the description and control configuration of the test,
and to print the test .
A limited number of lines of the test can be displayed at one
time on the editor screen. The configuration and description
information remains visible at all times, along with the Test
Profile name and matching configuration file.
15.7.2.1.
Test Profile Editor Key Functions

The PageUp, PageDn, End, and Home keys can be used within
the Test Profile editor, along with the arrow keys. The Delete
and Insert keys can be used to remove or add lines, respectively. The Esc key can be used to end the current operation.
15.7.2.2.
Test Description and Control Configurations

The first step in creating or editing a test is to establish a
description and control configuration.
From the Test Profile editor display screen, Press D to

enter a description.
The description window is displayed.
Enter the test description. Press Enter.
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Press C to setup the initial control configuration.

The control configuration is displayed.
Three items can be configured: load control, throttle control
and end test ramp rate.
15.7.2.3.
NOTE
The load control entry determines what value will control the
load applied to the test engine/vehicle.
The throttle control entry determines what value will control

the throttle position. This function is not generally used in
chassis dynamometer testing because the throttle is manually
controlled by the operator.
The end test ramp rate entry determines the time the system
will take to reduce load and close throttle after the end test
command appears in the Test Profile or is entered from the
handheld. Set this value to 5.0 seconds unless you have
specific goals.
Use the cursor keys to highlight the load control entry,
Press Enter.
Several options appear in a window below the load control

entry field.
The options available for control configuration depend upon the installed
configuration file. If the configuration file is changed from the SuperFlow
supplied file, the options may vary!
Select the load control item. In chassis dynamometer applications vehicle speed or engine speed are the most common
choices.
Press Enter.
Select end test ramp time.
Enter 5.0 seconds.
Press Esc to return to the Test Profile Editing Screen.
Test profile command entry / editing

The second step in creating or editing a Test Profile is to add
or modify the test steps, or control codes, in the main window.
Use the cursor keys to highlight the line you wish to edit or the
line before which a new step is to be added. Press the Insert
key to insert a new line, or press Enter to edit.
If insert was pressed, a new line is added and a NOP (no
operation) displays. Press Enter. The line changes to
designing new step and the step type menu appears at the top
of the screen.
E S T
D I T O R
The step type menu accesses all available Test Profile commands. Use the left and right arrow keys to select one of the
six step categories desired.
Press Enter. When the step category is selected, a menu of
step choices drops down from the menu bar.
Use the up and down arrow keys to select the desired step
type. Press Enter. The step selected is entered in the new or
edited line. If the step is a ramp step or other step which
requires user specified variables, the user will be prompted to
enter the value in the appropriate field.
NOTE
A complete description of the test commands under the Step Type menu follows
this section. In addition, a section on Test Profile development considerations is
also included. Both should be read before developing a Test Profile.
15.7.3.
Saving the test profile

Once the test creation / editing process is complete, press Esc
until the WinDyn Test Profile menu screen displays.
Press K-keep current test on disk to save.
Enter the name desired or the name of an existing test to
update or overwrite.
Press Enter to confirm.
If the file exists, select YES to overwrite it, or NO if you wish to
review editing.
15.8.
Test Profile Commands Reference

Test Profile commands are divided according to types of
functions they perform. The six function types and their
respective commands are described below:
15.8.1.
Ramp
Set
Branch
Action
If / When
Record
RAMP Commands
The ramp commands cause the controllers to smoothly change
the position of an actuator or its controlled variable, for example
torque or engine speed, from the present setpoint to a new
setpoint, in a specified time period. Some systems have both a
throttle controller and a load controller. Some, however, may
have only one controller, such as a chassis dynamometer.
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Constant acceleration ramps can be used, where the time to

next step is typically 2 to 1,800 seconds, or step ramps can be
created by using .1 seconds as the time to next step.
NOTE
In all ramp commands, the ramp controller to <value> statements give sample
controlled values for the controller. What the controller controls depends upon
the configuration of the system as defined in the configuration file (DEF). In
some cases, such as chassis dynamometers, only one controller, a load
controller, is used. Chassis dynamometers rely on the operator to apply throttle
manually. Thus all ramp commands could be shown with engine speed as the
#1 controller and engine torque as the #2 controller. In most engine control
applications, however, the Dyno (absorber) is controller #1 and the Engine
(throttle) is controller # 2.
NOTE
All user entered variables are shown within < > to delineate them from the
display text accompanying the commands. When entering data values or other
information into command entry fields, do not type the < > as they will invalidate
the command.
15.8.1.1.
Normal Ramp
Syntax
Linear ramp setpoints:
EngSpd to <V1>, EngTrq to <V2> in <t> seconds
<V1>: Any valid value for the controlled quantity
<V2>: Any valid value for the controlled quantity
<t>:
Ramp time in seconds. Valid range: 0.1 2100
Use
<V1> <V2> The V1 and V2 variables are values which each
controller will ramp to. The values depend on the configuration
of the control system. In manual mode V1 might be a percent of
throttle actuator travel, for example 50%. In servo mode, the V1
value might be a specified engine speed as in the example
above. The same is true for V2. Enter values for V1 and V2
which are applicable to the current control configuration.
<t>: The t value is the duration of the ramp action in seconds.
The t value must be a number between 0.1 and 2100. If the V1
value was set to 4000 rpm and the V2 to 90 lb-ft and the t value
to 10, the control system would ramp the engine speed and
torque values smoothly from the current settings to the V1 and
V2 settings in 10 seconds.
The normal ramp command is based on the modes that were
set by the configuration section. These modes will be used as
the default, and will automatically be inserted into the command line as its created. The available control options are
defined by the channel Configuration (DEF) program.
15.8.1.2.
E S T
D I T O R
Mode Change Ramp<R>

(normal ramp with control mode override)
Syntax (control mode change)
Load Control Mode: <controlled value>
Throttle Control Mode: <controlled value>
The values are valid controllable values for each controller.
These are selected by pressing Enter when the desired
controller is highlighted. The exact controlled values depend
upon the system configuration and thus cannot be predicted
here. Typically, the load control mode in an engine dynamometer application could be either torque or speed or might be set
to manual (0-100% of load).
Syntax (mode change ramp setup)
Same as normal ramp
Use
Once the Mode Change Ramp is selected, the Change Control
Mode screen displays.
Use the arrow keys to select the control you wish to change.
Press Enter to select the change in mode.
Repeat for the second controller if necessary.
When control changes are complete, press Esc.
The normal ramp value entry line displays. All functions from
this point are identical to the normal ramp discussed previously.
The mode change command is a normal ramp command with
the addition of control mode override. In addition to setting the
setpoints for load and throttle, the control modes for load and
throttle can be temporarily changed for the ramp. The system
will bumplessly switch to the changed modes as soon as the
Test Profile reads the line, and will stay in the changed mode
until another control line is input. The Test Profile editor
defaults to the normal mode after a mode change has been
exercised, so successive mode change commands are required
for continued operation in other than the configuration modes.
15.8.1.3.
Custom Ramp
Syntax
Ramp EngSpd to <value>, and EngTrq to <value>, in <t>
seconds.
<value>s: Engine and throttle can be any of the following:
Immediate value: Any positive number. The immediate value
sets controller setpoint to the entered value.
Data channel: Sets value of controller set point to value of a
data channel at the time the line is executed.
Constant (Specification): Sets the value of the selected controller setpoint to the value of another Constant (Specification)
Channel.
Unchanged: <t>: Ramp time in seconds.
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Use
The Custom Ramp commands offer more flexibility than the
normal ramp or mode change ramp when choosing the
controller setpoints. The ramp to load or throttle setpoints
can be an immediate value, data channel, constant (specification) channel, or may remain unchanged when only changing
one of two variables. The four options are discussed below.
Immediate values are fixed numeric values which are valid for
the controlled quantity in question. Immediate values are
simply fixed setpoints exactly like the setpoints entered in the
normal ramp and mode change ramp. Immediate values for
controllers ramp to the entered value. Immediate values for
the ramp time execute the ramp in a fixed number of seconds.
See Normal Ramp for more information on immediate values.
No change values for the custom ramp controller settings cause
the control system to hold the controlled value at its present
value. Often the No Change value is used for one controller, and
an immediate value is used for the other controller and an
immediate value is used for ramp time. This allows one controller to be isolated from the other during a ramp.
Using data and constant (specification) channels in the Custom
Ramp:
WARNING
It is important to remember that the data or constant channel value can be used
to set a controller to a meaningless value such as dyno water pressure or oil
temperature. This is not the intended use of the function and can cause
unpredictable results.
Data Channel and Constant (Specification) Channel values for

the controller setpoints cause the system to ramp the controlled
value to the value of the data or constant (specification) channel
at the moment the Test Profile line is executed. The controller
setpoint does not continuously change even though the data or
constant (specification) channel may be changing.
The most common use of the Custom Ramp is to perform
acceleration tests in which the rate of acceleration and the
starting and ending speed of the test are not fixed.
In this application, two ramps are used to control the engine
between a lower speed and an upper speed at a fixed acceleration with a specific % of full throttle (100% is most common). In this application, the first ramp is constructed to set
the engine at the lower speed and 100% throttle. Ramp time
for the first ramp is not critical as the ramp controls the engine
to the starting throttle and speed configuration. Often the first
ramp time can be set to 2 seconds and the engine commanded
to the starting speed with a setpoint command. The first ramp
is still needed to ramp to the desired ramp start throttle
position (100% in this case). The second ramp controls the
engine from the lower (ramp start) speed and 100% throttle to
the higher speed and 100% throttle at a specified acceleration.
The acceleration rate is a function of the time setting for the
E S T
D I T O R
second ramp. The faster the ramp is executed, the greater the
acceleration rate. The slower the ramp is executed, the slower
the acceleration.
This function could be achieved with normal ramps, but the
speed range of the test (the start and end speed) and acceleration at which the second ramp takes place (set by the duration
(time) of the ramp), are fixed. The test range and acceleration
rate in rpm/sec cannot be changed without editing the test.
Using the custom ramps permits the test to use constant
(specification) channels, for the start speed and end speed.
The constant (specification) channels can be defined and
edited by the operator from the handheld controller or from
WinDyn. This permits the operator to change the test start
and end points and the range of the test without modifying the
Test Profile. Similarly, the second ramp can use a constant
(specification) channel (time in seconds) defined by the output
of a calculated channel (range in speed divided by desired
acceleration in rpm/second) to calculate the time necessary to
achieve a specified acceleration over the specified test range.
To allow the operator to select a desired acceleration rate the
calculated channel uses a constant (specification) channel,
defined by the user to obtain the acceleration value. This value
is entered at the front panel by the user. See the discussion of
constant (specification) channels and calculated channels in
the Configuration (DEF) File Creation section of this manual.
15.8.2.
SET Commands
NOTE
the command.
15.8.2.1.
Set Data Screen

Syntax
Three sub-commands exist within the set data screen command:
Computer data screen
Set Computer Current Data Screen to - <1-10>
System Data Screen<R>
Set system (handheld controller) data screen to - <1-9>
Use
The SET DATA SCREEN commands are used to change the
data screens that appear on the handheld controller or computer data screen. Any of the nine (9) stored data screens can
be displayed on the handheld controller, while any of the ten
(10) computer current data display screens can be displayed
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on the computer. The computer must be in a current data

display mode for the commanded screens to be seen. The
handheld controller may be in any mode, and the commanded
screen will appear. The new data screen will remain on the
handheld and computer screen until a different screen is
commanded. The final data screen will remain on the display
device after the test ends.
15.8.2.2.
Set Data Filter

Syntax
Set automatic data filter rate to <x>
Valid values for x are 0-7. Zero turns off data filtering. Values 17 apply data filtering to all data channels, 7 being the maximum data filter rate.
Use
The set data filter rate over-rides the filter rate that may be
previously set in the system. It is best to have a low filter rate
when performing fast acceleration ramps while data is being
recorded, and a higher filter rate for steady state testing.
15.8.2.3.
Set Timer
Syntax
Set Timer <Timer #> to <xxxx>
Use
The set timer command allows any of the 0-9 timer channels
to be set from 0 to xxxx seconds. Timer channels 0-9 correspond with configuration channels 211-219. The timer increases in value as time goes on. The timer value can be
recorded as its own channel, used as part of a calculated
channel, or used as an input to other conditional IF/WHEN
commands.
15.8.2.4.
Set Counter
Syntax
Set Counter <counter #> to <xxxx>
Counter # is the number of the counter that is to be set.
xxxx is start value of the counter.
Use
The set counter function allows any of the 0-9 counters to be
set from 0 to xxxx. The counter will remain at its input value
until incremented or decremented with another Test Profile
command. The counters can be used in conditional IF/WHEN
statements within the Test Profile.
15.8.2.5.
Set Constant (Specification)

Syntax
Set Constant <ch#> to <value>
E S T
D I T O R
<ch# > is a valid constant (specification) channel number in

the current configuration. These are selected from the constant
(specification) channel screen which displays when the
constant (specification) function is selected.
<value>: Can be any one of the following:
Immediate value: Any positive number.
Data Channel: Value of a data channel at the time the line is
executed.
Constant: Sets the constant (specification) value of the selected
constant (specification) channel to the value of another constant (specification) channel.
Math function: Defines the value of the constant (specification).
Counter <counter #> - Sets the value of the constant (specification) channel to the value of a specified counter at the time the
constant (specification) command is executed.
Timer <timer #> - Sets the value of the (specification) constant
to the value of a specified timer at the time the line is executed.
Memory <memory #> - sets the value of the constant to the
value of the specified memory at the time the constant (specification) command is executed.
Use
Each constant (specification) channel is defined by the Channel Configuration (DEF) program. The constants (specifications) can be modified with many of the above options. The
flexible statements allow the constants (specifications) to be
used as status indicators, complex setpoints, calculated
channels inputs, etc. for use in more advanced test routines.
The constant (specification) values will be retained at the
conclusion of the test. Constants (specifications) are often used
to hold the value of calculated channels, timer or counters at a
given moment which may then be used as values in IF/WHEN
statements. Constants (specifications) are also useful in performing mathematical operations on or with other channels.
15.8.2.6.
Set Setpoint
Syntax
Set <controller> Setpoint = <value>
<controller>: Load or throttle controller.
<value>: Can be any one of the following:
Immediate value: Any positive number. Sets controller setpoint
to the entered value.
Data channel: Sets value of controller set point to value of a
data channel at the time the line is executed.
Constant (Specification): Sets the value of the selected controller setpoint to the value of another constant (specification)
channel.
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Math function: Defines the value of the controller setpoint by

mathematical operation.
Counter <counter #> : Sets the value of the controller setpoint
to the value of a specified counter at the time the line is
executed.
Timer <timer # > : Sets the value of the controller setpoint to
the value of the specified timer at the time the line is executed.
Memory <memory #> : Sets the value of the controller setpoint
to the value of the specified memory at the time the line is
executed.
15.8.2.7.
Set Limits On (Not Yet Implemented)
15.8.3.
BRANCH
15.8.3.1.
NOTE
the command.
GOTO
Syntax
GOTO <step #>
<step#> is any valid step number in the current test.
Use
The GOTO command will cause the Test Profile to execute the
Test Profile line number specified in <Step#>.
15.8.3.2.
CALL
Syntax
CALL Step # <step #>
<step#> is any valid step number in the current test.
Use
A CALL command will progress to a routine within the Test
Profile, and will continue to read down the lines of commands
until a RETURN statement is met, whereafter it will return to
the line after the original CALL command. Several layers of
CALL and RETURN may be built into the Test Profile. More
often than not, when a Test Profile CALL command is being
implemented, the routine it calls may not yet have been
entered. It is a common source of error that the CALL commands line number reference is in error. Therefore, when a
CALL command is implemented, do not fill in the called
function line number. When the called function is subsequently completed, return to the CALL command and enter
the appropriate line number. Once this is done, the line
number will automatically be updated by the test profile.
15.8.3.3.
E S T
D I T O R
Repeat
Syntax
REPEAT <x> times from step <step #>
<x> is any positive number.
<step #> is any valid step number in the current test.
Use
The REPEAT command allows the test to execute a test section
a specified number of times. This command is useful in
reducing the size of a Test Profile by reducing repeated syntax.
15.8.3.4.
Return
Syntax
Return
Use
The RETURN command will cause the Test Profile to go to the
line after the previous CALL command to resume the test
progression.
15.8.3.5.
Wait
Syntax
WAIT for <t> seconds
<t> is any positive number in seconds.
Use
The WAIT command will wait at the line number for a specified number of seconds.
15.8.3.6.
Stop
Syntax
Stop Test
Use
Stop Test will perform the same function as end test.
15.8.3.7.
Input wait
Syntax
Wait <t> seconds for operator input.
<t> is any positive number in seconds.
Use
The system can be configured to accept a numerical input for
a constant (Specification) channel or memory channel via the
ACTION-Display-Define Handheld Controller Soft Key Labels
function. When an input has been commanded, the brackets
will automatically open in anticipation for the operator input.
Normally, the test would wait indefinitely for the input. The
INPUT WAIT command allows the test to continue if an input
has not been received in the specified amount of time.
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15.8.4.
M a n u a l
ACTION
NOTE
the command.
15.8.4.1.
Display
Syntax
The Display command has four sub-commands:
Display Front Panel message (= handheld controller screen)
Display Computer message (not available on all systems)
Display annunciator message (SF-742 systems only)
Define Soft key labels<R> (see below)
The # entry is the desired display line number. Valid values
are 0, 1, 2.
The message entry within the [ ] defines the message to be
displayed. Up to 40 characters may be used.
The ^ch#^ commands the display of a specific data or constant channel (ch#). The caret ^ characters must be placed
before and after the channel number. Any valid data or constant channel may be used. The ^M#^ commands display a
specific memory channel
Use
The display commands cause operator defined information to
be shown on the displays available, depending on the system.
The following conditions apply. Three lines of display information can be shown on the handheld. Each line may have up to
40 characters. The # entry selects the display line on the
handheld (numbered vertically from the top down) on which
the message will display. If 0 is chosen, the lines will appear
according to first-in, first-out control of the three line current
data area that appears on the handheld. The computer monitor
message does not have a display line selector. Computer
display messages are displayed one 40 character line at a
time, each successive message overwriting the previous
message.
A data or constant channel can be displayed within the text of
a message, with continuously updated values, by placing the
caret symbol (^) before and after the channel number within
the message field (^ch#^). Be sure to add enough character
spaces before the first caret symbol and the channel number to
ensure that the data channel display has enough characters to
fit between the message text. For example, to continuously
show the engine torque on the second line of the handheld
controller display, the line in the Test Profile would be:
Display2: [Engine torque = ^c3^ lb-ft.] on front panel
15.8.4.2.
E S T
D I T O R
Display-Define Soft Key Labels

Syntax
Label Soft Keys (A-E): [ <label> ]
<label>: The label(s) for the key(s)
Use
The Define Soft Key Labels function allows the A-E keys on the
bottom row of the handheld controller to be labeled and
assigned functions. The labels occupy eight spaces above each
key. The display contains 40 characters. Thus, the labels
should be no longer than eight characters and should be
contained within consecutive eight character blocks when
entered in. Blanks can be inserted with the space bar. Text can
be centered or moved right by pressing the insert key.
The backspace key moves text left. The example below sets
the soft key labels for keys A, C and E:
Label Soft Keys (A-E): [ Stroke
NOTE
Displac
Bore ]
The keys function only if a When Soft Key function is called immediately after
the label function. Labeling alone will not define a soft key function. See When
Soft Key, under the IF WHEN commands later in this section for more
information. Therefore, only label a soft key when the function is available at that
moment, otherwise a blank area should be put above the key to prevent
labeling a function that is unavailable.
Special functions of the soft key labels

The Soft Key Label function can also enter data into Specification Channels. If a soft key label is set, for example, to enter
the engine stroke (Channel 83) from the Handheld Controller
front panel A key, use:
Label Soft Keys (A-E): [ î <ch#>^
The i instructs the soft key to open the constant channel

entry field. After the constant value is entered from the numeric keypad on the Handheld Controller, press Enter.
<ch#>: The number of the constant channel into which a value
will be entered.
As with soft key labels, the constant channel insert mode must
be defined within a contiguous eight character block above the
desired soft key. If the insert command was to be established
for the B key, the command would have to be placed within
the characters 9-16 (as counted from left to right) to be called
from the B key.
15.8.4.3.
Print
The print command has eight sub-commands. These are
described individually below.
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Syntax
Print message with Line Feed
Print with Line Feed: [ 40 character message]
Use
This command may print a line followed by a line feed,
depending on the printer. Forty characters per line are available for comments. Some printers may choose to buffer a line
command, and wait until the next line has been commanded
to print before performing the line feed.
Syntax
Print Message w/o Line Feed
Print w/o Line Feed: [...40 characters]
Use
This command will print the comment without a line feed. The
next line of data may be printed on top of the existing line.
Syntax
Send Form Feed to printer
This function is not yet implemented.
Use
This command will form feed the printer a specified number
of times.
Syntax
Send Line Feed(s) to printer
Line Feed the printer <x> times
Use
This command will line feed the printer x number of times.
This may be useful in separating data lines on the printout to
highlight specific sections, etc.
Syntax
Print Data Line with Labels
Print Date Line <x>, with Labels.
Use
This will print the specified data line (1-9) with the channel
labels (name and units) directly above the data value. The data
line is the data defined for any of the 9 handheld controller
screens.
Syntax
Print Data Line w/o Label
Print Data Line <x>, w/o Labels.
Use
This will print the specified data line without the labels
directly above the values. This command is typically used for
succeeding lines of data that would follow the initial command
that printed with the labels.
E S T
D I T O R
Syntax
Print Data Line as Recorded
Print Data Line <x>, as Recorded.
Use
Not yet implemented.
Syntax
Print Computer Current Data
Print Computer Current Data Screen.
Use
Not implemented.
15.8.4.4.
Alert
Syntax
Alert Operator
Use
Not yet implemented
15.8.4.5.
Pause Test
Syntax
Pause test and wait for operator response
Use
Pause Test allows the test to indefinitely postpone advancing
through the profile. Once any key on the handheld is pressed,
the test resumes. Pressing the G key on the Handheld Controller also resumes the test. During the paused state, the controller setpoints remain at the point present immediately preceding the pause command.
15.8.4.6.
Inc Counter
Syntax
Inc Counter <x>
X specifies which counter to increment one unit. Valid values
are 0-9.
Use
The Inc Counter command will cause a specified counter (0-9)
to be increased in value by 1. Often used in conjunction with
If/When commands to count events such as the number of
times a value exceeds or falls below a specified level.
15.8.4.7.
Dec Counter
Syntax
Dec Counter <x>
<x> specifies which counter to decrement one unit. Valid
values are 0-9.
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Use
The Dec Counter command will cause a specified counter (09) to be decreased in value by 1. The Dec Counter command is
often used in conjunction with If/When commands to countdown events after a number of iterations, such as the number
of times a value exceeds or falls below a specified level.
15.8.4.8.
Erase Memory
Syntax
Erase Data Memory
Use
Erase Data Memory will erase all data stored within the
WinDyn data storage area. Once deleted, it cannot be retrieved. This command does not affect data stored on the
computer hard disk. It is generally recommended to erase data
at the beginning of new test. Otherwise, the data file would
continue to increase in length until the memory was completely
filled. When the memory is filled, no new data can be stored.
15.8.4.9.
Roll Messages
Syntax
Roll Message
Use
The display messages that appear on the Handheld Controller
may be commanded to roll up on the display. For example,
the text on the third line down would be placed in the second
line down using this command.
15.8.4.10. Clr Messages

The clear messages command has four sub-commands:
Syntax
Clear at Front Panel<R>
Clears Handheld Controller messages.
Clear Soft Key Label<R>
Clears soft key labels.
Use
The clear messages commands cause the text message data to
be erased from the display. The display would remain blank
until more messages were displayed, or a data screen was
shown.
15.8.4.11. Keep Data
Syntax
The Keep Data command has two sub-commands:
Default File Name
E S T
D I T O R
Keep Stored Data on disk file [ <filename> ]

<filename>: Up to eight characters may be used to name the
file. The file is stored in the Default Data Files Directory as
specified in the Design | System | File Path Setup. For more
information on the Default Path, see Set Data File Drive and
Path in the WinDyn functions reference.
Use
The Keep Data command (default) causes the data within
WinDyn to be stored onto the computer disk, as defined in the
WinDyn path. The Default File name is defined in
WinDyn|Design|System Setup|File Names.... and will automatically increment to TEST_999. The data within WinDyn
will remain until it has been erased with the ERASE DATA
command.
The Keep Stored Data to File command saves the data to the
file name specified in <filename>.
15.8.4.12. Exit Screen
Syntax
Exit computer current data screen.
Use
This command causes the system to exit a Current Data
Screen to the special software overlay screen. This command
is functional only in special interface applications.
15.8.4.13. Clear When Queue
Syntax
Clear all WHEN statements from queue.
Use
The Clear When Queue command clears all WHEN statements
from the queue that would perform the WHEN task if the
WHEN conditional statement became true. To reactivate the
function, the WHEN command must be performed again.
Limits resetting:
The most common use of the Clear When Queue function is to
cancel a When Limit Flag function. In many cases, limit flags
are set to perform functions such as recording data when the
limit in question is triggered (flagged). Since limits can be
flagged only once, the when statement which calls the limit
flag action (When Limit Flag, see IF/WHEN commands) must
be removed from the when queue if the limit is to function
again. If the Clear When Queue command is not used, the
When Limit Flag function will not execute the next time the
limit flag is set. In some cases this is not critical, but in cases
where a limit flag function warns the operator with a display
message that oil temperature is high or water pressure is low,
failure to reset the when queue, and reactivate the limits
function, could result in an apparent failure of the limits
system when it simply was not properly reset after triggering a
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limits flag. This situation is usually not a concern in limit

action which shuts down a test and kills the engine because
further execution of the test is halted at that time.
A Clear When Queue statement might be run as part of a subroutine that is called if a When Limit Flag function is executed. In this case, the limit would trip and set a flag, a when
limit flag statement would call a subroutine, an appropriate
action would be taken, and, once that action was completed (if
it were not a system shutdown) in the next line, the Clear
When queue statement would reset the limit in question.
A Clear When Queue statement is also frequently used to
prevent unanticipated branching when multiple menu levels
of labeled soft keys (A-E) are used for operator interaction in an
autotest. If, for example, an operator is prompted to choose one
of the functions displayed at the A, C and E keys, and the
functions call a sub-routine which displays the new functions
at the A, C, and E keys, a Clear When queue statement must
be used.
15.8.4.14. Config Cmd Line
Syntax
The Configure Command Line function has two sub-commands.
Enable control system command line.
Disable control system command line.
Use
These commands switch the command line that appears on
the bottom (8th) row of the Handheld Controller. In the default
mode, with no soft key labels, the control command line may
remain visible, which may not be preferred for all tests.
15.8.4.15. Graphics Function
Not implemented.
15.8.4.16. Load Limits File
Syntax
Load <filename> Limits File from computer.
<filename> Any valid limits file.
Use
The Load Limits File command retrieves a limits configuration
file from the computer hard disk for eventual use within
WinDyn . After the file has been loaded into WinDyn , the
Limits Program must be turned ON. It is best to allow extra
time for the computer to access the disk before activating the
Limits Program.
This function is not yet available on SF-602 systems.
15.8.5.
IF/WHEN
15.8.5.1.
Overview of IF and WHEN commands
E S T
D I T O R
The IF command will perform the commanded function when

the line is read within the Test Profile progression. If the
conditions are true at that point, and that point only, the action
(CALL or GOTO) will take place. This differs from the WHEN
command. The WHEN function will place the command in
queue, and will not check for the condition to be true until it
occurs. Many WHEN statements can be within the queue
simultaneously. Once a WHEN statement is true, and Action is
therefore executed, it is no longer in the queue. The command
must be reloaded to be executed again.
15.8.5.2.
If Data Channel
Syntax
If Data Channel <ch#>, <condition> ,<value>, <GOTO or
CALL> Step <st#>
< ch#> can be any valid channel number defined in the
current configuration.
<Condition>s:
= equal
! not equal
< less than
<= less than or equal
> greater than
>= greater than or equal
<Value>s:
Immediate value - Any valid numeric value for the IF
channel.
Data channel - Any currently defined data channel number.
Constant (Specification) - Any currently defined constant
(specification) channel number.
<GOTO> Causes the test to branch and continue executing
from a specific test line.
<CALL> Causes the test to execute a specific line in the test
and, upon completion of the called function, return to the line
following the CALL function line.
<st#> Any valid step number in the Test Profile.
Use
The If Data Channel function is used to trigger an action when
a data channel returns a specific value. The action triggered
can be any Test Profile function.
SF-602
15.8.5.3.
M a n u a l
If Timer
Syntax
If Timer <t#>, <condition> ,<value>, <GOTO or CALL> Step
<st#>
< t#> Can be any valid timer (0-9).
<Condition>s:
= equal
! not equal
< less than
> greater than
<Value>s:
Immediate value - Any valid numeric value for the IF channel.
and, upon completion of the called function, and return to the
line following the CALL function line.
Use
The If Timer function is used to trigger an action when a timer
returns a specific value. The action triggered can be any Test
Profile function.
15.8.5.4.
IF counter
Syntax
If Counter <c#>, <condition> ,<value>, <GOTO or CALL> Step
<st#>
< c#> can be any valid counter number defined in the current
configuration.
<Condition>s:
= equal
! not equal
< less than
> greater than
E S T
D I T O R
<Value>s:
Immediate value - Any valid numeric value for the IF counter.
Use
The If Counter function is used to trigger an action when a
counter returns a specific value. The action triggered can be
any Test Profile function.
15.8.5.5.
If data lines
Syntax
If Data Lines , <condition> <value>, <GOTO or CALL> Step
<st#>
<Condition>s:
= equal
! not equal
< less than
> greater than
<Value>s:
Immediate value - Any valid number of data lines..
<CALL>> Causes the test to execute a specific line in the test
Use
The If Data Lines function is used to trigger an action if the
Data Lines <value> return a specific value at the moment the
function is executed. The action triggered can be any
TestProfile function.
SF-602
15.8.5.6.
M a n u a l
When Data Channel

Syntax
When Data Channel <ch#>, <condition> <value, see below>,
<GOTO or CALL> Step <st#>
< ch#> can be any valid channel number defined in the
current configuration.
<Condition>s:
= equal
! not equal
< less than
> greater than
<Value>s:
Immediate value - Any valid numeric value for the when
channel.
<GOTO> causes the test to branch and continue executing
<<CALL>> causes the test to execute a specific line in the test
Use
The When Data Lines function is used to trigger an action
when the Data Lines <value> return a specific value at any
time after this function is activated. The action triggered can
be any Test Profile function .
15.8.5.7.
When Limit Flag

Syntax
When limit flag <f#> is set, then <GOTO/CALL> Step <st#>
<<f#>> The limit flag id number.
<CALL> causes the test to execute a specific line in the test
Use
E S T
D I T O R
The when limit function may be used with limits flags that are
previously configured in the limits editor. Action = In Autotest.
Condition = In Limits. For the action to take place, a limits file
must be loaded, and the Limits must be activated.
15.8.5.8.
NOTE
The Limits file must be loaded and turned ON for the When Limit Flag to function
properly. The Load Limits File function under the Action Test Profile commands
menu and the Limits On and Limits Off functions under the Set Test Profile
commands menu can be used in the autotest to control the limits. For information
on loading and activating limits files, see Loading Limits and Creating a Limits
File. Limits are not currently available for SF-602 systems.
When Soft Key

Syntax
When soft key <key> is pressed, <GOTO> or <CALL> Step
<st#>
<key> Five keys are available: A, B, C, D, E.
<CALL> causes the test to execute a specific line in the test
Use
The soft keys perform their actions with the When Soft Key
command. Once the key is pressed and the command takes
place, the key is no longer active. It is best to reinsert the
command at the conclusion of a subroutine if repeated soft key
actuation is required.
NOTE
The When Soft Key function should be used with the Define Soft Key Label
functions under the Action, Display Menus of the Test Profile commands.
15.8.6.
RECORD
15.8.6.1.
Record data line (Manual)

Syntax
Record Data Line
Use
Current values of all channels are stored in the WinDyn
memory.
NOTE
Data must be saved to file to be permanent!
SF-602
15.8.6.2.
M a n u a l
No Automatic Recording
Syntax
No Automatic Recording
Use
Ends Automatic Data Recording. This deactivates any form of
automatic data recording previously activated in the Test
Profile. If data recording was already off, it has no effect.
15.8.6.3.
Time Interval Recording

Syntax
Record Data every <x> seconds
<x> Valid values for x are between 0.1-2700 seconds.
NOTE
Entering 0 seconds will cause data acquisition at 100 H2
Use
This causes the WinDyn system to record data at a specified
time interval until the automatic recording is commanded, the
memory becomes full, or the test stops.
15.8.6.4.
Data Interval Recording

Syntax
Record a data line for every <x> change of (selected channel)
<x> Valid values can be any valid numeric value for the
selected interval channel.
Use
Data can be recorded as a function of data channel change.
Extremely fast rates of change for the data channel can corrupt
the recorded data.
15.8.6.5.
Record a Comment Line

Syntax
Record: [40 character comment]
Use
A comment line can be recorded in the data file. It will be
placed within the computer data file wherever the comment
was recorded.
15.9.
Examples
On the following pages, a few typical examples of test profiles
are shown.
Actual test profiles shipped with the test system are regularly
improved or expanded and may differ from the examples shown.
E S T
D I T O R
Test Name - AUTOLUG .TPF

CFA Name - SF602 .CFA Test Steps - 100
[Test Configuration]Load Control Mode = EngSpd
Test Description:
[AutoLug Test
]
Ramp Time =
.1 seconds
[
]
1. Linear Ramp Setpoints (with control mode over-ride):
Load to 0.000, in .1 seconds.
2. Set DIGOUT[8] to 0
3. Display0: [
] on front panel
4. Display1: [
] on front panel
5. Display2: [Please enter Lugpoint 1 rpm Î20.0^
] on front panel
6. If Memory 20 < 1000.0, then GOTO Step # 88
] on front panel
] on front panel
11. Display2: [Please enter Lugpoint 4 rpm Î17.0^ ] on front panel
13. Display2: [Please enter Lugpoint 5 rpm Î16.0^ ] on front panel
15. Display2: [Please enter hold time (Sec.) Î14.0^
] on front panel
16. Display1: [Please run in direct at high idle.
] on front panel
17. Display2: [Press START when ready.
] on front panel
18. Label Soft Keys (A-E): [ START
]
19. When Soft Key A is pressed, GOTO Step # 22
20. WAIT for .1 seconds
21. GOTO Step # 20
22. Erase Data Memory
23. Clear Soft Key Labels
24. Display1: [
] on front panel
25. Display2: [Checking RATIO, please wait.
] on front panel
26. WAIT for 5.0 seconds
27. Set Ratio = Ratio1
28. Clear Front Panel Messages
29. Label Soft Keys (A-E): [ SKIP
]
30. NOP ***************************************************************
32. Set EngSpd setpoint = Memory20
33. Set Memory22 = Memory20
35. CALL Step # 69
36. NOP ***************************************************************
37. Clear all WHEN statements from que
38. Record Data Line
43. CALL Step # 69
44. NOP ***************************************************************
SF-602
M a n u a l

51. CALL Step # 69
52. NOP ************************************************************
59. CALL Step # 69
60. NOP ************************************************************
67. CALL Step # 69
68. GOTO Step # 88
69. NOP ************************************************************
73. Label Soft Keys (A-E): [Skip
Controlling to^m23.0^ rpm.
]
74. Set Memory22 = Memory22 + 10.000
75. Set Memory21 = Memory21 - 10.000
76. Set Counter 1 to 0
77. If EngSpd > Memory 22, then GOTO Step # 76
78. If EngSpd < Memory 21, then GOTO Step # 76
79. Inc Counter 1
81. If Counter 1 <
3, then GOTO Step # 77
82. Label Soft Keys (A-E): [Holding at^m23.0^ rpm.
]
83. Set Timer 1 to .0
84. If Timer 1 < Memory 14, then GOTO Step # 84
85. RETURN
86. NOP ************************************************************
Load to 0.000, in .1 seconds.
89. When VehPwr < 50.000, then GOTO Step # 92
91. GOTO Step # 90
95. Display0: [Test has completed. Please allow vehicle
] on front panel
96. Display1: [to come to a complete stop.
] on front panel
97. Display2: [Vehicle Speed is ^c11^ MPH.
] on front panel
99. Keep Stored data on disk file
100. End Test
E S T
D I T O R
Test Name - AUTOSTEP.TPF

Test Description:
[High Idle to Rated Speed Step Test
]
Ramp Time = 1.0 seconds
[For an engine dyno application
]
Load to 0.000, in 1.0 seconds.
3. Display0: [
] on front panel
4. Display1: [
] on front panel
5. Display2: [Enter Starting RPM
Î20.0^
] on front panel
6. Display2: [Enter Ending RPM
Î19.0^ ] on front panel
7. Display2: [Enter Step Size Rpm Î15.0^ ] on front panel
8. Display2: [Please Enter Hold time Î14.0^ ] on front panel
9. Display1: [Run engine at full throttle
] on front panel
10. Display2: [Press START when ready.
] on front panel
11. Label Soft Keys (A-E): [ START
]
14. GOTO Step # 13
18. Linear Ramp Setpoints:
EngSpd to 5000.0, in .1 seconds.
19. If Memory 19 > Memory 20, then GOTO Step # 44
20. NOP ************************************************************
21. If Memory 20 < Memory 19, then GOTO Step # 66
Controlling to^m20.0^ rpm.
]
34. Inc Counter 1
35. If Counter 1 <
]
40. Set Memory20 = Memory20 - Memory15
42. GOTO Step # 21
43. NOP ************************************************************
44. If Memory 20 > Memory 19, then GOTO Step # 66
SF-602
M a n u a l

Controlling at^m20.0^ rpm.
]
55. Inc Counter 1
57. If Counter 1 <
]
63. Set Memory20 = Memory20 + Memory15
64. GOTO Step # 44
65. NOP ************************************************************
66. Set EngSpd setpoint = 5000.0
68. Display0: [Test has Completed.
] on front panel
69. Display1: [Run engine to idle.
] on front panel
70. Display2: [Engine speed is ^c125^ RPM
] on front panel
72. Keep Stored data on disk file
73. End Test
E S T
Test Name - RATIO .TPF

[Test Configuration]Load Control Mode = Manual
Test Description:
[Roll speed ratio calculation for
Ramp Time =
.0 seconds
[Corrected Power and Speed in Manual.
1. Set Ratio = 0.000
3. Set Load setpoint = 0.000
4. Label Soft Keys (A-E): [Waiting for Power to be less than 50 HP.]
5. If VehPwr > 50.000, then GOTO Step # 5
7. Display0: [Beginning the Roll Speed to Engine Speed
] on front panel
8. Display1: [Ratio Test. This Ratio is used for the
] on front panel
9. Display2: [for Corrected Power and Speed.
] on front panel
11. Display0: [Please select Direct Gear, and run
] on front panel
12. Display1: [to rated Engine Speed. When ready, press
] on front panel
13. Display2: [the A Key to continue.
] on front panel
14. Label Soft Keys (A-E): [Continue
16. GOTO Step # 16
17. Set Ratio = Ratio1
20. Display0: [The Ratio has been set. It will now be
] on front panel
21. Display1: [used to calculate Corrected Horsepower ] on front panel
22. Display2: [and Corrected Vehicle Speed.
] on front panel
25. End Test
D I T O R
]
]
SF-602
M a n u a l
Test Name - SETPOINT.TPF

Test Description:
[PAR Test with roll ratio, and rack
]
Ramp Time =
.1 seconds
[point.
]
2. Set Set Pt = 0.000
5. Display0: [Beginning Rack Setpoint Test.
] on front panel
6. Display1: [
] on front panel
7. Display2: [
] on front panel
8. NOP ************************************************************
11. Set Memory27 = EngSpd
14. If Rack < 1.000, then GOTO Step # 14
15. Set Memory27 = EngSpd
18. Label Soft Keys (A-E): [skip searching for rack at^m27.0^ rpm.
]
21. If Rack > 5.000, then GOTO Step # 20
26. GOTO Step # 22
27. Set Rack10 = EngSpd
28. NOP ************************************************************
33. GOTO Step # 29
34. Set Rack70 = EngSpd
35. Set Set Pt = RackPt
37. End Test
16
Configuration Editor
16. Configuration Editor

16.1. Overview of Configuration (DEF) File Function and Creation.................... 3
16.2. Configuration File Editor ............................................................................ 3
16.3. Defining Data Channels ............................................................................ 3
16.3.1. Closed Loop Control Channels ...................................................................... 4
16.3.2. System Channels ......................................................................................... 5
16.3.3. Measured Data Channels .............................................................................. 6
16.3.3.1.Description and application ...................................................................... 6
16.3.3.2.Defining Measured Data Channels ........................................................... 7
16.3.4. Calculated Data Channels ............................................................................. 9
16.3.4.1.Description and application ...................................................................... 9
16.3.4.2.Defining Calculated Data Channels ........................................................ 10
16.3.5. Specification Channels ............................................................................... 11
16.3.5.1.Description and application .................................................................... 11
16.3.5.2.Defining Specification Channels ............................................................ 11
16.3.6. Interpolated Data Channels ......................................................................... 13
16.3.6.1.Description and application .................................................................... 13
16.3.6.2.Defining Interpolated Data Channels ...................................................... 14
16.4. Designing Handheld Controller Screens ................................................. 15

16.4.1.
Changing the handheld display ................................................................... 15
16.5. Designing a Control System .................................................................... 18

16.6. Saving and Loading Configuration Files ................................................. 19
16.6.1.
16.6.2.
Save Configuration File to Disk ................................................................... 19

Loading Configuration Files ......................................................................... 19
16.1.
D I T O R
Overview of Configuration (DEF) File Function

and Creation
The Configuration program is used to define the functions of
WinDyn. Input Channels, Output Channels, Handheld
Controller, and Control Functions are defined in the Configuration (DEF) program. Once defined, the configuration is stored
in a *.cfa file on the PC hard disk and downloaded into
WinDyn memory. The Configuration (DEF) file is required for
WinDyn operation. From the Configuration program, the
operator defines the four basic elements of WinDyn:
WARNING
16.2.
NOTE
Input and Output Channels
Control System
Handheld Controller
Other Configurations (accessory devices)
The Configuration program requires a thorough knowledge of the system and

the testing hardware. Most systems are preconfigured to customer specification
at the factory. Improper editing of the Configuration file could result in system
failure.
In the Configuration editor, Specifications are also referred to as

Constants.
Configuration File Editor

To open the configuration file editor, select Design | System
Configuration from the WinDyn Menu.
16.3.
Defining Data Channels

The first and most important element of Configuration file
configuration is channel definition. Channel definition ultimately determines all other functions of WinDyn. All information WinDyn inputs or outputs is carried by channels
defined in the Configuration File Editor. The WinDynsystem
uses six types of channels:
Control
System
Measured Data
Calculated Data
Entered Constant Data
Interpolated Data
The specifics, applications, and definition of each type are

discussed below
Section 16 - page 3
SF-602
16.3.1.
M a n u a l
Closed Loop Control Channels

Channels: 2, 3, 10, 11, 12
Input type: 2, 3 Strain Gauge: 10,11,12 Frequency
Control channels are data channels that can function as closed
loop feedback channels. Closed loop feedback channels allow
WinDyn to servo (adjust) a control device, such as control on
a dynamometer or a throttle actuator to produce a desired
value, such as 100 lb-ft of torque or 4000 rpm. The control
system uses the control channel to see the current value, for
example the current torque value, and compares the current
value to the desired value. The control system continues to
servo, for example, the throttle controller (up or down depending on whether the current value is higher or lower than the
desired value) until the current value, the value of the control
channel, matches desired value. This process of read current
value, compare to desired value and adjust
continues until the control system is placed in manual mode.
Five control channels are available for use by up to two
controlled devices, such as dynamometer load and throttle
controllers. This allows five different controlled values to be
defined for closed loop control. In other words, one or both
controllers could be used to execute closed loop control of up
to two of five possible values. The combination of a controller
controlling a specific value is called a mode. Up to ten different control modes can be used by combining the five control
channel values with the two available controllers.
The control channels are of two input types: channels 2 and 3
are strain gauge input channels, channels 10, 11, 12 are
frequency input channels. These channels are discussed by
input type below.
Control channels 2 and 3 are strain gauge inputs. These channels are most often used to read data from load cells/ strain
gauges to provide torque data directly from water brake, eddy
current, and DC/AC dynamometers. Most often, channels 2 and
3 are used to measure torque from the absorber in dynamometer based testing applications. One of the channels would
be used for engine or roll torque. In some chassis dynamometer
applications such as Go-Power and Taylor, the front and rear
rolls use independent strain gauges. In this case, both Channels
2 and 3 could be used as closed loop strain gauge inputs.
Any type of strain gauge application could be used for closed
loop control on Channels 2 and 3. Shear, tension, or compression data output could be read and controlled from a strain
gauge in a specific gravity fuel cell. See the discussion of
Measured Data Channels for more information on using strain
gauge data applications.
Channels 10, 11 and 12 are closed loop frequency input channels. These Channels are closed loop capable and used in the
same manner as Channels 2 and 3 which were discussed
previously. These channels are most often used to measure
engine speed or, in the case of chassis dynamometers, roll
Section 16 - Page 4
D I T O R
speed, from magnetic pickups. For example, in engine dynamometer applications, one frequency channel is often defined
for engine speed (rpm). If two controllers are available, throttle
and load, engine speed can be controlled in closed loop
fashion by servoing the throttle to the desired speed or by
servoing the absorber load to achieve the desired speed.
It is not necessary to define all five channels. At a minimum,
one channel must be defined if closed loop control is required.
Many testing applications use two control channels, one for
torque and one for speed. This allows tests to be conducted
that control closed loop speed or closed loop torque. Chassis
dynamometers frequently use only one controller (load) but
two control channels, one roll speed, and one roll torque.
Testing requirements vary considerably in terms of control
requirements.
16.3.2.
System Channels
Channels: 200-229
Input Type: Fixed, not user configurable
System Channels are non-configurable channels that supply
important information to WinDyn. The following table lists
the system channels and their functions. System Channels can
be read and displayed in the same manner as data channels.
System channels can be used as operators in calculated channels. System channels cannot be used for closed loop control.
Though the user cannot change the definition of the system
channels (channels 220-229), the system memories can be
assigned values by the user in Advanced Test Profile steps.
Internal memory can be used to store values for calculation,
display, or other purposes.
Channels 209 and 219 are used as the Specific Gravity Data
Channels when Series 10 Specific Gravity Fuel Systems are
employed.
Channels 210-218 are Test Timers. Test Timers are used by the
autotest to monitor timing functions. The timers are not user
accessible. See the Advance Test Profile section.
NOTE
System channels are not user definable.
Section 16 - page 5
SF-602
M a n u a l
System Channels 200-229

200 ........................................... Time of day-hours
201 ......................................... Time of day-minutes
202 ........................................ Time of day-seconds
203 ............................................ Timer (seconds)
Counts up from zero when WinDyn starts or is reset
204 ................................................. Test timer
Counts up from zero when an autotest starts or is reset.
205 .............................................. Runtime timer.
Counts total engine running time on dyno (between user resets)
206 .................................... Gravimetric input (unused)
207 ........................................ Controller #1 Setpoint
208 ........................................ Controller #2 Setpoint
209 .......................................... Specific Gravity #1
210-218 ................................. Autotest timers #1-#9
219 .......................................... Specific Gravity #1
220-229 ............................... Memory #0 - Memory #9
231 ............................................. Autotest Line #
NOTE
The system channels are not directly addressable.
16.3.3.
Measured Data Channels
16.3.3.1.
Description and application

Channels: 2-76
Input type: Sensor input plugs via sensor input box.
Measured Data Channels are user-defined channels that
measure the output of sensors directly. Data channels may be
used for any display function, calculated channel, or valid
Advanced Test Profile function. Four types of measured data
channels are available in the WinDyn system:
Strain gauge, ch 2-3

Analog voltage only, ch 4-6
Frequency, ch 7-12
Thermocouple / analog voltage, ch 13-76
Strain gauge channels can read any strain gauge input. See the
table on Page 5 for Input Channel Specifications. Channels 2-3
are normally accessed at the sensor input box. Channels 2 and 3
are also closed loop control channels. In most cases, only one
strain gauge is used for closed loop control of torque. The strain
gauge channels, including the selected closed loop channel
(Channel 2 or 3) may be used for any display function, calculated channel, or valid advanced test profile function.
Section 16 - Page 6
D I T O R
Analog voltage channels may be used to measure any sensor

device outputting analog voltage. See the table for input specifications. Analog voltage inputs are most commonly used for
pressure transducer inputs in dynamometer applications. If
more than three pressures/analog voltages are needed, a universal input panel configured for voltage inputs is available
and is connected to one of the four thermocouple / analog
voltage sixteen channel groups between Channels 13-76. If
more than three pressures are needed, a pressure expansion
panel is required and is connected to one of the four thermocouple / analog voltage sixteen channel groups between
Channels 13-76.
Frequency Channels 7-12 can read any sensor device that
provides TTL output for input specifications. Three frequency
Channels 10, 11, and 12 are used for closed loop control of a
measured frequency, usually speed output from a magnetic
pickup. If one frequency channel is used for closed loop
speed, for example, roll speed (chassis dynamometer) or
engine speed (engine dynamometer), the other channels may
be used as frequency data channels. If more frequencies are
required, a universal input panel configured for frequency
inputs is available and is connected to one of the four thermocouple / analog voltage sixteen channel groups between
Channels 13-76.
The Thermocouple / Analog voltage channels are four blocks
of 16 channels each which accept thermocouple or analog
voltage inputs via pressure expansion panels, thermocouple
expansion panels, or universal input panels. The Input panels
may be mixed in any combination of four panels totaling 64
input channels. Each individual 16-channel group (13-29, 2944, 45-60 and 61-76) must be either analog voltage or thermocouple. Thermocouples cannot be mixed in the same sixteenchannel group with analog voltages.
The thermocouple expansion panels offer 16 K-type thermocouple channels.
Pressure expansion panels offer 10 pressure channels per
panel of user specified range and sensitivity.
16.3.3.2.
Defining Measured Data Channels

From the WinDyn main menu, select Design | System
Configuration.
The channel edit screen displays in DOS format.
Enter the desired channel number. Channels 2-76 are valid
measured data channel numbers. Remember that Channels 2, 3
10, 11 and 12 are closed loop control channels and should be
used as data channels only when other data channels are in use.
NOTE
Currently defined channels may be viewed by typing CTRL+Z while in the

channel edit screen.
Section 16 - page 7
SF-602
M a n u a l
NOTE
If editing a channel, an edit password must be entered. If your system password

has not been set, just press Enter.
If changing a thermocouple channel to an analog voltage channel, the existing
thermocouple channel definition must be cleared using the Clear Channel
function from the channel edit menu.
If any channel number from 13 to 76 is entered in the above

step, the screen prompts you to select channel type. Two
options are available:
Thermocouple and Analog Voltage.
Enter A for analog or T for thermocouple. Remember, if one
channel in a 16 channel group (13-28, 29-44, 45-60, 61-77) is
set for thermocouple, all channels within the 16 channel group
will be set to that channel type.
Enter the name of the channel. Up to 6 alphanumeric characters are allowed. Press Enter.
Enter the units of the channel in the desired notation convention. The units do not affect the channel value or calculation.
This entry is for labeling purposes only! Press Enter.
Enter the data format. This entry specifies how many, if any,
significant digits are displayed after the units place in the data
display. Units selects displays of only whole numbers above 0.
Tenths displays one place to the right of the decimal (X.x),
hundredths two places to the right (X.xx) of the decimal,
thousandths three places right of the decimal (X.xxx).
Press Enter.
Enter the calibration method. Three methods are available:
Entry, Full Scale, and Special Formula.
Entry Calibration calibrates the sensor between one corresponding output voltage/displayed sensor value and a second
corresponding output voltage/displayed value. This method is
useful when it is desirable to calibrate a sensors useful
range which may not extend full scale.
Full Scale calibrates the sensor by taking the user specified
sensor output value at 0 volts and at Full Scale (4.096 volts)
and linearizing the sensor output between the zero and 4.096
V values. This method is useful with very linear sensors. If a
sensor has a known non-linearity, it may be better to use entry
calibration or use a calculated channel and an interpolation
table. Pressure transducers are 0 to 3.636 volts full scale.
Special Formula converts the channel into a calculated
channel. This function is used to create additional calculated
channels. The equation entry parameters are the same as
described for calculated data channels. See Calculated Data
Channels later in this section. With the assistance of
SuperFlow customer service, this function can also be used for
closed loop control of calculated channels. SuperFlow does
not recommend attempting this without assistance.
Section 16 - Page 8
D I T O R
Press Enter after the calibration method entry is complete.

After the calibration method is selected, enter the autozero
method. When defining a thermocouple channel three
methods are available: No, Auto, and By Command.
No autozero specifies that the system will not autozero the
channel. The No autozero method is more commonly used to
prevent zeroing of absolute output devices that should not be
autozeroed. Examples of such devices are barometric pressure
sensors and fuel specific gravity sensors. Such sensors always
output a reading and are never in a zero output condition.
Autozero By Command allows the sensor to be autozeroed
manually by the operator from the PC or the Handheld Controller. This is the most common autozero setting for control
channel type sensors. For information on performing this
function, see the WinDyn command functions reference.
The Auto selection for autozero method is not yet implemented.
Press Enter after the autozero method entry is complete.
Enter the data filter rate. Seven choices are available. Entering
one of the five values fixes the data filter rate of the sensor.
Entering None prevents data filtering. Entering Auto allows
data filtering to be specified by WinDyn or the Handheld
Controller. Press Enter after the data filter entry is complete.
The maximum and minimum displayed value for the channel
is only implemented for control channels.
After all fields are complete, the screen prompts if all entries
are correct or if corrections are required. Answer Yes to edit,
No to continue.
Once the above prompt is answered with a Yes, the screen
prompts you to print the channel information. Answer Yes or
No. The channel edit selects screen displays. The next channel may now be edited/created.
16.3.4.
Calculated Data Channels
16.3.4.1.

Channels: 100-129
Input: No device input, only values from other channels.
Calculated Data Channels are used to perform mathematical
operations using other data, system, control and constant
channels. The most frequent use of a calculated channel is to
compute power. For example, if Channel 3 = torque (absorber
strain gauge lb-ft) and Channel 10 = engine rpm, a calculated
channel would employ the following formula to calculate
horsepower:
C3*C10/5252.113
Section 16 - page 9
SF-602
M a n u a l
The value of a calculated channel is the value of the function at

a given time. Any channel with a numerical value may be used
as constant or variable in a mathematical operation. Other
common uses of calculated channels are for correction factors
or corrected figures such as SAE power and SAE torque.
16.3.4.2.
Defining Calculated Data Channels

From the WinDyn main menu, select Design | System Configuration. The channel edit screen displays in DOS format.
Enter the desired channel number. Channel numbers between
100-129, inclusive, can be calculated channels.
NOTE

NOTE

Enter the units of the channel in the desired notation convention.The units do not affect the channel value or calculation.
display. The Units option selects displays of only whole
numbers above 0. The tenths option displays one place to the
right of the decimal (X.x), the hundredths option two places to
the right (X.xx) of the decimal, thousandths three places right
of the decimal (X.xxx). Press Enter.
The calculation equation entry screen appears. Enter the
desired equation according to the conventions described on
the screen. For example, assume C3 is torque in lb-ft (strain
gauge) and C10 is speed in rpm. Then horsepower is
(C3*C10)/5252.113
Press Enter after the calculation equation is complete.
The maximum and minimum displayed value for the channel
is only required for control channels.
After all fields are complete, the screen asks if all entries are
correct or if corrections are required. Answer Yes to edit, No to
continue.
prompts you to print the channel information. Answer Yes or
No. The channel edit selects screen displays. The next channel may now be edited/created.
16.3.5.
16.3.5.1.
D I T O R
Specification Channels
NOTE
In the Configuration editor Specifications are also referred to as Constants

Channels: 77-99
Input: No device or sensor inputs. Entered values only.
Specification Channels are user-defined channels that hold
discreet values entered for a test engine or vehicle. The values
do not change as do measured data channel values. The operator can change the value of specification data channels from
the PC, or the Handheld Controller, or by the autotest. For
information on entering soft key values in autotests, see the
When Soft Key command under the IF/WHEN commands of
the Autotest Commands reference. Common uses for specification channels include dimensions such as bore and stroke,
spark pulses/revolution, or fuel specific gravity.
More complex uses of the specification channels include
values for acceleration ramp tests. For example, a specification
channel could be used to create a calculated channel for
determining the commanded time of acceleration in an
acceleration ramp test. In such a case, the constant holding
the acceleration value would be used as an operator in a
calculated channel. This permits the operator to change the
acceleration rate from the Handheld Controller or PC computer, thus conducting several timed ramp tests with different
acceleration values without rewriting the autotest.
Example:
Channel 95 - Start
Channel 96 - StopAt
Channel 97 - StpTim
Channel 98 - StpSiz
Since the ramp time is a calculated value, changing the

Channel 97 adjusts the ramp to meet a new acceleration value
without changing the Test Profile. For more information on this
and other applications, see Ramp, Normal, under the Test
Profile commands reference.
16.3.5.2.
Defining Specification Channels

From the WinDyn main menu, select Design | System Configuration. The channel edit screen displays in DOS format.
Enter the desired channel number. Valid specification channel
numbers are 77-99.
SF-602
M a n u a l
NOTE

NOTE

Enter the units of the channel in the desired notation convention. The units do not affect the channel value or calculation.
display. Units selects displays of only whole numbers above 0.
Tenths displays one place to the right of the decimal (X.x),
hundredths two places to the right (X.xx) of the decimal, thousandths three places right of the decimal (X.xxx).Press Enter.
The screen prompts for the constant default value. Enter the
constant value. Press Enter.
After all fields are complete, the screen asks you if all entries
No to continue.
Once the above prompts is answered with a Yes, the screen
prompts to print the channel information. Answer Yes or No.
The channel edit selects screen displays. The next channel
may now be edited/created.
A typical group of specification channels is shown here.Units
Channel Name
Units
Type
77 ........... EngBor .............. mm ................... Constant

78 ........... EngStr ............... mm ................... Constant
79 ........... EngCyl .............. Number ............ Constant
80 ........... EngCyc ............. Cycles .............. Constant
81 ........... Induct ................ Type ................. Constant
82 ........... ECM .................. Type ................. Constant
83 ........... SparkP .............. Pul/Rv .............. Constant
84 ........... A/FLam ............. Ratio ................ Constant
85 ........... FuelSG .............. Coeff ................ Constant
86 ........... FA xCd .............. ft-sq .................. Constant
87 ........... Cts/Rv ............... .............. Constant
88 ........... TirDia ................. inches .............. Constant
89 ........... TirLos ................ Coeff ................ Constant
D I T O R
90 ........... DrvEff ................ Ratio ................ Constant

91 ........... RrAxWt .............. lbs .................... Constant
92 ........... TotlWt ................ lbs .................... Constant
93 ........... EngRat .............. Ratio ................ Constant
94 ........... MCInrt ............... Ratio ................ Constant
95 ........... Start .................. mph .................. Constant
96 ........... StopAt ............... mph .................. Constant
97 ........... StepTm ............. second ............. Constant
98 ........... StpSiz ............... mph .................. Constant
99 ........... DrvRat ............... Ratio ................ Constant
16.3.6.
Interpolated Data Channels
16.3.6.1.

Channels: 130-139
Input: No device inputs. Entered values only
Interpolated Data Channels are interpolation tables that determine values from devices with non-linear signal output. Such
devices include flow turbines (air and fluid). Before they are
integrated into a system, flow turbines are manually tested to
determine flow rates for given signal output. The resulting
table of output signal vs. flow values is entered into an Interpolation Table when defining an interpolated channel. An
interpolation channel holds the table of values. Interpolation
channels cannot be used alone. They are used with data
channels and calculated channels to interpolate the raw input
signal from a data channel through the interpolation table.
For example, begin with the following channel definitions:
Channel 133, an Interpolation Channel, is defined for a
gasoline flow turbine interpolation table. Channel 8, a frequency channel, is configured to measure flow turbine analog
frequency input. To derive the gallons/hour flow values from
the flow turbine input frequency at Channel 8, define a calculated channel C58 as follows:
C8T133
Strictly speaking, this syntax, used in the calculated channel
equation entry field, is not an equation.It instructs the channel
to modify the value of Channel 58 through the Interpolation
Table, Channel 133 (T133). Thus the gph flow values for the
fuel turbine frequency are displayed at calculated Channel 58.
Another use of Interpolation Channels is to define input-output
correspondence for complex mathematical functions. Equations can be solved for two values, input and output, and the
data entered into the table. This is useful when a complex
mathematical operation such as an integral, derivative, or
differential function is to be performed on an input signal.
SF-602
16.3.6.2.
M a n u a l
Defining Interpolated Data Channels

Configuration. The Channel Edit Screen displays.
Enter the desired channel number. Valid channel numbers are
130-139.
NOTE
NOTE
Currently defined channels may be viewed by pressing CTRL+Z while in the


The screen prompts you to select fixed or variable interval.

Fixed interval tables use an operator-defined interval to
determine the sample (x) values for which corresponding
output (F(x)) values will be assigned. Variable interval tables
allow the operator to assign any sample value (x) for a corresponding output (F(x)) value. In most cases, the choice of fixed
or variable type Interpolation Table is based on the interpolation data provided with the sensor to be interpolated. For
example, most flow meters are provided with variable interval
interpolation data.
Select fixed or variable interval with the arrow keys on the PC
keyboard. Press Enter.
If fixed interval was selected above, the screen prompts you to
enter the input value (x) value. The software will start at zero
and calculate upward 21 incremental values of the specified
interval. Press Enter.
The screen displays the table of values and highlights the first
F(x) value. Enter all the values, pressing Enter after each.
The values can be edited by using the arrow keys on the PC
keyboard to highlight the desired F(x) value.
After all 21 fields are complete, the screen asks if all entries
No to continue.
NOTE
By itself, an interpolation channel is only a table of input/output values. To

interpolate data, use a calculated channel to read the output of a data or
calculated channel through the interpolation table. See the discussion of using
interpolated channels at the beginning of the interpolated data channel section.

prompts to print the channel information. Answer Y or N. The
Channel Edit Select Screen displays. The next channel may
now be edited/created.
16.4.
Designing Handheld Controller Screens
16.4.1.
Changing the handheld display
NOTE
D I T O R
This is a brief explanation of how to change your Hand Held screens. If there
are any problems or questions, please contact SuperFlow before proceeding.
Call Customer Service at (719) 471-1746.
Handheld Controller screens display measured, constant,

calculated, and system data channels. The display of 9 channels can be grouped into screens for convenience.
NOTE
Channels must be defined before data screens can be designed.
NOTE
Handheld Controller screens are used only to organize data into 9 items of data
available in each of nine screens.
1. Press the Start button on Windows:

Choose Programs
Then Windows Explorer
A. Find directory labeled WinDyn, then SF602. Find file
labeled SF602.cfd and move it to the Config directory.
NOTE
Note: If this file is not in this directory it should already be in the Config
directory.
B. Close Windows Explorer.

2.
3.
In WinDyn choose Design.

Then System Configuration
A blue screen with the following choices should appear:
WinDyn Data Definition (DEF) Ver-5.0 Configuration file name: Memory

C - CLEAR channel specification
O - OTHER Configurations
D - DELETE configuration file
P - PRINT Listing
E - EDIT channel specification
Q - QUIT and return to WinDyn
G - GET (Open) config from disk
S - Design console data SCREENS (74x)
K - KEEP (Save) config to disk
Z - Design control system (74x)
SF-602
M a n u a l
4. Press the G key - Get (OPEN) Configuration from Disk.

This is the next screen you should see:
GET Configuration File
Enter the required file name - SF602
Files on - d:\windyn\sf602\config\
SF602
5.
NOTE
Ctrl Z will display all channel information
6.
NOTE
Choose SF602
Press the S key for Design console data screens.

This is an example of the screen that will appear:
The labeling is for the SF-740 Unit, however it is used on the SF-602 also.
Data Screen Design

SF-740 Data Screen # 1
EngSpd
VehPwr
VehSpd
Man T
Fuel T
Exh T
Man P
Fuel P
Exh P
<The Active Command Line...>
Computer Data Screen # 1
EngSpd Man T Man P VehPwr Fuel T Fuel P VehSpd Exh T Exh P
Use this screen to design the SF-740 data screens and the computer data screens.
Use the LEFT and RIGHT arrow keys to position the block on the entry you want to
change, then press Enter. Or press any of the keys listed below. An entry designated
as <none> will show up as a blank entry on the data screens, and an entry designated as indicates that an undefined channel has been selected. Press:
S - to select a different data screen number
P - Print a copy of the data screen selections
Enter - to alter the selected en
Esc - to Exit
D I T O R
The representation of the screen appears at the top of the Edit

Screen. Nine channels of data may be displayed.
The editor defaults to designing Screen #1. To change the
screen, press the S key, enter the desired screen (1-9), and
press Enter.
When the desired screen is available for editing, the first of the
nine display channels is highlighted. Use the arrow keys to
select the desired display field of the Stored Data Screen, and
press Enter.
Enter the channel number (or special channel number at the
bottom) that is to be displayed. Press Enter.
NOTE
Press CTRL-Z for channel list display.
The channel name appears on the mock display screen and

the position selected in the nine horizontal display selectors.
Repeat until all necessary channels are defined.
Select S from the menu to begin display set up for next data
screen. Enter the next screen to be configured/edited. (9
screens are available with 9 display channels each for a total
of 81 displayed channels).
Screen 9 also defines the channels to be displayed on the LCD
displays on the sensor input boxes, when the SET program is
not used
Select P to print a copy of the screen definition.
Press Esc to return to the Configuration (DEF) main menu.
7.
If changes were made press the K key Keep (save)

configuration.
8.
Save changes as SF602, it will ask you if you want to Overwrite the existing file. Choose YES. At this time it will tell
you it is done with the compilation, Press any Key to continue.
Hit any key and you will return to the first screen.
9.
Press the Q key Quit and return to WinDyn. The system

will ask you if you are sure you want to Quit Choose YES.
10.
At WinDyn, load the CFA file by pressing the CFA Icon

under the word FILE. Choose SF602.cfa and press OK.
Then load the TGP file by pressing the TGP Icon under the
word FILE. Choose SF602.tgp and press OK.
11.
Back at WinDyn choose Test Group arrow down to INSTALL arrow right and Down to Calibration and press
Enter. Now choose SF602.cal and press OK.
12.
Follow above instructions with the exception of choosing

Calibration. Choose Control System and press Enter.
Now choose SF602.ccp. and press OK.
SF-602
16.5.
M a n u a l
Designing a Control System

Once defined, channels are assigned to the two controllers in
WinDyn. The channels assigned to the controller permit
closed loop control of engine and/or dynamometer. In most
applications, the controllers are engine and dynamometer
controllers. At least one control channel must be assigned to
each channel if closed loop control is desired. For example, if
a torque channel (strain gauge input) is assigned to the engine
controller, and a speed (engine rpm) channel is assigned to the
dynamometer controller, the following control modes are
possible:
Dynamometer controller:
Absorber (load) controls speed
Engine Controller:
Throttle (position) controls torque
If several control channels are assigned to each controller, e.g.,
speed and torque for each channel, two modes are available
for each controller. To set up the control system:
NOTE
Channels should be defined prior to designing a control system, in particular

control channels must be defined.

Configuration.
Then select Z - Design control system. Press Enter.
The Control Channel Input Type screen displays. For Channels 7-12, highlight the desired channel, and press Enter.
Select the input type: TTL or Voltage. Press Enter.
Select Exit. Press Enter.
The Control Configuration screen displays.
If a throttle controller is used to configure the engine controller,
use the arrow keys on the PC keyboard to select the channels
(2, 3, 10, 11, 12) that will be used as control channels. Only
channels, which are defined in the current configuration, can
be used as control channels. Select the desired channels. In
most cases, either Channel 2 or 3 would be con-figured for
strain gauge output and at least one of Channels 10, 11 or 12
would be configured for engine or roll speed.
Typically, the engine throttle controller is configured for one
torque (strain gauge Channel 2 or 3) and one speed Channel
(10, 11 or 12). In this configuration, the engine controller could
control to speed or torque in closed loop mode. More than one
channel might be used if Channel 2 was configured for torque
(strain gauge) and Channel 3 was configured as calculated
channel for power. In this configuration, the engine controller
can control to torque, power, or speed.
Once the engine controller setup is complete, select Done.
Repeat the above process for the dyno (absorber) controller.
D I T O R
Select Done when the dyno controller setup is complete.

The screen prompts to confirm the data. Answering No reenters the controller setup screen, answer Yes to continue.
If yes was selected above, the screen prompts to save the
control system to a file. Enter the eight-character file name.
Press Enter.
Answer Yes to accept, No to exit the control system setup
screen.
16.6.
Saving and Loading Configuration Files
16.6.1.
Save Configuration File to Disk

Once a configuration is complete, select Keep Configuration
on Disk. The *.cfa file loads into WinDyn when configuring
the system. Each time a configuration is saved, the program
overwrites the old files.
16.6.2.
Loading Configuration Files

To load a Configuration File, Select Test Group | Install |
Configuration.
Select the name of the Configuration File to load. Press Enter.
NOTE
WinDyn will display only Configuration files (*.cfa) located in the path
directories specified for Configuration files. See Design | System Setup | File
Paths on the main menu.
The lower tool bar on WinDyn and the Handheld Controller

display will show that a new configuration file is installed.
17
WinDyn
Software Architecture
17. WinDyn Software Architecture

17.1
WinDyn Software Architecture ........................................................... 3

Executable Components .............................................................................................. 3
Non-Executable Components ....................................................................................... 3
17.2. Executable Components ........................................................................... 3

17.2.1.
Data Acquisition System ..................................................................... 4
17.2.2.
Communication Interface ..................................................................... 4
17.2.3.
DAC740.DLL ......................................................................................... 4
17.2.4.
WinDyn.exe ........................................................................................ 4
17.2.5.
Stored.exe ............................................................................................ 5
17.2.6.
DataLib.exe .......................................................................................... 5
17.2.7.
Editors ................................................................................................ 5
17.2.8.
Custom Applications ........................................................................... 5
17.2.9.
OLE Interface ...................................................................................... 5
17.2.10.
Excel.exe ............................................................................................ 6
17.2.10.1.Overview .............................................................................................. 6
17.2.10.2.Workbooks ........................................................................................... 6
17.2.11.
Xload16.dll ............................................................................................. 7
17.3. Non-Executable Components (Files) ........................................................ 7

17.3.1.
Initialization File .................................................................................. 7
17.3.2.
Help Files ............................................................................................ 7
17.3.3.
Comments File .................................................................................... 8
17.3.4.
Configuration Files ............................................................................... 8
17.3.5.
Limits Files .......................................................................................... 8
17.3.6.
Autotest Files ...................................................................................... 8
17.3.7.
Control System Files ........................................................................... 8
17.3.8.
Switch Files ........................................................................................ 9
17.3.9.
Display Files ....................................................................................... 9
SF-602
M a n u a l
17.3.10.
Test Group Files .................................................................................. 9
17.3.11.
Stored Data Files ................................................................................ 9
17.3.12.
CSV Files ............................................................................................ 9
17.3.13.
Calibration Files ................................................................................. 10
17.3.14. Specification Files ...................................................................................... 10
Section 17 - Page 2
17.1
I N
Y N
O F T W A R E
R C H I T E C T U R E
WinDyn Software Architecture

SuperFlows WinDyn software system is composed of Executable components (programs) and Non-Executable components
(files).
Executable Components
Software executables that comprise the WinDyn software
system.
Non-Executable Components
User configurable files utilized by the WinDyn software
system.
17.2.
Executable Components
The WinDyn software system is composed of several software
executables as shown in the following diagram.
Section 17 - page 3
SF-602
17.2.1.
M a n u a l
Data Acquisition System

This box represents some type of data acquisition or control
system. Examples include dynamometers, flow benches, and
automotive emissions systems
17.2.2.
Communication Interface
This box represents a software adapter between the data
acquisition system and Dac740.dll. The function of the communication interface is to format the data to or from the data
acquisition system into a form acceptable to Dac740.dll.
Communications interfaces have been written for the SF74XX,
SF-7100, SF901 console, SF602 and SF200 dynamometers, and
flow bench computer systems.
17.2.3.
DAC740.DLL
This is a Windows Dynamic Link Library (DLL) which contains
a library of routines written by SuperFlow to facilitate data
handling and communication to and from dynamometer data
acquisition systems. The function of this library is to provide a
set of routines which define a common interface to real-time
and stored data for application-level programs. With this DLL,
an application program can perform such operations as obtain
the current value of some data channel, its name and units,
record data lines, send and receive files, read stored data from
disk files, and calibrate channels.
17.2.4.
WinDyn.exe
This is SuperFlows run-time graphical user interface program.
WinDyn provides access to editors for system configuration,
run-time screens, and post-data acquisition programs such as
Stored.exe and Excel.exe. Examples of the run-time screen
display types available include analog meters, vertical bar
graphs, tabular data displays, time-based strip charts, live
video, digital readouts, and digital switches.
Section 17 - Page 4
17.2.5.
I N
Y N
O F T W A R E
Stored.exe
This is SuperFlows program for viewing and printing tabular
stored data (either from the data acquisition memory or from
disk). The data may be viewed as it is being recorded.
17.2.6.
DataLib.exe
This is SuperFlows database program used for managing and
archiving stored test data.
17.2.7.
Editors
Editors are required to configure the various functions of the
data acquisition/control system. Examples include channel
configuration, limits, autotest, switch, and control system. Note
that real-time screens are edited using WinDyn itself.
17.2.8.
Custom Applications
Custom applications can be written using the Dac740.dll to
provide the user with data in a unique way. An example of this
is the software which was written for the Mexico City emissions program. If a programmer is given the appropriate header file and documentation, he/she could write an application
which could access the data acquisition system as required.
17.2.9.
OLE Interface
This is an interface which exposes certain functions of the
Dac740.dll to automation using the magic of Microsofts OLE
system. Basically, OLE is a form of interprocess communication for use in Windows. What this interface does is allow
OLE automation clients access to Dac740.dll functions. Currently, we have only made available OLE routines for manipulating stored data. This interface facilitates use of our
Dac740.dll by such programs as Excel, and such programming languages as Visual Basic. There is the possibility of a
secondary market here for software writers who can write
Visual Basic applications which access our stored data. Two
implementations of this interface have been created. Sfole.dll
is a 16-bit dynamic link library version for use with 16-bit OLE
Section 17 - page 5
SF-602
M a n u a l
clients such as Excel version 5.0. Sfole.exe is a 16-bit executable version which can be used with either 16-bit or 32-bit OLE
clients. The advantage of Sfole.dll is that it is considerably
faster than Sfole.exe due to the fact that function calls only
have to transcend 1-executable task boundary. The advantage
of Sfole.exe is that the thinking required between a 32-bit
executable such as Excel 7.0 and our 16-bit Dac740.dll is
handled automatically by the OLE system.
17.2.10.
Excel.exe
17.2.10.1. Overview
In addition to the test data view, print, and plot functions built
into WinDyn (via the Stored Data Viewer), WinDyn also
provides an optional automatic interface to Microsoft Excel.
This interface allows you to automatically display and plot
your WinDyn test data using Microsoft Excel. WinDyn users
already familiar with Microsoft Excel may prefer this alternate
method of viewing and plotting test data due to Excels advanced data analysis and plotting functions.
17.2.10.2. Workbooks
Three workbooks have been written to work in conjunction
with Microsoft Excel. These workbooks include macros written
in Visual Basic for Applications designed to automate the
repetitive steps of loading data into the worksheet cells and
plotting it.
NOTE
1.
2.
Section 17 - Page 6
1.
Single.xls is designed to view a single data file in

several different ways.
2.
Multiple.xls is designed to view up to three files

simultaneously for test comparisons (overlays).
3.
Windyn.xls is the menu interface for handling the

dynamic loading of Single.xls and Multiple.xls.
The WinDyn to Microsoft Excel interface is provided on a set of install

disks separate from the main WinDyn install kit.
Programmers can modify and customize any of the Visual Basic for
Applications routines which SuperFlow provides to implement the
WinDyn to Microsoft Excel interface. There is the possibility of a
secondary market here for software writers who can write Excel macros
or add-ins.
17.2.11.
I N
Y N
O F T W A R E
Xload16.dll
This is a utility program which expedites the loading of stored
data into the worksheet cells of Excel. This is a 16-bit dynamic
link library which does not use OLE. This program will only work
with 16-bit versions of Excel (EXCEL version 5.0c is recommended).
17.3.
Non-Executable Components (Files)

There are several non-executable files required for the operation of WinDyn. The WinDyn program automatically
handles the interaction between itself and the executables
which process each of these files.
17.3.1.
Initialization File
The initialization file is called SUPERFLO.INI and is located in
the Windows subdirectory. This file is installed when you
install WinDyn and contains startup configuration information
for all of the SuperFlow Windows executables. This file can be
modified using an ASCII text editor. Certain entries in this file
are also updated by the various Windows executable programs.
17.3.2.
Help Files
Help files in Windows have a .HLP extension. We have provided help files for all SuperFlow executable programs.
Section 17 - page 7
SF-602
17.3.3.
M a n u a l
Comments File
A comments file with the name COMMENTS.TXT exists in the
WinDyn programs directory. This is an ASCII text file which is
intended to contain any user comments that should be stored
along with the stored data file. The maximum size of this file
is 5280.
17.3.4.
Configuration Files
System configuration files are in the form .CFA extension.
These files are edited using DEF.EXE, the old DOS editor
originally written for the SF740 system. These files contain
information which describe the various data channels such as
name, display units, channel type, etc. The compiled versions
of these files are loaded into the dynamometer systems directly, and also into the communications interface programs
for the systems. A configuration file is required for data display, test and limits editing, etc.
17.3.5.
Limits Files
Limits files have a .LMT extension. These files are edited
using a limits file editor. Once edited, limits files are loaded
into the data acquisition system for processing.
17.3.6.
Autotest Files
Autotest files have a .TPF extension. These files contain
system automation scripts to facilitate testing. Autotest files are
edited using an autotest editor. Once edited, autotest files are
loaded into the data acquisition/control system for processing.
17.3.7.
Control System Files

Control system files have a .CCP extension. These files configure the control system in most systems. The files are edited
using the DOS editor CTRLPARM.EXE. Control system configuration includes setting controller phase and control system
gains. Once edited, control files must be loaded into the
control system for processing.
Section 17 - Page 8
17.3.8.
I N
Y N
O F T W A R E
Switch Files
Switch files are found in two forms, editable (.SCA) and
compiled (.SCF). These files configure the digital switch/relay/
input system on SF742X series systems. Switch files are edited
using the DOS editor SWED.EXE. Once edited, switch files
must be loaded into the data acquisition/control system for
processing.
17.3.9.
Display Files
Display files have a .CDF extension. These files contain the
information which describes how the current data screens will
appear. Display files are edited by WinDyn itself.
17.3.10.
Test Group Files

Test group files have a .TGP extension and facilitate the loading
of the above configuration files. These files are edited using the
test group editor of WinDyn. The user can specify configuration, display, autotest, limits, calibration, control, specifications
and switch files which can be loaded when ever the test group
file is loaded.The test group file also has information regarding
stored data channel ordering and WinDyn startup options.
17.3.11.
Stored Data Files

Stored data files have a .SFD extension. These files contain a
copy of the .CFA format of the configuration file, a copy of the
COMMENTS.TXT file, and the data in the old .DDF format.
17.3.12.
CSV Files
Comma Separated Variable (CSV) files can be used to import
data into Excel, or export data to various mathematical
programs. To import data into Excel, CSV files must conform
to a particular format [see DEMO.CSV, or Excel help file].
Section 17 - page 9
SF-602
M a n u a l
17.3.13.
Calibration Files
Calibration files are used to calibrate the data acquisition
system dyno to a specific set of data acquisition sensors.
17.3.14.
Specification Files
Specification files are used to set the values for important test
parameters such as Engine Bore and Stroke.
18
WinDyn How To...
18. WinDyn How To...

18.1. Setup WinDyn to run a test ....................................................................... 3
18.1.1.
18.1.2.
18.1.3.
18.1.4.
18.1.5.
18.1.6.
Load a Test Group ......................................................................................... 3

Check the Test Data File Path ....................................................................... 3
Check the Manual Save Data Filename ........................................................ 3
Check the Test Description ........................................................................... 3
Check the Test Specification Values ............................................................. 4
Autozero Sensors ......................................................................................... 4
18.2. Run a Current Data Display using a different Configuration File ............... 4
18.2.1.
18.2.2.
18.2.3.
18.2.4.
18.2.5.
Edit the desired Display Screen .................................................................... 4

Use Save As to save the Display Screen under a new name ...................... 5
Assign the new Configuration to the Display Screen ..................................... 5
Save the Display Screen .............................................................................. 5
Run the new Display Screen ......................................................................... 5
18.3. Modify a WinDyn Calculated Channel...................................................... 6

18.3.1.
18.3.2.
18.3.3.
18.3.4.
18.3.5.
18.3.6.
18.3.7.
18.3.8.
Set the Configuration File Path ..................................................................... 6

Display the Configuration Editor .................................................................... 6
Get (Open) the desired Configuration ............................................................ 6
Determine the Calculated Channels channel number .................................... 7
Edit the Calculated Channel .......................................................................... 7
Keep (Save) the modifications ...................................................................... 7
Exit the Configuration Editor ......................................................................... 7
Reinstall the Modified Configuration .............................................................. 7
18.4. Remove WinDyn Completely from a Computer. ....................................... 8

18.4.1.
18.4.2.
18.4.3.
18.4.4.
18.4.5.
18.4.6.
18.4.7.
18.4.8.
Save Existing Test Group files and Data files ............................................... 8

Close all Running Applications ...................................................................... 8
Run the Uninstall Program ............................................................................ 8
Delete the WinDyn Folder ............................................................................. 8
Delete the file SUPERFLO.INI ...................................................................... 8
Delete the SuperFlow folder from the Windows Registry ............................... 9
Delete the SuperFlow environment variable from autoexec.bat ..................... 9
Restart Windows 95 ...................................................................................... 9
18.1.
I N
Y N
O W
Setup WinDyn to run a test

This section describes the WinDyn steps necessary to properly configure the system for testing, from loading a Test Group
to auto-zeroing the remote test systems sensors. It may not be
necessary to perform each of these steps before running every
single test, but the WinDyn operator should be aware of all
the steps in order to ensure accurate test results. This section
assumes the dynamometer has already been successfully
calibrated.
18.1.1.
Load a Test Group

First, load a Test Group. Select Test Group | Open Test Group
from the main menu. From the displayed list, select the desired
Test Group and click OK. The selected Test Group will load.
18.1.2.
Check the Test Data File Path

After the Test Group is finished loading, check the test data file
path. This path is where WinDyn will store all test data files.
Select Design | System Setup | File Paths from the main
menu. Verify that the path in the top Data Path box is correct.
Type in a new path if desired. Click OK to save any changes. If
the new path typed in does not already exist, WinDyn will
automatically create it.
18.1.3.
Check the Manual Save Data Filename

Next, check the Manual Save Data file name. This is the
default file name WinDyn will use when creating Test Data
files. Select Design | System Setup | File Names from the
main menu. Verify that the file name in the Manual-Increment
Filename box is correct. Type in a new file name if desired.
The last 4 characters must be numbers. WinDyn will increment the numbers at the end of this name each time data is
saved to disk. This allows the operator to simply click OK
when saving data, instead of typing in a new file name each
time. Click OK to save any changes.
18.1.4.
Check the Test Description

Next, check the Test Description. Select Design | Test Description from the main menu. The notes listed here will be automatically saved as part of each test data file. Type in any
desired notes and click OK.
Section 18 - page 3
. . .
SF-602
18.1.5.
M a n u a l
Check the Test Specification Values

Next, check the current Specifications. Select Calibrate |
Specifications from the main menu. The window that appears
shows the Specifications currently in use for testing. These
values should have been set correctly when the Test Group
was loaded, if a Specifications file is included as part of the
Test Group you loaded. If the Specification values are not
correct, select File | Open | Saved Specifications from the
Specifications window menu. From the displayed list, select
the desired Specifications file and click OK. The values
associated with the selected Specifications file will appear.
Verify that they are correct (press Enter if you need to make
changes), then select File | Install Specifications from the
menu. Select File | Exit to close the Specifications window.
18.1.6.
Autozero Sensors
Finally, Auto-zero the test systems sensors. Verify that the
engine is NOT running, then select Calibrate | Channels from
the main menu. In the Calibrate Channel window that appears, click the Zero All button. Read the message that appears, then click Yes. This will auto-zero all the appropriate
channels listed in the box located to the left of the Zero All
button. When the auto-zero process is complete, click Done to
close the Calibrate Channel window.
WinDyn is now setup and ready to run a test.
18.2.
Run a Current Data Display using a different

Configuration File
This document describes how to assign a new Configuration file
to an existing WinDyn Current Data Display Screen. This allows
you to use any WinDyn Display Screen with any Configuration
file. This document applies to WinDyn Version 1.10.
18.2.1.
Edit the desired Display Screen

Display the desired Current Data Display Screen in Edit mode
as follows: From the WinDyn main menu, select Screens |
Edit Screen Displays | Existing Screens. Click on the desired
Display Screen from the displayed list, and then click OK. The
Display Screen will appear in Edit mode.
Section 18 - Page 4
SF-602 manual V2- 1125 Sect18 .PM6.5, 5/1998
18.2.2.
I N
Y N
O W
Use Save As to save the Display Screen under a new name

From the WinDyn main menu, select Screens | Edit Screen
Displays | Save Screens As. In the box that appears, type in a
new name for the Display Screen (for example: TESTSCRN)
and then click OK.
18.2.3.
Assign the new Configuration to the Display Screen

Displays | Assign Configuration. Click on the desired Configuration from the displayed list, and then click OK.
18.2.4.
Save the Display Screen

Displays | Save Screens to save your changes. Next, select
Screens | Edit Screen Displays | Close Screens to finish the
edit session.
18.2.5.
Run the new Display Screen

At this point, you have two (2) identical Display Screens, the
only differences being that each runs under a different Configuration, and each has a unique file name. Run the new
Display Screen using the new Configuration as follows: First
click on the Configuration (CFA) button located on the
WinDyn toolbar (select Window | Toolbar from the WinDyn
main menu if the toolbar is not currently visible). Click on the
new Configuration from the displayed list, and then click OK;
this will load the new Configuration. Next, click on the Run
Screens button located on the WinDyn toolbar. Click on the
newly named Display Screen from the displayed list, and then
click OK. The Display Screen will appear in Run mode.
The WinDyn Display Screen is now running under the new
Configuration. You may assign the new Configuration and
Display Screen to a Test Group, if desired.
Section 18 - page 5
. . .
SF-602
18.3.
M a n u a l
Modify a WinDyn Calculated Channel

This document describes the steps necessary to modify the
mathematical formula associated with a WinDyn Calculated
Channel. This document applies to WinDyn Version 1.10.
18.3.1.
NOTE
Note on viewing Calculated Channels: If you wish to only view a Calculated

Channel (in order to see how WinDyn is calculating data) and you do not need
to make any changes to the channel, use the Configuration Utility provided with
WinDyn. First select Tools | Configuration Utility from the WinDyn main menu.
When the Configuration Utility appears, press F2 to display a list of available
Configurations. Click on the desired Configuration and then click Open. Click
the Sort By Name check box to sort the list of Calculated Channels by channel
name. Scroll to the desired channel and select it with the Left mouse button. The
formula for the Calculated Channel will be displayed. Select Help | Contents
from the Configuration Utility menu to read about the format of WinDyn
Calculated Channels.
Set the Configuration File Path

First, verify the path where the Configuration Editor will look
for files. Select Design | System Setup | File Paths from the
WinDyn main menu. Verify that the path in the Configuration path box points to the directory where the Configuration
file you wish to modify resides. Type in a new path if desired.
Click OK to save any changes.
Note that the DOS based Configuration Editor has a limitation
on the file path length. This means that the editor cannot
see Configuration files if the file path string (displayed in the
Configuration path box) contains more than 30 characters.
Therefore, configuration files must reside in a directory whose
file path is less than 31 characters before you can edit the
configuration file.
18.3.2.
Display the Configuration Editor

Select Design|System Configuration from the WinDyn main
menu. The DOS based Configuration Editor (WinDyn Data
Definition) will appear showing the editors main menu
screen.
18.3.3.
Get (Open) the desired Configuration

Press the G key on the keyboard. A list of available Configurations will be displayed. Type in the name of the desired
Configuration (for example: US901E) and press the Enter key.
A listing of the channels in the Configuration you selected will
be displayed (in yellow).
Section 18 - Page 6
18.3.4.
I N
Y N
O W
Determine the Calculated Channels channel number

Now you need to know the channel number of the Calculated
Channel you wish to edit. Press Ctrl-Z on the keyboard to view
the Current Defined Channels screen. This screen displays a
list of all the defined channels in the Configuration file you are
currently editing. From the displayed list, find the channel
name of interest and its associated channel number. Press the
Escape key to exit the Current Defined Channels screen.
18.3.5.
Edit the Calculated Channel

Press E to enter the Channel Edit screen. Type in the
channel number for the Calculated Channel you wish to edit
and press Enter. Then press the Enter key three (3) more times
to view the Calculated Channels formula. Type in the desired
modification(s) to the formula. Then press the Enter key five (5)
more times to return to the Channel Edit screen. Finally,
press the Escape key to return to the main menu screen.
18.3.6.
Keep (Save) the modifications

To save the changes, press K and then press Enter. The editor
will ask you if want to overwrite the existing file; press Y for
yes. The compile screen will appear; if there are any errors
in the formula you modified, this is where the error(s) will be
displayed. Repeat the preceding edit steps to fix any errors.
Once the compile screen reports no errors, press any key to
return to the main menu screen.
18.3.7.
Exit the Configuration Editor

To exit the Configuration Editor, press Q and then press Y in
response to the message Quit? This will return you to the
WinDyn main window.
18.3.8.
Reinstall the Modified Configuration

Finally, reinstall the modified Configuration as follows: Click
on the Configuration (CFA) button located on the WinDyn
toolbar (select Window | Toolbar from the WinDyn main
menu if the toolbar is not currently visible). From the displayed
list of Configurations, click on the Configuration you just
modified, and then click OK; this will load the modified
Configuration and make your changes active.
The Calculated Channel is now modified and active. If desired, you may now run a Current Data Display Screen that
shows the channel of interest in order to verify that the new
calculation is correct.
Section 18 - page 7
. . .
SF-602
18.4.
M a n u a l
Remove WinDyn Completely from a Computer.

This document describes how to completely remove WinDyn
from a computer. This document applies to WinDyn Version
1.10. This document is written for the SF901 system, but may
be applied to all SuperFlow WinDyn1.10 systems by replacing your systems name wherever you see 901 (e.g.,
MCDyno, 602, 7100, 74x). Note that this procedure is not
necessary when merely upgrading to a newer version of
WinDyn.
18.4.1.
Save Existing Test Group files and Data files

If you DO NOT wish to save any existing WinDyn files
(including your Test Data files and your Test Database) you
may skip to Step 2. Otherwise, use Explorer to copy the
\WinDyn\901\ folder (and all subfolders) to a temporary
directory. This will save all existing Test Groups, Configurations, Screens, Specifications, Calibrations, Controls, Switch
Configurations, Autotests, Limits, Data Files, and the Test
Database for later use if you reinstall WinDyn.
18.4.2.
Close all Running Applications

Before continuing, be sure to close all software applications
that are currently running, especially any SuperFlow applications such as WinDyn or WComlink.
18.4.3.
Run the Uninstall Program

Click the Start button, point to Programs, point to SuperFlow
WinDyn, and then click on Uninstall WinDyn for SF901.
Follow the uninstall programs instructions.
18.4.4.
Delete the WinDyn Folder

Use Explorer to delete the \WinDyn\ folder (and all
subfolders) from the hard disk. Answer Yes to all prompts.
18.4.5.
Delete the file SUPERFLO.INI

Use Explorer to delete the following file:
C:\WINDOWS\SUPERFLO.INI
Section 18 - Page 8
18.4.6.
I N
Y N
O W
Delete the SuperFlow folder from the Windows Registry

CAREFUL
Follow the instructions in this step very carefully. Unintentionally deleting or

modifying entries in the registry can cause your computer to behave erratically
or even to stop functioning.
Use the Registry Editor to delete the SuperFlow Windows 95

Registry entry. To do this, click the Start button, point to
Programs, and then click on MS-DOS Prompt. In the DOS
window that appears, type REGEDIT and press Enter. The
Registry Editor will appear showing various registry folders.
Expand the HKEY_CLASSES_ROOT folder. Scroll down and
find the SuperFlow folder. Click on the SuperFlow folder to
highlight it, then press the Delete key. Answer Yes to the
confirmation. From the Registry Editor menu, select
Registry|Exit to close the Registry Editor. In the DOS window
(which is still displayed) type in EXIT and press Enter. The
DOS window will close.
18.4.7.
Delete the SuperFlow environment variable from autoexec.bat

Use a file editor to delete the SuperFlow environment variable
line from the AUTOEXEC.BAT file:
(For example: SET SUPERFLOW=C:\WINDYN\PROGRAMS).
Delete the entire line, then save the modified autoexec.bat file.
18.4.8.
Restart Windows 95
Click on start, and select Shut Down. Select Restart the
Computer? and click Yes.
SuperFlow WinDyn is now completely removed from the
computer.
Section 18 - page 9
. . .
19
Advanced PC
Troubleshooting
19. Advanced PC troubleshooting

19.1. Troubleshoot PC device conflicts in Windows 95 ...................................... 3
19.1.1.
19.1.2.
19.1.3.
19.1.4.
19.1.5.
19.1.6.
Viewing the Device Manager ......................................................................... 3

Understanding the Symbols (!, X, and i) ................................................... 3
Viewing the Device Properties Sheet ............................................................ 3
Changing Resource Settings ......................................................................... 4
Viewing and Excluding Resources ................................................................ 4
Disabling a Device ........................................................................................ 4
19.2. Troubleshoot Printing Problems in Windows 95 ........................................ 5

19.2.1.
19.2.2.
19.2.3.
19.2.4.
19.2.5.
19.2.6.
19.2.7.
19.2.8.
19.2.9.
19.2.10.
19.2.11.
19.2.12.
19.2.13.
19.2.14.
19.2.15.
19.2.16.
19.2.17.
19.2.18.
19.2.19.
19.2.20.
19.2.21.
19.2.22.
19.2.23.
19.2.24.
19.2.25.
Read Printers.txt ........................................................................................ 5

Read Online Help .......................................................................................... 5
Reset the Printer ........................................................................................... 5
Use the Print Troubleshooter ......................................................................... 5
Print from an MS-DOS Prompt ..................................................................... 6
Print from Notepad and WordPad .................................................................. 6
Verify Printer Properties ................................................................................ 7
Check the Device Manager Settings ............................................................. 7
Perform Hard Disk Maintenance .................................................................... 7
Use ScanDisk and Disk Defragmenter .......................................................... 8
Remove and Reinstall the Printer Driver ........................................................ 8
Remove and Reinstall the Printer Port .......................................................... 9
Use the Generic/Text Only Printer Driver .................................................... 10
Use the LPT1.DOS printer port ................................................................... 10
Use the Alternate Lpt.vxd File ..................................................................... 10
Change the Printers Emulation Mode ......................................................... 11
Disable the Enhanced Capabilities Port ...................................................... 11
Simplify the Document ............................................................................... 12
If You Can Print from a DOS Command Prompt But Not Windows- ................
Based Programs ......................................................................................... 12
If Printing Problems Occur Only in One Application .................................... 13
Solving Network Printing Problems ............................................................. 13
Solving Printing Speed Problems ................................................................ 15
Using Windows 3.1 Printer Drivers .............................................................. 16
Windows 3.x Required Disabling Fast Printing Direct To Port ...................... 16
Additional Information ................................................................................. 16
19.3. Troubleshoot Startup Problems in Windows 95 ....................................... 17

19.3.1.
19.3.2.
19.3.3.
19.3.4.
19.3.5.
19.3.6.
Try to start Windows 95 in Safe Mode ......................................................... 17

Windows 95 Does Not Start in Safe Mode .................................................. 17
Windows 95 Starts in Safe Mode ................................................................ 18
Check for problems in the System.ini or Win.ini files .................................. 19
Troubleshoot Protected-Mode Driver Problems ............................................ 19
Additional Notes ......................................................................................... 20
SF-602
M a n u a l
19.4. Troubleshoot Video Problems in Windows 95 ......................................... 21

19.4.1.
19.4.2.
19.4.3.
19.4.4.
19.4.5.
19.4.6.
19.4.7.
19.4.8.
Section 19 - Page 2
Determine if Video Driver is Windows 3.1 or Windows 95 ............................ 21

Using Windows 3.1 Display Drivers ............................................................. 21
Adjust Advanced Graphics Settings ........................................................... 22
Verify the correct Monitor type is selected .................................................. 23
Eliminate Memory Conflicts ........................................................................ 24
Verify the Adapter Driver Files are valid ...................................................... 24
Contact the Manufacturer of the Display Adapter ........................................ 25
Information on specific drivers, hardware, and utilities ................................ 25
19.1.
D V A N C E D
P C
R O U B L E S H O O T I N G
Troubleshoot PC device conflicts in Windows 95

This document describes how to use Device Manager to examine and change software configurable devices. This document
lists steps you can use to troubleshoot hardware configuration
problems and device conflicts using Device Manager. This
document applies to the Windows 95 operating system.
Note that if a device uses jumper pins or dip switches then the
device is not software configurable; you must therefore configure the device manually.
19.1.1.
Viewing the Device Manager

Click the Start button, point to Settings, and then click Control
Panel. Double-click the System icon. Click the Device Manager
tab.
19.1.2.
Understanding the Symbols (!, X, and i)

If there is a problem with a device, it is listed in the hardware
tree list under Computer. The problem device has a symbol
indicating the type of problem:
A black exclamation point ! on a yellow field indicates the
device is in a problem state. A device in a problem state can
still be functioning. A problem code explaining the problem is
displayed for the device.
A red X indicates a disabled device. A disabled device is a
device that is physically present in the system, consuming
resources, but does not have a protected-mode driver loaded.
A blue i on a white field on a device resource in Computer
properties indicates that Use Automatic Settings is not
selected for the device and that the resource was manually
selected. It does not indicate a problem or a disabled state.
19.1.3.
NOTE
Some sound cards and video adapters do not report all the resources they are
using to Windows 95. This can cause Device Manager to show only one device
in conflict or no conflicts at all. This can be verified by disabling the sound card,
or using the standard VGA video driver too see if the conflict is resolved. (This is
a known problem with S3 video cards and 16-bit Sound Blaster sound cards, or
those sound cards using Sound Blaster emulation for Sound Blaster
compatibility.)
Viewing the Device Properties Sheet

When you select a specific device in Device Manager, then
click the Properties button, you see a property sheet. The
property sheet always has a General tab.
Section 19 - page 3
SF-602
M a n u a l
NOTE
Some devices may have other tabs besides the General tab. Not all property
sheets have the same tabs; some devices may have a Resources tab, Driver
tab, and Settings tab, or some combination of these.
At the top of the property sheet, there is a description of the

device. When you click the Resources tab, the window in the
middle of the tab indicates which resource types are available
for the selected device.
The scroll box at the bottom of the Resources tab displays a
Conflicting Device list. This list will show any existing conflicts for this device along with an error code.
19.1.4.
Changing Resource Settings

Note the Use Automatic Settings check box on the Resources
tab. If Windows 95 successfully detects a device, this check
box is selected and the device should function correctly.
However, if the resource settings are based on Basic Configuration <n> (where <n> is any number from 0 to 9), it may be
necessary to change the configuration by selecting a different
basic configuration from the list. If the particular configuration
you want for the device is not listed as a basic configuration, it
may be possible to click the Change Settings button to manually adjust the resource values.
As an example, to edit the Input/Output Range setting,
follow these steps:
19.1.5.
1.
Click the Use Automatic Settings check box to clear it.
2.
Click the Change Setting button.
3.
Click the appropriate I/O range for the device.
Viewing and Excluding Resources

If you click Computer, then Click properties, you see a property sheet with a View Resources tab and a Reserve Resources tab.
The View Resources tab displays the resources allocated by
Windows 95 or inherited from a Plug and Play BIOS or PCI bus
computer.
The Reserve Resources tab is used to exclude a resource
from use by Windows 95.
19.1.6.
Disabling a Device
To disable a device in Device Manager, uncheck the Original
Configuration (Current) check box located on the General tab
on in the devices Properties sheet.
Section 19 - Page 4
19.2.
D V A N C E D
P C
Troubleshoot Printing Problems in Windows 95

This document contains a number of troubleshooting options
that may help solve printing problems in Windows 95.
19.2.1.
Read Printers.txt
Windows 95 includes a file called Printers.txt. This file is
located in the Windows folder and contains information about
known printing issues. This file may help you solve printing
problems.
19.2.2.
Read Online Help

There is extensive online help available in Windows 95. To
read help for your printer driver, click the Start button, point to
Settings, and then click Printers. Click the Right mouse button
over the printer of interest and select Properties. Click the
question mark button at the top of the window, and then click
the printer option field you want to read about. A help window
will appear with detailed information about that option.
19.2.3.
Reset the Printer

Try turning off the printer. After 5 to 10 seconds, turn the
printer back on. Many printing problems are the result of a
printers memory being full of downloaded fonts.
Hewlett-Packard LaserJet 4:
If you print to a Hewlett-Packard LaserJet 4, change the graphics mode from Vector to Raster. This takes less memory, and is
especially useful if you receive an Error 21 error message on
the printer.
19.2.4.
Use the Print Troubleshooter

Windows 95 includes a Print Troubleshooter tool. Before you
perform any troubleshooting steps, try the Print Troubleshooter
tool. To use the Print Troubleshooter tool, follow these steps:
1. Click the Start button, then click Help.
2. On the Contents tab, double-click the Troubleshooting topic.
3. Double-click the If You Have Trouble Printing topic.
NOTE
Note that the Windows 95 Resource Kit also includes a Print Troubleshooter
tool. This tool is more detailed than the Print Troubleshooter in Windows 95. This
tool is available on request from SuperFlow Customer Service (File:
EPTSW95.exe).
Section 19 - page 5
SF-602
19.2.5.
M a n u a l
Print from an MS-DOS Prompt

If you cannot print at all in Windows 95, try the following steps:
NOTE
1.
Verify that the printer is turned on and is online without any

printer errors.
2.
Perform a self-test on the printer. The method for performing a

self-test is different for different printers. Check your printers
documentation for instructions. If the self-test fails, contact
your printer manufacturer for assistance.
3.
If possible, set up the printer on your local computer. Verify

that no printer sharing devices or daisy-chained devices (such
as SCSI CD-ROMs) are between the computer and printer.
4.
Restart your computer. Press the F8 key when you see the
Starting Windows 95 message, then choose Safe mode
command prompt only.
Windows-based applications cannot print when you start Windows 95 in Safe

mode.
5.
Type the following line and then press ENTER:

copy c:\autoexec.bat lpt1
For a PostScript printer, type
copy c:\<path>\testps.txt lpt1
where <path> is the location of the \Windows\SYSTEM\
directory.
NOTE
If your printer is not connected to LPT1, substitute the correct port name in the
lines above.
These commands copy a file to the printer. If the file is not

printed, there may be a problem with the port, the cable, or the
printer. You may want to try using a different printer cable or a
different printer. When you print to a laser printer, you may
need to press the Form Feed key after the printer has received
the print job; otherwise, the printer may not eject the paper.
19.2.6.
Print from Notepad and WordPad
Section 19 - Page 6
1.
With the printer still connected locally, restart your computer

normally.
2.
Click the Start button, point to Programs, point to Accessories,

then click Notepad or WordPad.
3.
Type some text in Notepad or WordPad and then try to print

the text.
19.2.7.
D V A N C E D
P C
Verify Printer Properties

Incorrect printer property settings can cause poor or incomplete output, or can cause your printer not to print at all.
Follow these steps to check the printer property settings:
19.2.8.
NOTE
1.
Click the Start button, point to Settings, then click Printers.
2.
Use the right mouse button to click the printer you want to
check, then click Properties on the menu that appears.
3.
Verify that the printer properties (such as printer memory and

paper size) are correct.
For PostScript printers, you must copy the TESTPS.TXT file to the printer port to
determine the appropriate available printer memory setting for the Device
Options tab. The TESTPS.TXT file lists a Max Suggested VM (KB) value for the
printer. Use this value on the Device Options tab. See the Print from an MSDOS Prompt section of this article for information about how to print the
TESTPS.TXT file on PostScript printers.
Check the Device Manager Settings

1.
19.2.9.
NOTE
If you cannot print from Notepad, verify that the port is set up
correctly in Device Manager (for example, verify that there are
no conflicts and that the ports resources are set correctly).
To open Device Manager, use the right mouse button to click My Computer and
then click Properties on the menu that appears.
2.
Click the Device Manager tab, double-click Ports (COM &

LPT), then double-click the appropriate port for your printer
[for example, Printer Port (LPT1)].
3.
Click the Resources tab and verify that the settings are correct
for your printer port. For example, the input/output range for a
standard LPT1 port is 0378-037A (a physical LPT2 port typically uses I/O 278). Also verify that the conflicting devices list
reads No conflicts.
Perform Hard Disk Maintenance

There should be at least 3 megabytes (MB) of free space on the
hard disk that contains your temporary directory.
Remove Temporary and Spool Files:
1.
Restart your computer. Press the F8 key when you see the
Starting Windows 95 message, then choose Safe mode
command prompt only.
Section 19 - page 7
SF-602
M a n u a l
NOTE
Windows-based applications cannot print when you start Windows 95 in Safe

mode.
2.
Type set (without quotation marks) and press ENTER. Note

the location of the TEMP variable.
3.
Change to the directory noted in step 2. For example, if TEMP

is set to C:\WINDOWS\TEMP, type the following line and then
press ENTER:
cd \windows\temp
Delete any temporary files in this directory. Temporary files
typically have a .TMP extension. To delete these files, type the
following line and then press ENTER:
del *.tmp
4.
NOTE
You should not delete these files from within the Windows 95 graphical user
interface (GUI) because Windows 95 or a Windows- based application may be
using one of these files.
5.
6.
19.2.10.
Type the following line and press ENTER to change to the

spool directory:
cd \windows\spool\printers
Delete any spool files in this directory. Spool files typically
have a .SPL extension. To delete these files, type the following
line and then press ENTER:
del *.spl
Use ScanDisk and Disk Defragmenter

If the hard disk becomes fragmented or there are cross-linked
files on the hard disk, you can encounter printing problems. To
check for these problems, follow these steps:
19.2.11.
1.
Restart your computer normally.
2.
Click the Start button, point to Programs, point to Accessories,

point to System Tools, then click ScanDisk.
3.
When ScanDisk is finished, click the Start button, point to

Programs, point to Accessories, point to System Tools, then
click Disk Defragmenter.
Remove and Reinstall the Printer Driver

Follow these steps to remove and reinstall the printer driver:
Section 19 - Page 8
1.
2.
Use the right mouse button to click the printer you want to
remove, then click Delete on the menu that appears.
19.2.12.
P C
3.
If you are prompted to remove all the files associated with the
printer, click Yes.
4.
5.
Double-click the Add Printer icon and follow the instructions

in the Add Printer Wizard to reinstall the Windows 95 printer
driver.
Remove and Reinstall the Printer Port

1.
D V A N C E D
NOTE
If a conflict exists or the ports settings are incorrect, use

Device Manager to remove the printer port.
To open Device Manager, use the right mouse button to click My Computer and
2.
Click the Device Manager tab, double-click Ports (COM &

LPT), then click the appropriate port for your printer [for
example, Printer Port (LPT1)].
3.
Click the Remove button and then restart your computer.
4.
Click the Start button, point to Settings, then click Control Panel.
5.
Double-click the Add New Hardware icon, and let Windows 95

detect the hardware in your computer.
You can use the Debug tool in the \Windows\Command\
folder to verify the port settings as follows:
1.
NOTE
At a command prompt, type the following lines, pressing

ENTER after each line:
debug
d 40:0
The first row of numbers contains the COM and LPT port I/O addresses. In the
following example
F8 03 F8 02 00 00 00 00 - 78 03 00 00 00 00 00 f7 01
F8 03 is COM1, F8 02 is COM2, 78 03 is LPT1, and 00 00
denotes that no port exists. These I/O addresses must match
the I/O addresses in Device Manager.
2.
Type q (without quotation marks) and press ENTER.
Section 19 - page 9
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19.2.13.
M a n u a l
Use the Generic/Text Only Printer Driver

If you have problems printing in Windows 95, try the Generic/
Text Only printer driver. To do so, follow these steps:
19.2.14.
1.
2.
If the Generic/Text Only driver is displayed go to step 3,

otherwise, double-click the Add Printer icon and follow the
instructions in the Add Printer Wizard to install the Generic/
Text Only printer driver.
3.
Right click on the Generic/Text Only driver, then click on Set

As Default.
4.
Try to print a document.
Use the LPT1.DOS printer port

If you have problems printing to a local printer, try the
LPT1.DOS port. This method is similar to printing to a file and
then copying the file to the printer port. To enable the
LPT1.DOS port, follow these steps:
19.2.15.
1.
2.
Use the right mouse button to click on the printer you are
using, then click Properties on the menu that appears.
3.
On the Details tab, click Add Port.
4.
In the Add Port dialog box, click Other, click on Local Port,
click OK, then type LPT1.DOS (without quotation marks) in
the Enter A Port Name box. Click OK.
5.
Use the Alternate Lpt.vxd File

There is an alternate Lpt.vxd file that resolves the following
problems:
You cannot print or you receive timeout error messages on
recent Compaq computers when you print to any bi-directional
printer.
You experience problems printing to any bi-directional printer
on a computer with a PS/2-style LPT port. Symptoms include
an extra page being printed, PJL commands appearing on the
printout, or other various symptoms.
You cannot use Device Manager to set an ECP port to run in
standard LPT mode. This can occur on computers with a Plug
and Play BIOS that enumerates only ECP parallel ports.
This file is available on request from SuperFlow Customer
Service (File: LPT.vxd).
D V A N C E D
P C
To install the alternate Lpt.vxd file, follow these steps:
19.2.16.
NOTE
1.
Using Windows Explorer, rename the Lpt.vxd file in the

\Windows\System\ folder to Lpt.old.
2.
Copy the Lpt.vxd file from the \Drivers\Printer\Lpt\ folder on

the Windows 95 CD-ROM to the \Windows\System\ folder on
the hard disk.
3.
Restart Windows 95.
4.
Note that the alternate Lpt.vxd file has the same file size and date as the original
file. The version number of the alternate Lpt.vxd file is 4.00.503 or 4.00.951. You
can determine the version number by using the right mouse button to click the
Lpt.vxd file, and then clicking Properties on the menu that appears.
Change the Printers Emulation Mode

Many printers have emulation modes that allow you to print
with a different printer driver. Refer to the printer documentation or manufacturer about using emulation modes on your
printer.
19.2.17.
NOTE
NOTE
Most printers require that you change a setting on the printer to use emulation
modes.
1.
2.
Double-click the Add Printer icon and follow the instructions

in the Add Printer Wizard to install the printer driver for the
printer that your printer emulates.
For PostScript printers, try installing the Apple LaserWriter II NTX driver (this is a
PostScript driver that works with most PostScript printers).
Disable the Enhanced Capabilities Port

If you have problems printing or experience garbled printout
using an enhanced capabilities port, follow these steps to
disable the enhanced capabilities port:
1.
In Control Panel, double-click System.
2.
On the Device Manager tab, double-click the Ports (COM &

LPT) branch.
3.
Double-click the ECP port.
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19.2.18.
M a n u a l
NOTE
4.
On the Driver tab, click Change Driver.
5.
Click Show All Devices.
6.
In the Manufacturers box, click Standard Port Types. In the

Models box, click Printer Port, and then click OK. Click OK
until you return to Control Panel.
7.
Follow the steps in the Try the Alternate Lpt.vxd File section
above to install the alternate Lpt.vxd file.
You may also need to change printer-related settings using the computers
CMOS setup utility to disable the enhanced capabilities port. For information
about doing so, please consult the computers documentation or manufacturer.
The alternate Lpt.vxd file does not work for some Compaq computers and you
cannot disable the ECP port on these computers. If you cannot print to an inkjet,
dot-matrix, or LaserJet printer from a Compaq computer due to problems with
the ECP port, the alternate Lpt.vxd file does not fix the problem, and you cannot
disable the ECP port in the computers CMOS settings, obtain the Sp1516.exe
file from Compaq. This file contains a driver that is loaded in the Autoexec.bat
file to disable the ECP port.
Simplify the Document

If you cannot print a complex document, try removing some of
the graphic elements in the document, or convert all the fonts
in the document to a printer-resident font such as Courier.
If a specific graphic object in a document is printed poorly,
make sure the graphic object is compatible with the printer.
For example, an Encapsulated PostScript (EPS) graphic object
is intended for use on PostScript printers only. On a nonPostScript printer, such a graphic object will be printed poorly
in an otherwise satisfactory printout.
19.2.19.
If You Can Print from a DOS Command Prompt But Not WindowsBased Programs
If you can print from a command prompt but not from any
Windows-based application, there may be a problem with the
spool settings or with bi-directional communication.
1.
2.
Use the right mouse button to click the printer you are trying to
print to and then click Properties on the menu that appears.
3.
Click the Details tab, click the Spool Settings button, then click
the Print Directly To The Printer option button.
4.
If your printer supports bi-directional communication, click the

Disable bi-directional support for this printer option button.
19.2.20.
NOTE
NOTE
D V A N C E D
P C
Bi-directional printing relies on the 1284 IEEE specification. If your printer cable
does not conform to this specification and is not of reasonable length, bidirectional printing does not work in Windows 95.
5.
Click the OK button.
6.
Try to print from Notepad or WordPad.
7.
If you can print from Notepad or WordPad, try different combinations of spool settings and bi-directional support until you
find a combination that works. For example, try disabling bidirectional support with RAW and EMF spool data format
settings. Also, try bi-directional support with the RAW spool
data format.
RAW is the only spool data format supported for PostScript printers.
If Printing Problems Occur Only in One Application

If you can print from Notepad, WordPad, and other applications, try the following steps:
19.2.21.
1.
What exactly is the printing problem? Does the application

print graphics properly, or are you having problems with just
one font?
2.
Does the problem occur in one document only, or all documents within the application? As a test, try to print a blank
page inside the application. If this prints, the application may
have problems with memory or fonts.
3.
Are you using a 32-bit or 16-bit application? 32-bit applications

use the system registry to obtain needed information, while 16bit applications may use .INI files. If you are having a printing
problem with a 16-bit application, perhaps an .INI file needs to
be modified to accommodate the application.
4.
Reinstall the application.
5.
Contact the manufacturer of the application for specific

settings that might affect printing.
Solving Network Printing Problems

If you have problems printing to a network printer, try these steps:
1.
Print to a local printer.
2.
Print to a file, then copy the file to the print server. To try this,
follow these steps:
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a. Click the Start button, point to Settings, then click Printers.

b. Use the right mouse button to click the printer you want to
use, then
click Properties on the menu that appears.
c. Click the Details tab, then click File in the Print To The
Following Port box.
d. Print a document from any application. When you are
prompted, enter a
filename for the print job.
e. Click the Start button, point to Programs, then click MSDOS Prompt.
f.
At the MS-DOS prompt, type the following line and then

press ENTER
copy <path><filename> <printer port> /b

where <path> is the location of the file you created in step D,
<filename> is the name of the file you created in step D, and
<printer port> is the port the printer is attached to.
The /b switch denotes a binary file and causes the whole
file to be printed. Without the /b switch, the whole file may
not be printed. The printer may stop printing the file at the
first CTRL+Z character it encounters in the file.
3.
Capture a printer port for the network printer rather than using
a universal naming convention (UNC) connection. To do so,
follow these steps:
a. Click the Start button, point to Settings, then click Printers.
b. Use the right mouse button to click the printer you want to
use, then click Properties on the menu that appears.
c. Click the Details tab, then click the Capture Printer Port
button.
d. Click the port you want to capture (such as LPT2) and the
path to the network printer (such as \\ServerName
\PrinterShare).
NOTE
If you want this connection to be available each time you start Windows 95, click
the Reconnect At Logon check box to select it.
4.
Try to print the document from another computer on the network.
5.
If you still cannot print to the network printer, perform standard network troubleshooting steps, such as:
- Try to browse the print server.
- Remove and reinstall your network protocols.
6.
D V A N C E D
P C
If you have multiple network clients installed, try removing

one of the clients. To do so, follow these steps:
a. Use the right mouse button to click Network Neighborhood,
and then click Properties on the menu that appears.
b.
Click one of the network clients, and then click Remove.
c. Click OK.
d. Restart your computer, and try to print again.
19.2.22.
Solving Printing Speed Problems

Printing speed in Windows 95 is measured in one of two ways:
Return to application (RTA) speed. This is defined as the
length of time from when you click Print to when you regain
control of the system. Printer page drop speed. This is
defined as the length of time from when you click print to
when the print job is complete.
You can affect each of these times by changing spool settings.
To change spool settings, follow these steps:
1.
2.
Use the right mouse button to click the printer you want to use,
3.
Click the Details tab, then click the Spool Settings button.
For faster RTA speed:
a. Click Start printing after first page is spooled.
b. In most cases, choose EMF as the spool data format.
NOTE
PostScript printers support only the RAW spool data format.
For faster printer page drop speed:

a. Click the Print Directly To The Printer option button.
-orb. Click Start printing after last page is spooled. (Note that
this is how the Windows 3.1 spooler works.) In some
cases, this option prevents laser printer engines from
turning on and off during a print job.
NOTE
Printing to the LPT1.DOS port may be slower than printing to the LPT1 port.
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19.2.23.
M a n u a l
Using Windows 3.1 Printer Drivers

Windows 95 supports over 800 printers directly and can also
use Windows version 3.1 and 3.11 printer drivers. When you
install Windows 95, if a Windows 95 printer driver is available
for the printer you are using, that printer driver is installed. If
there is no Windows 95 printer driver available for your
printer, the Windows 3.x printer driver is left in place and
should work with Windows 95.
NOTE
Windows 3.x printer drivers cannot take advantage of some of the printing
enhancements in Windows 95.
A newer printer driver for Windows 95 may be available in the

future from Microsoft or from your printers manufacturer.
Contact your printers manufacturer for further details.
19.2.24.
Windows 3.x Required Disabling Fast Printing Direct To Port

If you had to disable the Fast Printing Direct To Port option in
Windows 3.1 or Windows for Workgroups 3.x, you should
disable the Check Port State option in Windows 95. To do so,
follow these steps:
1.
2.
3.
Click the Details tab, click the Port Settings button, then click
the Check Port Status check box to clear it.
The BIOS in some computers incorrectly reports that the
printer port is busy or not available. By default, Windows 95
checks for these errors. Clearing the Check Port State check
box causes Windows 95 to ignore these messages.
19.2.25.
Additional Information
Try the following steps to enable the Print TrueType As Graphics option:
1.
2.
3.
Click the Fonts tab, then click the Print TrueType As Graphics
option.
Try these steps to lower the printers resolution:

1.
2.
3.
Click the Graphics tab, then click a lower resolution or dots per
inch (DPI) for your printer.
19.3.
D V A N C E D
P C
Troubleshoot Startup Problems in Windows 95

This document describes troubleshooting steps that may help
you solve problems related to starting Windows 95. This
document lists troubleshooting tips you can use if your computer stops responding (hangs) or returns an error message
(such as a fatal exception error or an invalid VxD error). This
document is meant to provide you with a general strategy for
isolating the problem.
19.3.1.
Try to start Windows 95 in Safe Mode

If Windows 95 does not start, try to start it in Safe mode. To
start Windows 95 in Safe mode, press the F8 key when you see
the Starting Windows 95 message, and then choose Safe
Mode from the Startup menu.
If Windows 95 does not start in Safe mode, see the Windows
95 Does Not Start in Safe Mode section below. If Windows 95
starts in Safe mode, see the Windows 95 Starts in Safe Mode
section below.
19.3.2.
Windows 95 Does Not Start in Safe Mode

Any of the following conditions can cause Windows 95 not to
start in Safe mode:
1.
The computer is infected with a virus.
2.
The computers CMOS settings are not correct. Check your

computers CMOS settings to make sure they are correct.
(You may need to contact the computer manufacturer to verify
these settings.)
3.
There is a hardware conflict. These conflicts can include, but

are not limited to, PCI BIOS settings, IRQ conflicts, redundant
COM ports (for example, two COM1 ports, or an internal
modem set to the same COM port as an existing serial port),
and defective RAM chips.
4.
A setting in the Msdos.sys file needs to be changed (for example, the Logo setting should be set to zero).
5.
You need to use the Vga.drv or Vga.vxd video drivers from the
Windows 95 CD-ROM. These files are located in the
Drivers\Display\Vga folder. For example, these drivers may be
helpful if you have an Intel Triton PCI controller or a Cirrus Logic
5401 or 5402 VGA video adapter. For more information about
these files, please see the Readme.txt file in the same folder.
If you still cannot start your computer in Safe mode after
checking these items, reinstall Windows 95 in a new, empty
folder. This step helps to establish whether the problem is
related to a remnant of the previous operating system (such as
a configuration setting) or a hardware problem.
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19.3.3.
M a n u a l
Windows 95 Starts in Safe Mode

If Windows 95 starts in Safe mode, step through the startup
process to see if any devices fail to load. To do so, restart your
computer, press F8 when you see the Starting Windows 95
message, and then choose Step-By-Step Confirmation from
the Startup menu.
The following table lists several startup options. The options
are labeled Boot A, Boot B, Boot C, and Boot D. Try each
option and note your results. To use a boot option, press Y or N
as outlined in the option in the table below each time you are
prompted whether you want to load a particular device.
Load DriveSpace Driver?

Process the system registry?
Create a startup log file (Bootlog.txt)?
Process your startup device drivers (Config.sys)?
Device=<path>\Himem.sys?
Device=<path>\Ifshlp.sys?
Device=<path>\Dblbuff.sys?
Device=<path>\Setver.exe?
Process your startup command file (Autoexec.bat)?
Load the Windows graphical user interface?
Load all Windows Drivers?
Boot A
Boot B
Boot C
Boot D
(Y)es
(Y)es
(Y)es
(N)o
(Y)es
(Y)es
(Y)es
(Y)es
(N)o
(Y)es
(N)o
(Y)es
(Y)es
(Y)es
(N)o
(Y)es
(Y)es
(Y)es
(Y)es
(N)o
(Y)es
(Y)es
(Y)es
(Y)es
(Y)es
(Y)es
(Y)es
(Y)es
(Y)es
(Y)es
(Y)es
(Y)es
(N)o
(Y)es
(N)o
(Y)es
(Y)es
(Y)es
(Y)es
(Y)es
(Y)es
(Y)es
(Y)es
(Y)es
Boot A:
If Windows 95 does not start under these conditions, try the
Boot D option. If Windows 95 starts, there is a problem with a
driver or terminate-and-stay-resident program (TSR) loading in
the Config.sys or Autoexec.bat file, or there is a problem with a
Windows 95 protected-mode driver.
Boot B:
Boot C option. If Windows 95 starts, there is a problem with a
driver or TSR loading in the Config.sys, or Autoexec.bat file.
You can pinpoint the problem by stepping through these files.
There may also be a problem with a TSR loading in the
Winstart.bat file if one is present on your computer. Rename
the Winstart.bat file and try the Boot B option again. The
Winstart.bat file is usually located in the Windows folder, and
is used to load TSRs that are required for Windows- based
programs, but are not needed in MS-DOS sessions.
For information about how to rename a file, click Start, click
Help, click the Index tab, type renaming (without quotation
marks), and then double-click the Renaming files topic.
Boot C:
Boot D option. If Windows 95 starts, there is a problem with a
D V A N C E D
P C
Windows 95 protected-mode driver. For more information

about these problems, see the Troubleshooting ProtectedMode Driver Problems section of this article.
Boot D:
steps in the System.ini section below. If Windows 95 starts,
there is a problem with the system registry.
19.3.4. Check for problems in the System.ini or Win.ini files

To determine whether the System.ini or Win.ini file is causing
a problem, try the following steps:
1.
Rename the System.ini file in the Windows folder to System.sav.
2.
Copy (do not rename) the System.cb file in the Windows folder
to System.ini.
3.
Add the following line to the [boot] section of the System.ini

file and then save the file:
drivers=mmsystem.dll
4.
Rename the Win.ini file in the Windows folder to Win.sav.
5.
Restart your computer.

If this works, there is a problem with an entry in the System.ini
or Win.ini file. Examine these files more closely to determine
the exact cause of the problem.
If Windows 95 does not start when you step through the boot
process, start your computer in Safe mode, and then change
the video driver to the standard VGA driver.
NOTE
When you copy the System.cb file to System.ini, your mouse may stop working.
If this occurs, add the following lines to the appropriate sections of the new
System.ini file:
[boot]
mouse.drv=mouse.drv
-and[386Enh]
mouse=*vmouse, msmouse.vxd
19.3.5.
Troubleshoot Protected-Mode Driver Problems

If Windows 95 starts only when you press N at the Load All
Windows Drivers? prompt, try the following steps:
1.
Start Windows 95 in Safe mode.
2.
Use the right mouse button to click My Computer, and then

click Properties on the menu that appears.
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3.
On the Device Manager tab, disable any devices in the following categories:
Display adapters
Floppy disk controllers
Hard disk controllers
Keyboard
MouseNetwork
adapters
PCMCIA
socketPorts
SCSI controllers
Sound, video, and game controllers
To disable a device, follow these steps:
NOTE
a.
In Device Manager, double-click the category name,

and then double- click the device.
b.
On the General tab, click the Original Configuration

(Current) check box to clear it, and then click OK.
c.
If Windows 95 does not start, go to the System.ini section of this article.
4.
Once Windows 95 restarts, enable the devices you disabled in

step 3. Enable the devices in the following order:
- Com ports
- Hard disk controllers
- Floppy disk controllers
- Other devices
To enable a device, follow these steps:
a. In Device Manager, double-click the category name, and
then double- click the device.
b. On the General tab, click the Original Configuration
(Current) check box to select it, and then click OK.
c. While the properties for each device are open, click the
Resources tab and make sure there are no conflicts listed
in the Conflicting Devices list.
5.
19.3.6.
Additional Notes
For information about known hardware issues, please see the
Hardware.txt file in the Windows folder on your hard disk.
For additional troubleshooting assistance, check the Bootlog.txt
file in the root directory on your hard disk. This file lists the
loading status of all real-mode and protected-mode drivers. If
Windows 95 does not start, the Bootlog.txt file lists the last
driver that loaded successfully, and lists a LoadFail entry for
each driver that failed to load before the problem occurred.
19.4.
D V A N C E D
P C
Troubleshoot Video Problems in Windows 95

This document describes how to troubleshoot video display
problems or error messages relating to the video display driver
when starting or using Windows 95.
Video problems that occur when Windows 95 is started normally, but do not occur when Windows 95 is started in Safe
(F8) mode are usually related to the display driver that Windows 95 is attempting to use.
19.4.1.
Determine if Video Driver is Windows 3.1 or Windows 95

To determine whether you are using a Windows 3.1 or Windows 95 video driver, follow these steps:
19.4.2.
1.
Use any text editor (such as Notepad) to open the System.ini

file in the Windows folder.
2.
In the [Boot] section, search for the display.drv= line. If this

line reads anything other than the following line, the driver
you are using is designed for Windows 3.1 (or an earlier
version of Windows):
Display.drv=Pnpdrvr.drv
If you are using a video driver designed for Windows 95, go to
the Advanced Graphics Settings section in this document.
Otherwise, continue with the following section (Using Windows 3.1 Display Drivers).
Using Windows 3.1 Display Drivers

If no Windows 95 display driver is available for your video
adapter, try using the Windows 3.1 drivers available from the
adapters manufacturer. Consult the documentation included
with that driver for information about how to install the driver.
NOTE
If you use a Windows 3.1 display driver in Windows 95, you cannot use new
Graphics Device Interface (GDI) features such as:
Animated cursors:
Animated cursors will not function when using Windows 3.1
display drivers.
Dynamic resolution changes:
In many circumstances, you can change the video resolution
in Windows 95 without restarting Windows 95. If you change
the color depth or the video driver you are using, you must
restart Windows 95.
VGA fallback mode:
If Windows 95 detects a problem with the video card or video
driver, it restarts with the VGA driver.
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The Windows 95 virtual flat frame buffer device (Vflatd.vxd):

Vflatd.vxd provides a frame buffer that can be up to 1 MB in
size. Windows 3.1 video drivers are limited to a 64K-frame
buffer that affects your available system resources.
If the Windows 3.1 display driver does not work properly in
Windows 95, use the standard VGA driver included with
Windows 95. To do so, follow these steps:
1.
In Control Panel, double-click Display.
2.
Click the Settings tab, and then click Change Display Type.
3.
Click the Change button in the Adapter Type section, and then
click Show All Devices.
4.
In the Manufacturers box, click (Standard Display Types).

This is located at the top of the list.
5.
In the Models box, click Standard Display Adapter (VGA), click

OK, and then click Close.
6.
Click Close.
If you continue to experience problems, continue with the
following section.
19.4.3.
Adjust Advanced Graphics Settings

Windows 95 has a built-in method for troubleshooting video
problems. There is a slider you can adjust to change the way
Windows 95 uses the video card. It is a good idea to start with
the setting on the right (the Full setting) and move the slider
one setting to the left until you find the setting that works best.
To use the slider to change the way Windows 95 uses the
video card, follow these steps:
1.
Click on Start, point to Settings, and then click on Control Panel
2.
Double-click on the System icon. Click the Performance tab,

and then click the Graphics button.
3.
Note that the Hardware Acceleration slider has four settings

(Full, Most, Basic, and None). Each of these settings is described below.
- Full
This is the default setting and allows for full hardware acceleration.
- Most
This setting adds the following items:
- SWCursor=1 to the [Display] section of the System.ini file.
Setting SWCursor to 1 disables the hardware cursor.
NOTE
D V A N C E D
P C
This setting is similar to using the /Y switch with some versions of the MS-DOSlevel Microsoft Mouse driver.
The Most setting applies to Western Digital (WD) or S3-compatible drivers. If you have problems with the way the mouse
pointer appears on the screen, try this setting.
- Basic
- SafeMode=1 to the [Windows] section of the Win.ini file.
Setting SafeMode to 1 allows for basic acceleration only (for
example, pattern bit block transfer [bitblt] and screen-to-screen
bitblt).
- MMIO=0 to the [Display] section of the System.ini file.
Setting MMIO to 0 disables memory-mapped I/O for S3compatible drivers.
Try the Basic setting if your computer seems to stop responding
(hang) randomly and you have an S3-compatible video driver.
- None
- SafeMode=2 to the [Windows] section of the Win.ini file.
Setting SafeMode to 2 disables all video card acceleration (for
example, the GDI calls the device-independent bitmap [DIB]
engine directly for screen drawing, rather than using the
display driver).
- MMIO=0 to the [Display] section of the System.ini file.
Setting MMIO to 0 disables memory-mapped I/O for S3compatible drivers.
Try the None setting if your computer seems to hang randomly,
you have an S3-compatible video driver, and the Basic setting
does not resolve the problem.
following section.
19.4.4.
Verify the correct Monitor type is selected

Use the following steps to verify that your monitor is selected
correctly in Windows 95.
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WARNING
NOTE
It is possible to cause damage to your monitor if you select a monitor type that
exceeds the capabilities of your monitor. Consult the monitors documentation or
manufacturer for specific information about its capabilities.
1.
In Control Panel, double-click Display.
2.
Click the Settings tab, and then click Change Display Type.
3.
Click the Change button in the Monitor Type section, and then
click Show All Devices.
4.
In the Manufacturers box, click the manufacturer of your

monitor.
If your monitors manufacturer is not listed, click (Standard Monitor Types).
5.
In the Models box, click the monitor you are using, click OK,
and then click Close.
6.
Click OK.
following section.
19.4.5.
Eliminate Memory Conflicts

Determine whether the problem is a result of a conflicting
driver in memory. For information about how to do so, please
see the following document available from SuperFlow Customer Service:
Title: Troubleshoot Startup Problems in Windows 95
following section.
19.4.6.
Verify the Adapter Driver Files are valid

To verify that the display adapter driver files are valid, run
Windows 95 Setup again and choose the Verify option when
you are prompted. The Verify option causes Windows 95 to
check all files and replace any that are missing or damaged.
following section.
19.4.7.
D V A N C E D
P C
Contact the Manufacturer of the Display Adapter

If none of these troubleshooting steps correct the problem,
contact the display adapters manufacturer for information
about obtaining an updated Windows 95 driver.
19.4.8.
Information on specific drivers, hardware, and utilities

The following describes switches that correct some display
problems that can occur in Microsoft Windows 95.
The [boot] section of the SYSTEM.INI file (located in the
Windows folder) should contain the following line for any
Windows 95 version of a display driver:
DISPLAY.DRV=PNPDRVR.DRV
The actual video driver (such as VGA.DRV or S3.DRV) is
loaded from the registry. This allows support for dockable
personal computers that have different adapters for the laptop
versus the docking station.
Setting the monitor type in the display properties does not
affect the refresh rate output by your display adapter. To
change this, you must run a utility supplied by your display
adapter manufacturer or computer manufacturer. Some
display utilities must be run in the AUTOEXEC.BAT file;
however, on other computers, display type is set in BIOS
configuration programs.
Examples of display utilities from adapter manufacturers
include the following:
ATI: INSTALL.EXE
Cirrus Logic: MONTYPE.EXE, CLMODE.EXE
Diamond Stealth: STLMODE.EXE
Tseng Labs: VMODE.EXE
Western Digital: VGAMODE.EXE
The sections below describe different video cards and the
requirements for these drivers to work correctly in Windows 95.
ATI Mach 8/32/64
This adapter must be configured correctly using the ATI
INSTALL.EXE program for Windows 95 to use high-resolution
modes properly. Correct setting of your monitor type is especially important. This is because the high-resolution modes
may not be available for selection, or the computer may fail
when attempting to switch to that mode.
Compaq QVision 2000
These adapters use the Matrox MGA controller.
Matrox MGA
These adapters are supported with Windows 95 drivers. The
VGA driver is installed by Setup.
Diamond Stealth 64
For True Color support (16.7 million colors) add TrueColor=24
in the [DISPLAY] section of the SYSTEM.INI
SF-602
M a n u a l
Diamond Viper
Setup preserves Microsoft Windows 3.1 drivers for this adapter
when Setup is run from within Windows 3.1. Setting up
Windows 95 from MS-DOS causes the Windows 95 VGA driver
to be installed. If this occurs, the Diamond Viper setup program should be used to install the Windows 3.1 drivers into
Windows 95. Copy the latest Viper files from the Drivers
directory on the Windows 95 CD.
IBM ThinkPad
This laptop uses Western Digital controllers. Older versions of
these laptops require the IBM VESA driver file to be loaded in
Autoexec.bat (Ibmvesa.com) or in Config.sys (Vesa.exe) for 256color and high-resolution modes to be supported by the Windows 95 Western Digital display driver. Newer versions of
these laptops do not require the use of the IBM VESA driver.
S3-Based Video Adapters
Windows 95 provides a hardware acceleration slider that can
be used to correct graphics problems:
- If you have problems with your mouse pointer, disable the
hardware cursor by setting the slider to the Most setting.
- If you experience miscellaneous hangs with your S3 adapter,
disable memory-mapped I/O by setting the slider to the Basic
setting.
If you continue to have problems, try the None setting.
NOTE
Manually adding HighColor=15 (no quotes) to the [Windows] section of the

WIN.INI file corrects incorrect color at 16 bits per pixel using a 555 format.
20
Service and
Calibration
20. Maintenance & Service

20.1. Inspection and Maintenance Instructions ................................................... 5
20.2. Maintenance Record ................................................................................. 9
20.3. System Calibration .................................................................................... 12
20.3.1. Calibration Overview ................................................................................... 12
20.3.1.1.Definition of terms ................................................................................. 12
20.3.1.2.Check measurement accuracy .............................................................. 13
20.3.1.3.Perform calibration ................................................................................. 13
20.3.2. Recommended Calibration Schedule ........................................................... 13
20.3.2.1.Calibration schedule for average dynamometer user .............................. 13
20.3.2.2.Calibrate when unexpected readings occur ............................................ 13
20.3.3. Roll Torque Calibration ................................................................................. 14
20.3.3.1.Install calibration arm ............................................................................. 14
20.3.3.2.Verify calibration arm length ................................................................... 15
20.3.3.3.Autozero all channels ............................................................................ 16
20.3.3.4.Calculate actual torque value ................................................................. 17
20.3.3.5.Add calibration weights to arm ............................................................... 17
20.3.3.6. Note displayed torque value .................................................................. 18
20.3.3.7.Enter actual torque value ....................................................................... 18
20.3.3.8.Remove calibration weights ................................................................... 20
20.3.3.9.Add calibration weights again ................................................................ 20
20.3.3.10.Remove calibration weights and arm .................................................... 20
20.3.3.11.Zero torque reading .............................................................................. 20
20.3.3.12.Save Calibration data ........................................................................... 20
20.3.4. Fuel Measurement System ......................................................................... 21
20.3.4.1.Fuel System Weight Calibration ............................................................. 21
20.3.4.2.Fuel System Volume Calibration ............................................................ 22
20.3.5. Barometric pressure sensor (channel 76) .................................................... 23
20.3.6. Pressure transducers (channels 62~71) ...................................................... 23
20.3.7. Temperature channels (type K thermocouples) ............................................ 24
20.3.8. Engine tachometer ...................................................................................... 25
20.3.9. Air flow sensor (SuperFlow air turbine) ........................................................ 25
20.4. Loading a *.prg file into your SF-602 test system ..................................... 26
20.4.1. Install Wizard .............................................................................................. 26
20.4.1.1.Overview ............................................................................................... 26
20.4.1.2.Using ..................................................................................................... 26
20.4.1.3.Functional Description... ........................................................................ 27
20.4.2. From WComNet .......................................................................................... 28
20.5. Dynamometer Cover Plates ..................................................................... 33

20.5.1.
20.5.2.
Cover plate removal .................................................................................... 33

Cover plate replacement ............................................................................. 33
SF-602
M a n u a l
20.6. Bearing Lubrication ................................................................................. 34

20.6.1
Bearing lubrication ...................................................................................... 34
20.7. Roll Lock Maintenance, Service .............................................................. 35

20.7.1.
20.7.2.
20.7.3.
20.7.4.
20.7.5.
20.7.6.
20.7.7.
Roll lock system description ....................................................................... 35

Hydraulic cylinder ....................................................................................... 35
Brake shoe adjustment ............................................................................... 35
Brake shoe removal .................................................................................... 36
Brake shoe installation ............................................................................... 36
Hydraulic cylinder disassembly ................................................................... 37
Hydraulic cylinder assembly ....................................................................... 37
20.8. Packing Gland Maintenance, Service ...................................................... 38

20.8.1.
20.8.2.
20.8.3.

Absorber packing removal .......................................................................... 39
Absorber packing installation ...................................................................... 40
20.9. Load Cell Maintenance............................................................................ 41

20.9.1
20.9.2
Load cell lubrication .................................................................................... 41

Load cell Linkage ........................................................................................ 41
20.10. Speed Sensor Adjustment ....................................................................... 42

20.10.1. Speed sensor adjustment ........................................................................... 42
20.11. Absorber Check Valve ............................................................................. 42

20.11.1. Absorber check valve ................................................................................. 42
20.12. Outlet Water Valve Adjustment ................................................................. 43

20.12.1 Water manifold valve adjustment ................................................................ 43
20.13. Load Control Valve .................................................................................. 44

20.13.1. Water control valve removal ........................................................................ 44
20.13.2. Load control valve cam adjustment ............................................................ 44
20.14. Dynamometer Rollset Repairs ................................................................. 44

20.14.1 Rollset component description .................................................................... 44
20.14.2 Major dynamometer repairs possible within the frame ................................. 45
20.14.3 Major dynamometer repairs that require shaft removal ................................ 45
20.15. Roll Shaft Removal .................................................................................. 46

20.16. Roll Removal from Shaft .......................................................................... 47
20.17. Absorber Disassembly ............................................................................ 48
20.18. Absorber Assembly ................................................................................. 49
20.19. Roll Installation onto Shaft ....................................................................... 51
20.20. Roll Shaft Installation ............................................................................... 52
20.21. Single Roll Shafts Alignment ................................................................... 53
Section 20 - Page 2
SF-602 manual V2-1125 Sect20 .PM6.5, 5/1998
E R V I C E
A N D
A L I B R A T I O N
20.22. Dual Roll Shaft Alignment ....................................................................... 54

20.23. Roll Axial Alignment ................................................................................ 55
20.24. Absorber to Frame Assembly................................................................... 55
20.25. Absorber Rotor Clearance Adjustment .................................................... 55
20.25.1. Absorber rotor to stator clearance check .................................................... 55
20.25.2. Absorber rotor to stator clearance adjustment ............................................. 56
20.26. Bolt Tightening Specifications ................................................................. 57

20.27. Service and MaintenanceTips ................................................................. 58
20.27.1. Service and maintenance tipsfuel hose fittings s .........................................
58
Section 20 - page 3
20.1.
E R V I C E
A N D
A L I B R A T I O N
Inspection and Maintenance Instructions

The SF-602 should be periodically serviced according to the
inspection and maintenance schedule below. Depending on
your location, maintenance contracts may be available from
SuperFlow. Contact your Service representative for details.
Record reference information for your system below.
Date of delivery:
Date of installation / training by SuperFlow:
By:
Date of first use:
The following table allows you to keep track of monthly and 3monthly service.
Please fill this out with the date of the service, the type of
service (3-monthly or yearly), and the name of the technician
who performed the service. A check-sheet for 3-monthly and
yearly maintenance is included for your records. Copy this
original for each scheduled maintenance.
Section 20 - page 5
SF-602
Section 20 - Page 6
M a n u a l
S
E R V I C E
A N D
Technician:
Note 1: Lubricate at central lubrication block. Use Lithium II high temperature water repellent automotive chassis gre
Note 2: Use Lithium II high temperature water repellent automotive chassis grease.
A L I B R A T I O N
Section 20 - page 7
Date:
SF-602
Section 20 - Page 8
M a n u a l
20.2.
E R V I C E
A N D
A L I B R A T I O N
Maintenance Record
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Section 20 - page 9
SF-602
M a n u a l
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
Date:
Type:
Technician:
E R V I C E
A N D
A L I B R A T I O N
602 Roll Torque Calibration Log

SuperFlow recommends keeping track of torque calibration values.
This allows detection of trends possibly indicating load cell problems.
Calibrate if torque deviation exceeds 0.5%.
Date
6/11/98
Technician
John Doe
Nominal
torque value
3500
Actual
(measured)
torque value
3489
Calibration
coefficient
1964.1
SF-602
M a n u a l
20.3. System Calibration

The sensors used on the SF-602 should be periodically calibrated for the highest measurements accuracy
NOTE
Technical specifications of all sensors can be found in the datasheets included

in the Accessories and options section of this manual.
NOTE
To avoid accidental miscalibration, a safeguard has been built into the

calibration editor. Calibration entries which exceed +/- 10% change from the
original calibration value will be rejected. If, for any reason, the real error
exceeds this 10% and the calibration must be adjusted by a greater value, you
will have to modify the configuration file first, using the DEF Configuration Editor.
Final calibration can then be performed following the methods described below.
Of course, apparent calibration drifts of more than 10% should be investigated
as they may point to a defective sensor or a problem with the electronics.
20.3.1.
Calibration Overview
20.3.1.1.
Definition of terms
Actual value
The true value present at a sensor, transducer, or channel. In most

cases this is based on a reference standard and/or calculations that are
used to calibrate the channel.
Displayed reading
The channel reading that can be observed on the handheld, PC

computer screen, or test data printout.
The maximum amount of difference between the displayed reading
and its actual value. It is usually expressed as a percentage of fullscale output.
Accuracy
Linearity
The maximum deviation of the output of an instrument from a

straight line through the calibration points.
Hysteresis
The maximum difference in displayed reading for a given amount

when the calibration reference is applied in increasing and then in
decreasing steps.
Definition file
The default configuration file that initially defines the calibration

of the channels.
Calibration file
A computer file that is created when a channel is calibrated. This

file modifies the output of the definition file to create the calibrated
readout that is displayed on the handheld, PC computer screen, and
printout.
20.3.1.2.
E R V I C E
A N D
A L I B R A T I O N
Check measurement accuracy

Checking the measurement system accuracy is performed by
applying a known reference standard to a transducer. The
resultant displayed reading is then compared to the applied
value. If the displayed reading is within the accuracy specifications, calibration is typically not required.
20.3.1.3.
NOTE
The precision of the measurement system is only as accurate as the standards

used during the calibration process. It is critical that all reference standards
(weights, pressures, etc.) be as accurate as possible. Calibrating with incorrect
or inaccurate standards is a common error that produces invalid test results.
Perform calibration
If the displayed reading deviates from the actual value by more
than the system accuracy specifications, the channel should
be calibrated. It is also acceptable to calibrate if the difference
is very small, and within the accuracy specifications. Calibration involves the application of a reference standard to the
channel transducer. The actual value is then entered through
the handheld or the PC computer. With the SF-602 calibration
software, the displayed reading will change to equal the actual
value. To prove acceptable repeatability, the reference standard is removed and reapplied.
20.3.2.
20.3.2.1.
Recommended Calibration Schedule

NOTE
The SF-602 should be turned on for at least 30 minutes before checking the
system accuracy or calibrating.
Calibration schedule for average dynamometer user

For new SF-602 users, the roll torque calibration should be
checked every three months . The three month interval
coincides with the recommended mechanical maintenance
schedule which includes greasing the bearings and checking
other items on the rollset. Other sensors should be checked
every year.
20.3.2.2.
Calibrate when unexpected readings occur

If an unexpected displayed reading occurs, it is typically
caused by the unit under test (the vehicle), not the dynamometer or measurement system. To prove that the unexpected
reading is not a function of the measurement equipment, it
may be useful to check the calibration of the affected channel.
SF-602
20.3.3.
20.3.3.1.
M a n u a l
Roll Torque Calibration

NOTE
The torque system setup voltages will be adjusted during the equipment
installation by SuperFlow Customer Service Engineers, and should not require
readjustment. The adjustment procedures for these voltages are not presented
in this manual. For additional details, contact the SuperFlow Customer Service
Department.
Install calibration arm

1.
WARNING
Remove the cover plates above the absorbers.
The cover plates are heavy and awkward. Use lifting equipment and perform
the removal with an assistant.
2.
Remove the T-handle pins from the forward absorber, and

remove the absorber anti-rotation chains. Install the calibration
arm in place of the chains.
Calibration arm attached to absorber, figure 20.1
3.
Reinsert the T-handle pins to lock the calibration arm into

position.
WARNING
The calibration arm is heavy and awkward, and is sometimes difficult to install.
Use two people to install the calibration arm. One person installs the pins while
the other person holds the end of the arm. It may be helpful to move the arm
vertically while placing the T-handle pins fully into the mounting holes. The use
of lifting equipment should also be considered.
E R V I C E
A N D
A L I B R A T I O N
Calibration arm installation, figure 20.2
20.3.3.2.
NOTE
Older dynamometers may not have T-handle pins or anti-rotation chains. If no

pins are present, obtain (2) diameter bolts which are at least 5" long. Slide
the bolts through the outer tabs of the absorber, through the calibration arm, and
finally into the inner tabs to secure the calibration arm into position.
Verify calibration arm length

The hole from which the weights hang is at the end of the
calibration arm. For a standard SF-602 dynamometer, the
horizontal distance from the center of the hole to the centerline
of the absorber is 10.9375 feet (3.3334 m). For older dynamometers that have been upgraded with new electronics, it is
recommended that the effective calibration arm length be
measured. To measure the arm length, hang a plumb bob
from the center of the calibration arm hole, and mark its
location on the floor. Carefully measure from this mark to the
centerline of the forward absorber.
NOTE
Checking the calibration arm length is not required for an SF-602 system that
includes a new dynamometer.
NOTE
The centerline of the forward absorber can be found by dividing the distance
between the two calibration arm mounting holes.
SF-602
M a n u a l
Calibration arm length measurement, figure 20.3
20.3.3.3.
Autozero all channels
NOTE
If chains or other supports are used to hold the calibration weights, these items
should be hung from the arm before the torque channel is zeroed. This
procedure is recommended in general, and is required if the exact weight of the
supports is unknown.
1.
NOTE
Unlock the rolls.
If you cannot detect a difference in the torque reading when the rolls are locked,
it is not necessary to unlock the rolls before autozeroing.
2.
Zero the channel readings by performing the steps below.
Handheld autozero steps, figure 20.4
3.
20.3.3.4.
E R V I C E
A N D
A L I B R A T I O N
Lift the end of the calibration arm and release several times,
note if there is a change in the torque reading,each time the
arm has stabilized. Change should be no greater than 20lb-ft
( 27 Nm)
Calculate actual torque value

The calibration roll torque is calculated by multiplying the
length of the arm by the sum of the weights. If the weight of
the support or hanger is known exactly, its weight can be
added to the calibration weights. This may include any
chains, bolts, or brackets that are used to suspend the weights
from the calibration arm. If the weight of the support or
hanger is unknown, it should be attached to the arm during
the zeroing procedure. The effect of the arm itself was removed when the system was zeroed in the previous step.
1. Calculate the expected torque value without the hanger or support weights:
Equation: Calibration Arm Length x Weight = Roll Torque
Example 1:
10.9375 x 400 pounds = 4,375 pound-feet.
3.3334 m x 181.4 kg = 604.7 kg-m (5,932 N-m).
2. Including the weights of the hanger or supports, calculate the expected torque:
Equation: Cal. Arm Length x (Weight + Support Weight) = R. Torque
Example 2:
10.9375 x (400 + 12.3 pounds) = 4,510 pound-feet.
3.3334 m x (181.4 + 5.6 kg) = 623.3 kg-m (6,115 N-m).
20.3.3.5.
Add calibration weights to arm

The sum of the calibration weights should equal 300-500
pounds (136-227 kg). Precision calibration weights are recommended. If precision weights are not available, the weights
that are used should be weighed on a very accurate scale. The
weights should hang from the center of the hole.
1.
Hang all the calibration weights from the calibration arm hole.
Verify the weights hang directly beneath the hole as shown below.
Method to suspend weights, figure 20.5
2.
Allow the weights to stabilize. This may take several seconds.
SF-602
20.3.3.6.
M a n u a l
Note displayed torque value
NOTE
For most SF-602 systems, the roll torque reading is obtained on channel 2, and
is displayed on handheld screen number 5. The roll torque reading may appear
on a different screen for some systems.
From the handheld, perform the following steps to observe the

displayed torque reading:
Handheld screen number 5 steps, figure 20.6
20.3.3.7.
Enter actual torque value

If the displayed torque deviates from the actual torque by more
than 1%, the torque system should be calibrated. A new
torque value can also be entered if the reading differs only a
small amount.
NOTE
To avoid accidental miscalibration, a safeguard has been built into the

calibration editor. Calibration entries which exceed +/- 10% change from the
original calibration value will be rejected. If, for any reason, the real error
exceeds this 10% and the calibration must be adjusted by a greater value, you
will have to modify the configuration file first, using the DEF Configuration Editor.
Final calibration can then be performed following the methods described below.
Of course, apparent calibration drifts of more than 10% should be investigated
as they may point to a defective sensor or a problem with the electronics.
1.
E R V I C E
A N D
A L I B R A T I O N
To prepare to enter the actual value (based on the weight times

the arm length calculations), perform the following steps:
Handheld prepare to enter actual torque value steps, figure 20.7
2.
To enter the actual torque, perform the following steps:
Handheld enter actual torque steps, figure 20.8
3.
The initial calibration process is complete.
SF-602
20.3.3.8.
20.3.3.9.
M a n u a l
Remove calibration weights

1.
Remove the calibration weights.
2.
If the weight supports were zeroed with arm in step 20.29.3.

make sure they are still attached to the arm.
3.
Zero the torque system as per step 20.29.3.
Add calibration weights again

1.
NOTE
To check the repeatability of the torque measurement system,

hang the weights again. This confirms the success of the
previous calibration steps.
The linearity of the torque measurement system can be checked by applying the
weights in several steps. The hysteresis can also be checked by first adding
and then by removing the weights in steps
2.
If the displayed reading is not equal to the actual value, repeat

the calibration procedure.
20.3.3.10. Remove calibration weights and arm

1.
Remove the weights from the calibration arm.
2.
Remove the calibration arm.
3.
Reinstall the absorber anti-rotation chains and T-handle pins.

Verify the pins are locked into place with the detent pins.
4.
Replace the cover plates.
20.3.3.11. Zero torque reading

Zero the torque channel as per section 20.29.3. The torque
system is ready to resume testing.
20.3.3.12. Save Calibration data
It is recommended to Save the new calibration to the .CAL file
on the PC hard disk, so it can be reloaded into the system
when necessary. To do this, perform the following step:
From Windyn:
Select Test Group and Receive|Calibration from the
main menu. Select the default calibration file name (preferred
method) or save the calibration file under a new name and
click on Enter.
A message will appear to confirm that the file saving operation
completed succesfully. Click on OK.
20.3.4.
NOTE
E R V I C E
A N D
A L I B R A T I O N
If a new calibration file name is selected, make sure the test group information is
updated with the correct calibration file!
Fuel Measurement System
These steps will walk you through the proper procedure for
calibrating your fuel system.
On the new SF-602 systems the fuel card is located under the
top cover of the roll-around fuel system.
In a standard WinPac system, the fuel card is located on the
electronics tray beneath the computer monitor.
20.3.4.1.
NOTE
Verify that the red light is blinking on the fuel card. If the red light is not blinking,
the card is not functioning correctly. Try removing power from the card and
reapplying. This should take care of the problem; if not contact your local
SuperFlow Customer Service Representative for assistance.
Fuel System Weight Calibration

1. Ensure that the fuel can is empty. Fill the fuel can for a
few seconds, then empty it completely. The pump will
stop automatically after it has emptied.
2. Press the STOP key to access the Start Menu on the
Handheld Controller.
3. Press the I key for CONFIG, followed by the B key
for Calibration.
4. Under the menu FUEL SYSTEM, press the B key for
WEIGHT
5. The hand-held display will show an empty weight. If you
have a roll-around fuel cabinet, place the calibration stand
on the fuel can now.
SF-602
M a n u a l
NOTE
On WinPac systems, the tie-down chains are used instead of the calibration
stand. Hang the tie-down chains onto the can
Wait for the weight to stabilize and then press any key on
the hand-held.
6. At this time add your calibration weight (making sure that
nothing is touching the cabinet). The weight needs to be a
precision calibration weight, measured to the nearest tenth
of an ounce (to the nearest gram), and then converted to a
decimal form.
7. Wait for the weight to stabilize, then press any key on the
hand-held.
8. The hand-held display will prompt you to enter the CAL.
WEIGHT. Type in the added weight you are using (this
value is to be entered in a decimal number, not in oz.) and
then press ENTER on the hand-held.
9. Now remove the calibration weight(s).
Fuel System Weight Calibration is now complete
20.3.4.2.
Fuel System Volume Calibration
NOTE
Before you attempt a Fuel Volume Calibration, you must first perform a weight
calibration or you may end up with an incorrect volume calibration.
1. You must have a fuel source hooked-up to the system

before you start this calibration. Take an API measurement
from this source. Some petroleum manufacturers provide
reference fuels with known API for calibration purposes.
2. Empty the fuel can. This can be done from the hand-held
fuel system setup.
3. Press the STOP key to access the Start Menu on the
Handheld Controller.
4. Press the I key for CONFIG, followed by the B key
for Calibration.
5. Under the menu FUEL SYSTEM, press the D key for
VOLUME.
6. Depending on the fuel level in the can, the system will
automatically fill the fuel can. If there is fuel in the can it
will first empty then fill then fuel can.
7. Once the fuel can has filled and automatically shut the
pump off, the hand-held display will prompt you for an
API measurement from the attached Fuel Source.
NOTE
The accuracy of this procedure will be based on the accuracy of your API
measurement and correction.
E R V I C E
A N D
A L I B R A T I O N
8. Enter in your corrected API number and press the ENTER key on the hand-held.
9. Now press the E key for EXIT twice to take you back to
the Start menu.
10. Press the D key for FUEL PUMPS and empty the fuel can.
11. Press the E key to EXIT
Fuel System Volume Calibration is now complete.
20.3.5.
Barometric pressure sensor (channel 76)

The barometric pressure sensor is installed on the printed
circuit board (PCB) inside the sensor box.
1.
Obtain an accurate, uncorrected barometric pressure reading

in InHg (for US units systems) or in kPa (for metric units
systems) from a mercury barometer. If you have no mercury
barometer, contact a local airport or weather service and ask
for the station pressure.
2.
Calibrate the sensor using the handheld controller or using

WinDyn:
2.1. Using the handheld controller:
Select Configure (I), then Calibrate (B), then Edit (C).
Select channel 76
Select Current Value (C)
Enter the correct value obtained in 1. above and press
Enter ( )
Verify that your entry was correct and, if so, press Yes (A)
Select Exit (E) and again Exit (E)
If a PC is connected, answer Yes (D) to the Save
changes question.
Select Exit (E) to return to the start menu
2.2. Using WinDyn:
Select Calibrate channels from the main menu
Select channel 76
Select Calibrate
Enter the correct value obtained in 1. above and press OK
Select Done
20.3.6.
Pressure transducers (channels 62~71)

Pressure transducers use the calibration provided by the
transducer manufacturer. This calibration is already programmed in the DEF Configuration Editor program. This will
provide an accuracy of better than 1% of full scale. If you have
pressure sources and calibrated pressure measurement
equipment with a higher accuracy, it is possible to calibrate
the pressure sensors as follows:
1.
Verify that no actual or residual pressure is being applied to

the sensor which you want to calibrate. Zero the pressure
transducer using the handheld controller or using WinDyn:
SF-602
M a n u a l

Select Autozero (F), then Single Channel (C).
Select the pressure channel to zero.
Select Exit (E).
1.2. Using WinDyn:
Select Calibrate channels from the main menu.
Select the pressure channel to zero.
Select Zero.
Select Done.
2.
3.
4.
Apply a pressure to the pressure sensor using a controlled

(constant) pressure source
Measure this pressure with your calibration equipment
Calibrate the sensor using the handheld controller or using WinDyn:
Select Configure (I), then Calibrate (B), then Edit (C).
Select the pressure channel to which the pressure is being
applied.
Select Current Value (C).
Enter the correct value obtained in 2. above and press
Enter ( ).
Verify that your entry was correct and, if so, press Yes (A).
Select Exit (E) and again Exit (E).
If a PC is connected, answer Yes (D) to the Save changes
question.
Select Exit (E) to return to the start menu.
4.2. Using WinDyn:
Select Calibrate channels from the main menu.
Select the pressure channel to which the pressure is being
applied.
Select Calibrate.
Enter the correct value obtained in 1. above and press OK.
Select Done.
20.3.7.
NOTE
The standard configuration files have been designed for standard SF-602
pressure transducer configurations. If different sensor ranges are used, the
configuration files should first be changed using the DEF Configuration Editor
before attempting to calibrate the sensors using the method described above.
Temperature channels (type K thermocouples)

The temperature channels do not normally require field
calibration. If temperatures appear to be incorrect, compare
the temperature readings of your SF-602 to an accurate calibrated thermometer. Should calibration be necessary, follow
this procedure:
1.
You will need an accurate thermocouple calibrator (this is an

instrument which is capable of simulating the thermocouple
sensor signal for a temperature of your choice)
2.
Remove the thermocouple panel from the box but make sure it
is plugged into the NGE sensor system
3.
4.
5.
6.
7.
8.
20.3.8.
E R V I C E
A N D
A L I B R A T I O N
Set switches 1 and 2 to the CALZ position

Using a precision digital multimeter (DMM), measure amplifier
output voltage between TP2 and TP3. Adjust R14 until the
voltage reads zero.
Set the switches back to RUN
Set the thermocouple calibrator to room temperature and plug
it into one of the thermocouple inputs. Adjust R9 until the
temperature readout for this channel on the SF-602 matches
the temperature on the calibrator.
Set the thermocouple calibrator to 1800 degF (US units) or to
1000C (metric units). Adjust R13 until the temperature readout for this channel on the SF-602 matches the temperature on
the calibrator.
Set the thermocouple calibrator back to room temperature and
verify that the room temperature input reads correctly.
Engine tachometer
The engine tachometer does not require calibration other than
entering the correct number of pulses per revolution in the
Specifications file.
For the engine tachometer, use Specifications channel 87. The
default value is 113 pulses per revolution.
20.3.9.
Air flow sensor (SuperFlow air turbine)

The air flow sensor will be one of three available air turbines
produced by SuperFlow. These turbines are individually
calibrated and linearized at SuperFlow. The calibration is
tracked by turbine serial number (engraved near the cable on
the side of the turbine). Contact your Service representative
with this serial number if you cannot locate the calibration
information for your sensor.
SF-602
M a n u a l
The calibration values normally supplied with the air turbine

consist of:
an offset: this is the minimum flow required to produce
an output signal
a frequency at a flow of 900 cfm (424.71 l/s)
These values must be calibrated for each turbine in channel 8
using the DEF Configuration Editor. See the section on the
Configuration Editor for more details.
Advanced users only
For the utmost accuracy it is possible to obtain the complete
air turbine calibration sheet from SuperFlow. This sheet
includes the output frequency of the turbine for ten different
test flow ranges. An interpolation channel will need to be
defined for this information. Should you wish to use this
feature, you will have to modify your air flow channel calculations and references to include this channel.
20.4.
Loading a *.prg file into your SF-602 test

system
NOTE
The *.prg file is the application program which determines what system you are
using (e.g. a CycleDyn or a SF-602), how the system operates, what menus are
available on the handheld controller, how system calibration procedures work,
and much more. The *.prg file resides in Flash memory inside the sensor box of
your system. No *.prg file should be loaded unless specifically requested and
provided by SuperFlow Customer Service personnel. A new *.prg file will
typically be sent to you if a system software update is available.
20.4.1.
Install Wizard
20.4.1.1.
Overview
This procedure is accessed from the WinDyn main menu via
Tools|Update Remote System Software. Selecting this
function allows you to automatically update the software
located in the SuperFlow NGE data acquisition systems found
on your network. These systems may contain sensor boxes,
handhelds, fuel systems, table top systems, and other devices
as appropriate for your NGE system type.
20.4.1.2.
Using
Step 1: Prior to updating the system software:
a) Install any EPROMs that may have been provided,
b) ensure that the system is powered on and functioning
correctly within the network for this computer, and
E R V I C E
A N D
A L I B R A T I O N
c) ensure that that the dynamometer is not in use and no tests

or calibrations are in progress.
Step 2: Select Tools|Update Remote System Software from the
WinDyn main menu.
Step 3: After reviewing the initial information on the SuperFlow
Automated System Update Program window, click Proceed
to proceed.
Step 4: A warning message will appear. Please review and click OK
when ready to proceed.
Step 5: This procedure will now interrogate your network to locate
and identify any SuperFlow systems. When completed, a new
window will appear instructing you to select the system to
update. Click OK after selecting the system. If your system
does not appear, click Cancel and try to correct the problem
before running the procedure.
Step 6: The update procedure will automatically proceed. No further
user intervention is required. Please wait until the entire
procedure is complete (about 1 minute). The SuperFlow
Automated System Update Program window will indicate the
current action being performed. A status bar will be updated
to indicate an approximate percent completion of the entire
procedure. Please do not perform any other WinDyn function
while the update is in progress.
Step 7: Wait until the procedure indicates Update complete.... The
status bar will have been removed and the Finish button
enabled. Click the Finish button to exit procedure.
This system has now been updated and is ready to use.
20.4.1.3.
Functional Description...
This procedure first interrogates your network to locate and
identify any SuperFlow systems. You will then be prompted to
select the system to update from a list. After the selection is
made, this procedure will first retrieve the current calibration
information for the system. Following this, the software for your
system will be downloaded into each node. These nodes may
be a sensor box, handheld, fuel system, table top unit, and other
devices as appropriate for your NGE system type. Following the
download, each node is reinitialized and communications will
be reestablished with WinDyn. After this initialization, the
previously saved calibration information will be returned to your
system. The system will then be ready to use.
NOTE
If you have a 602 product with a fuel system, this procedure will not retain the
fuel system calibration information. After performing this update procedure, you
will need to recalibrate your fuel system.
SF-602
20.4.2.
M a n u a l
From WComNet
1. Minimize the WinDyn window by clicking on the minimize button in the top right hand corner of the display.
2. Click on the WComNet button on the task bar at the

bottom of the screen.
3. Click on Configure|System in the WComNet window. The

display will now show the WComLink System Configuration screen
. n e e r c s
4. Click on Query
5. Click on the pull-down arrow under Devices on
SuperFlow Net. There should be one label,
aMCDyno...01.
6. Click on aMCDyno...01
7. Click on Op System
8. Enter the password booga (in lower case!).
9. The display will read:
Connected to SuperOS node
System ready...
E R V I C E
A N D
A L I B R A T I O N
10. Click on Tx File

11. A file selection dialog box opens. <show this box> We
assume the new *.prg file has been provided to you on a
floppy disk. Install the floppy disk in the A drive and
change the drive selection to the A drive in the dialog
box.
NOTE
If a new *.prg file was downloaded via modem or provided to you in another
manner, you will have to select the proper drive letter and file location in this
dialog box. Make sure you select the new file and not the original *.prg!
12. At least one file with the extension .prg should appear.
Your customer service engineer will inform you of the
proper filename. Click on that file name to select it. Verify
that this file is now shown in the File name box and
click on OK.
NOTE
On SF-250 CycleDyn Pro systems you will have to download two *.prg files, one
for the A processor and one for the B processor. To download the second (B)
.prg file, return to step 10. above once the first (A) file is successfully
downloaded.
13. The *.prg file will now be saved to the Flash memory
inside the sensor box of your test system. The display will
show a message similar to this:
SF-602
M a n u a l
NOTE
For the B file in SF-250 systems, the same message will appear but with
reference to the B processor.
14. Click on Exit to return to the WComNet System Configuration window.

15. Click on OK to restore normal communication between the
PC and the test system. WcomNet status should show
Connected to MCDyno.
16. Exit WinDyn and WComNet. Power off the Sensor Box,
wait 5 seconds, and power it back on.
17. Press the System Status (C) key on the handheld controller.
The *.prg filename will be displayed. Confirm that it is
the new version which you just installed.
For SF-250 Pro systems: press the B-Proc (B) key to check
the B-processor *.prg.
Press Exit (E) to return to the power up menu.
Press Start Menu (A).
18. Restart WinDyn.
E R V I C E
A N D
A L I B R A T I O N
4. Click on Query
5. Click on the pull-down arrow under Devices on
SuperFlow Net. There should be two labels,
aSF602Dyno...01 and
aSF602Dyno...02
6. Click on aSF602Dyno...01 to select the sensor box mode.
7. Click on Op System
8. Enter the password booga (in lower case!).
9. The display will read:
Connected to SuperOS node
System ready...
SF-602
M a n u a l
10. Click on Tx File

11. A file selection dialog box opens.We assume the new *.prg
file has been provided to you on a floppy disk. Install the
floppy disk in the A drive and change the drive selection
to the A drive in the dialog box.
NOTE
If a new *.prg file was downloaded via modem or provided to you in another
manner, you will have to select the proper drive letter and file location in this
dialog box. Make sure you select the new file and not the original *.prg!
12. At least one file with the extension .prg should appear.
Your customer service engineer will inform you of the
proper filename. Click on that file name to select it. Verify
that this file is now shown in the File name box and
click on OK.
NOTE
On SF-602 systems you will have to download two *.prg files, one for the A
processor and one for the B processor. To download the second (B) .prg file,
return to step 10. above once the first (A) file is successfully downloaded.
13. The *.prg file will now be saved to the Flash memory
inside the sensor box of your test system. The display will
show a message similar to this:
NOTE
For the B file, the same message will appear but with reference to the B
processor.
E R V I C E
A N D
A L I B R A T I O N
14. Click on Exit to return to the WComNet System Configuration window.

15. Click on OK to restore normal communication between the
PC and the test system. WcomNet status should show
Connected to aSF602Dyno...01 .
16. Exit WinDyn and WComNet. Power off the Sensor Box,
wait 5 seconds, and power it back on.
17. Press the System Status (C) key on the handheld controller.
The *.prg filename will be displayed. Confirm that it is
the new version which you just installed.
Press the B-Proc (B) key to check the B-processor *.prg.
Press Exit (E) to return to the power up menu.
Press Start Menu (A).
18. Restart WinDyn.
NOTE
To download a new .prg into the fuel system, use the same procedure as above
but select aSF602Dyno...02 in Step 6. to select the fuel system node.
20.5.
Dynamometer Cover Plates
20.5.1.
Cover plate removal

WARNING
The cover plates are heavy and awkward. Use lifting tools to remove the cover
plates.
1. Remove the cap screws for the section to be removed.

2. Install lifting eyes into the threaded holes in the cover plates.
3. Carefully remove the covers.
20.5.2.
Cover plate replacement

NOTE
After the roll shaft assemblies have been removed, overhauled, or replaced, it is
necessary to check the roll-to-cover plate clearance to make sure there is no
interference.
1. Reposition the cover plates onto the dynamometer. Align

the holes.
2. If there is interference, it may be necessary to reposition
the roll shaft assemblies or enlarge the cover plate holes to
relieve the interference.
3. Install the cover plate bolts, and tighten to 35 lb-ft (47.5 N-m).
SF-602
M a n u a l
20.6.
Bearing Lubrication
20.6.1
Bearing lubrication
The SF-602 has a centralized lubrication manifold for greasing
the shaft bearings. Use automotive LITHIUM II chassis grease
for all bearings and pivot points. Lubrication points are shown
in figure 8.1. These should be serviced after 250 hours of
operation. For intermittent usage (10 trucks per day) this will
be about four times a year. For heavy usage (20 trucks per
day), this should be about once a month. It is preferable to
lubricate the system often with small amounts of grease rather
than going for long periods and then lubricating heavily.
Frequent, light lubrication will prolong bearing life. The
quantity of lubrication for each of the eight pillow bearings is
0.40 ounces (an approximately equivalent volume is 1 inch x 1
inch x inch volume of grease).
WARNING
Do not over-lubricate the bearings. This will cause the bearings to run at too
high an operating temperature and reduce bearing life.
Lubrication points, figure 20.9.
E R V I C E
20.7.
Roll Lock Maintenance, Service
20.7.1.
Roll lock system description
A N D
A L I B R A T I O N
The roll lock system consists of a pair of external lined brake

shoes that press against one roll of each shaft assembly. The
shoes are applied by a hydraulic cylinder between the shoes
which, in turn, is actuated by an air operated master cylinder
just under the absorber covers. When the brake shoes are
released, return springs attached to the shoes prevent them
from dragging on the rolls. Grease fittings are attached to the
pins. The pins should be lubricated at the same interval as the
dynamometer bearings.
WARNING
20.7.2.
Air pressure to the master cylinder should never exceed 100 psi.
Hydraulic cylinder
The fluid level in the brake cylinder reservoir should be
checked when the absorber covers are removed for lubricating
the dynamometer. Only standard automotive brake fluid
should be used in the system.
WARNING
Do not use hydraulic fluids or hydraulic jack oil, as these can cause damage to
the seals in the cylinders. SuprFlow recommends DOT 3 brake fluid.
If the fluid level becomes low enough to expose the ports on

the bottom of the reservoir, it will be necessary to refill and
bleed the system. Such a loss of fluid indicates a major leak,
and the system should be examined before bleeding. The
system is bled by applying the roll locks (see sections 2 or 5).
Loosen the bleed screw on the hydraulic master cylinder, and
allow the fluid and air to escape. Tighten the bleed screw, and
repeat until only fluid is released from the system.
20.7.3.
Brake shoe adjustment

As the linings wear, the system may require adjustment to
prevent the rolls from slipping when mounting a vehicle. With
the roll lock air supply turned off, loosen the lock nut retaining
the end clevis to the piston rod on the hydraulic cylinder.
With an open end wrench, rotate the piston rod at the square
adjusting flat until the clearance between the lower tip of the
shoes and the rolls is 1/16 - 1/8 inch (1.6 3.2 mm), as shown
in figure 20.10.. Retighten the clevis lock nut after adjusting.
SF-602
M a n u a l
Brake system, figure 20.10.
20.7.4.
20.7.5.
Brake shoe removal

1.
Turn off the air system to the master cylinder.
2.
Remove the shoe return springs, as shown in figure 20.10.
3.
Disconnect the hydraulic line. Plug the line, and cap the
cylinder fitting.
4.
Remove the hydraulic cylinder clevis pins, and remove the

cylinder from the frame.
5.
Remove the brake shoe pivot pins, and remove the shoes from
frame.
Brake shoe installation
1.
Assemble the shoes and shoe pivot pins.
2.
Hold each shoe against the roll and note the contact point.
3.
If the shoe does not contact the roll over most of the lining
length, it will be necessary to adjust the pivot pin plates.
4.
Loosen the six bolts securing the pivot plates to the brake
support angles.
5.
Slide the pivot end of shoe horizontally until the shoe contacts
the roll evenly.
6.
Tighten the six bolts securely.
7.
Assembly the hydraulic cylinder and clevis pins.
8.
Attach the return springs.
9.
Adjust the cylinder clevis until there is a clearance of 1/16-1/8

inch (1.5-3 mm) between the lower tip of each shoe and the roll.
10.
Actuate the roll locks several times to insure that they are
applying and retracting properly.
20.7.6.
A L I B R A T I O N
1.
Turn off the air to the brake system.
2.
Drain the brake fluid from the system.
3.
Remove the cylinder from the frame.
4.
Remove the clevis end from the piston rod. Remove the
retaining ring. Withdraw the end cap, and remove the second
retaining ring.
Do not clamp on the hydraulic cylinder body. The bore may become distorted
and prevent proper operation.
5.
20.7.7.
A N D
Hydraulic cylinder disassembly
WARNING
E R V I C E
NOTE
Pull the piston and shaft assembly from the cylinder body.
If the piston assembly is difficult to remove, carefully apply low air pressure to
the cylinder inlet port to break it loose.
6.
Clamp the rod in a vise at the wrench flats, and remove the
piston end lock nut.
7.
Disassemble the piston, piston seal, and o-ring seal.
8.
Examine the parts for wear or corrosion damage. Replace if

necessary.
Hydraulic cylinder assembly
WARNING
1.
Coat a new o-ring with brake fluid, and assemble the rod, oring and piston.
2.
Assemble the piston rod nut to the shaft and tighten to 100 lb-ft
(135 N-m). With a pointed punch, stake the nut to the shaft.
3.
Coat the piston seal with brake fluid and assemble in the
groove in the piston. Make sure the lip of the seal is toward the
locknut end.
4.
Coat the cylinder walls with brake fluid and carefully install
the piston assembly into the bore of cylinder.
Take care not to damage the piston seal when passing over the retaining ring
grooves.
5.
Inspect the bronze bushing in the cylinder end cap. If it is

worn excessively, remove the damaged bushing, and press in
a new bushing. After installation, the bushing may require
reaming to size. This can be done on a connecting rod or
piston pin honing machine.
6.
Install a new shaft wiper seal in the cylinder end cap. Verify
the lip of the seal is facing away from the bronze bushing.
SF-602
M a n u a l
7.
Install the first retaining ring. Slide the cylinder end cap over
the shaft and into the cylinder bore. Install the second retaining ring.
8.
Assemble the end clevis and lock nut.
9.
Install the cylinder between the brake shoes, and assemble the
clevis pins.
10.
Bleed the hydraulic system.
11.
Adjust the brake shoe clearance.
12.
Actuate the roll lock system several times to verify proper

operation.
20.8.
Packing Gland Maintenance, Service
20.8.1.
Absorber packing adjustment

The absorbers use a Teflon coated packing material in the
water seal packing glands. The glands are designed to leak a
small amount, and do require periodic adjustment. It is
acceptable to operate the vehicle on the dynamometer without
water flowing through the absorbers for short periods. To
adjust the packing, perform the following steps.
WARNING
1.
Lock the rolls. Install a vehicle onto the dynamometer. See

section 5 for additional information.
2.
Unlock the rolls and run the vehicle at approximately 5 mph

(8 kph).
3.
From the handheld, set the load control valve position to 100%.
4.
While rolls are rotating, adjust the packing glands on the

absorbers, as shown in figure 8.3. Tighten the nuts evenly, 1/4
turn at a time. Adjust so there is only a slight continuous
trickle or a few drops per second leaking from the glands.
Use extreme caution when making adjustments near rotating machinery.
5.
Allow the dynamometer to operate for several minutes to verify

a consistent leakage rate.
6.
Set the load control valve at 0%.
7.
Lock the rolls, and turn off the water supply pump.
E R V I C E
A N D
A L I B R A T I O N
Absorber packing glands, figure 20.11.
WARNING
20.8.2.
If the area around the seal becomes hot, loosen the gland ring nuts evenly.
Allow the dynamometer to operate for several minutes with the glands leaking
significantly before readjusting.
Absorber packing removal

1.
Remove the four bolts retaining the gland ring and slide the
ring away from the packing.
2.
Thread the packing removing tool into the first packing ring
and pull the packing from the housing. Remove all three
packing rings from the housing.
Packing removal tool, figure 20.12.
NOTE
The packing removal tool, part number 4000P-0601, is not included with the
standard SF-602 system. Call SuperFlow Customer Service to place an order
for the tool.
3.
With a mirror, inspect the shaft wear sleeve for burning,

excessive wear, or flaking of plating. If the sleeve is damaged,
it must be replaced. See section 8.13, absorber disassembly, if
replacement is required.
4.
If the sleeve is in good condition, new packing may be installed.
SF-602
20.8.3.
M a n u a l
Absorber packing installation

1.
NOTE
Cut three pieces of packing material so the ends overlap inch

(19mm) when wrapped around the wear sleeve.
If supplied by SuperFlow, packing material is pre-cut to lenght
2.
After bevel cutting the three rings, install the first ring between
the wear sleeve and the housing with the ends at the top.
3.
Push the first packing ring all the way into the shoulder in the
bearing housing.
4.
Install the second ring with the ends at the bottom, and the
third ring with the ends at the top.
5.
Loosely assemble the gland ring. Do not tighten the bolts.
6.
Rotate the roll assembly and note the seal leakage.
7.
The gland ring should not be tightened against the packing

until leakage occurs.
8.
Adjust the gland ring until the proper leakage rate is attained
(1-2 drops per second or 1-2 cups per minute).
20.9.
Load Cell Maintenance
20.9.1
Load cell lubrication
E R V I C E
A N D
A L I B R A T I O N
The load cell rod ends should be lubricated at the same

schedule as the bearings.
Load cell, figure 20.13.
20.9.2
Load cell Linkage
NOTE
1.
To service the load cell or linkage, the units can be removed

by loosening the two setscrews, and withdrawing the pivot
pins on each end.
2.
If any part of the load cell assembly is replaced or removed,

the center distance between the rod ends must be measured
before the parts are disassembled. When reassembling the load
cell, set the rod ends to the measured dimension. Be sure to
tighten the jam nut after making this adjustment. If the load
cell components are removed or replaced, the length must be
adjusted after it is assembled between the absorbers. Adjust
this link so that it is level with the top of the frame. The use of
a level will facilitate this adjustment. Be sure to tighten the
jam nuts after making this adjustment.
After servicing the load cell or the load link, it is necessary to perform the
calibration procedure (see calibration section).
SF-602
M a n u a l
20.10. Speed Sensor Adjustment
20.10.1.
Speed sensor adjustment

1.
Using a feeler gauge, check the clearance between the toothed

sprocket and the tip of the magnetic speed sensor. The air gap
should be 0.045 -0 .055 inch (1.1 - 1.4 mm).
2.
If adjustment is necessary, loosen the jam nut and rotate the

sensor to the proper clearance. Tighten the jam nut.
3.
Check the clearance at several points on the sprocket by

rotating the rolls.
Speed sensor adjustment, figure 20.14.
20.11. Absorber Check Valve
20.11.1.
Absorber check valve

Each absorber has two check valves located on the sides of
each stator. These valves must be installed correctly for
proper operation and control of the absorbers. The check
valves allow air to enter the absorbers when the water is
emptying, resulting in faster removal of the dynamometer load.
E R V I C E
A N D
A L I B R A T I O N
1.
When installing a check valve, note the direction of the flow as

indicated by an arrow stamped on the valve body. The arrow
should point toward the absorber. If no arrow is visible, blow
through both ends of the valve. The closed side should be
toward the absorber.
2.
The valves are attached to elbow fittings and should be positioned so that the valve axis is vertical. See figure 20.15.
Absorber check valve, figure 20.15.
20.12. Outlet Water Valve Adjustment
20.12.1
Water manifold valve adjustment
The rate at which the water leaves the absorbers is controlled

by two gate valves. The valves are normally set at two turns
open from the fully closed position, but different settings may
be required depending on the installation. The adjustment of
the valves is typically performed by a Customer Service
Engineer during the installation and commissioning of the
dynamometer system.
WARNING
Do not operate the dynamometer with the outlet valves closed. Serious
absorber damage would occur.
SF-602
M a n u a l
20.13. Load Control Valve
20.13.1.
Water control valve removal

1. The water control valve acts both as control valve and shut
off valve. Therefore, in order to remove it from the dynamometer, the water supply manual shut off valve upstream
of the control valve must be closed.
2. Turn off the air supply to the interconnect box.
3. Turn off the electrical circuit disconnect to the interconnect box.
4. Remove the hoses from the valve, and remove the valve
from the frame.
5. Refer to the valve manual for detailed service information.
20.13.2.
Load control valve cam adjustment

If the load control valve is repaired or replaced, it may be
necessary to adjust the position of the cam. See Appendix
section for part identification.
1. Remove the cam cover on the valve body.
2. Be sure the valve is in the closed position.
3. Loosen the bolt holding the cam to the valve shaft.
4. Rotate the cam by hand until the roller follower is aligned
with the radial cam mark between numbers 4 and 5. See
the Masoneilan valve manual.
5. Tighten the cam bolt to 6 lb-ft (8 N-m) torque. Do not overtighten.
6. Replace the cam cover.
20.14. Dynamometer Rollset Repairs
20.14.1
Rollset component description
Three pillow block bearings support each roll shaft assembly. At

each shaft bearing, setscrews are installed to prevent the shaft
from moving side-to-side. For secure setscrew holding, a divot is
made in the shaft with a drill before the setscrew is installed.
The pillow block shaft bearings are bolted to the rollset frame.
Shims are placed between the pillow block bearings and the
rollset frame to achieve the proper vertical alignment. After
the pillow block bearings are bolted into the proper position,
holes are drilled through the bearing body and the rollset
frame, and tapered pins are installed.
E R V I C E
A N D
A L I B R A T I O N
The rolls are attached to the shaft with expanding tapered

hubs. The rolls can be adjusted side-to-side on the shaft.
Several measurement are performed to align the shafts with
respect to each other, the rollset frame, and the rollset cover
plates.
The inboard side of the absorber is supported by a bearing. A
pillow block bearing supports the outboard side of the absorber.
The absorber stators can be moved side-to-side on the shaft to
adjust the absorber rotor to stator clearance.
20.14.2
Major dynamometer repairs possible within the frame

Several of the dynamometer rollset components can be serviced or replaced without removing the roll shaft assembly.
The following repairs can be performed without removing the
roll shaft assembly from the frame:
1. Absorber repair or replacement (see sections 8.13, 8.14,
8.20, and 8.21)
2. Wear sleeve replacement (see section 8.13)
3. Outer shaft bearing replacement (with adequate support of
the shaft)
20.14.3
Major dynamometer repairs that require shaft removal

The following repairs require the entire roll shaft assembly to
be removed from the frame:
1. Replacement of the intermediate shaft bearing
2. Replacement of the shaft bearing closest to the absorber
3. Roll service or replacement
4. Shaft service or replacement
For a complete rebuilding of the dynamometer, the sequence
of events is:
20.15. Roll shaft removal from frame (including absorber).
20.16. Roll removal from shaft
20.17. Absorber disassembly
20.18. Absorber assembly
20.19. Roll assembly onto shaft
20.20. Roll shaft placement into frame
20.21. Single roll shaft alignment
20.22. Dual roll shaft alignment
20.23. Roll axial alignment
20.24. Absorber rotor clearance adjustment
20.25. Absorber to frame assembly
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20.15. Roll Shaft Removal

Servicing of the outboard shaft pillow bearing may be done
without the disassembly of the rolls from the shaft. If other
repairs are necessary, or if the intermediate bearing needs to
be replaced, it will be necessary to remove the entire roll shaft
assembly from the dynamometer frame. To remove a roll shaft
assembly, perform the following steps:
WARNING
1.
Remove all the cover plates.
2.
Disconnect the load cell linkage from the absorber.
3.
Remove the magnetic speed pickup and bracket.
4.
Disconnect the lubrication lines from the pillow bearings.
5.
Remove the six bolts retaining the shaft bearings to the frame.
6.
Remove the two bolts and nuts retaining the outboard trunnion
bearing to the bracket.
7.
Disconnect all four water hoses from the elbow fittings on the
bottom of each absorber.
8.
Attach a lifting sling to the roll rims as shown in figure 20.16.
Do not attempt to lift roll-shaft assembly with a narrow-spread lifting sling or over
the ends of the assembly, such as shown in figure 20.16.
Incorrect methods to lift roll shaft assembly, figure 20.16
NOTE
E R V I C E
A N D
A L I B R A T I O N
A single roll-shaft assembly weighs approximately 2,500 lbs (1,134 kg).
Correct methods to lift roll shaft assembly, figure 20.17.
9.
Raise the assembly slightly, and verify the tapered pins locating the pillow bearings have loosened.
10.
Remove any shims between the pillow bearings and the frame.
Note the proper locations for assembly.
11.
Lift the roll shaft assembly from the frame.
12.
If all new pillow bearings are to be installed, it is recommended that only one roll-shaft assembly be removed, repaired
and replaced at a time. This will greatly simplify the realignment of the rolls, covers, and frame.
20.16. Roll Removal from Shaft

1.
Carefully measure the distance between the rolls. Measure

from the outside of the left roll to the outside of the right roll,
and measure the distance between the rolls. Measure the
distance from the roll to the end of the shaft. These measurements will be used when reassembling the rolls to the shaft.
2.
With the roll shaft assembly resting on a reasonably flat

surface, remove the three socket head bolts from each tapered
bushing on the sides of each roll.
3.
Install two of the three bolts into the bushing retracting holes and
tighten until the bushing breaks free of the hub. See figure 20.18.
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4.
Securely support the shaft, and remove the bushings and roll
from the shaft.
20.17. Absorber Disassembly

The absorbers can be serviced in the frame. The stators, rotor,
and bearing housings may be removed while the shaft is in
place. For a complete rebuilding of the dynamometer that
includes the removal of the shafts, many of the following steps
are redundant.
1. Disconnect the load cell, torque transfer bar, and water
hoses from the absorber.
2. Remove the pipe plug from the end of the outboard trunnion.
3. Remove the four bolts retaining the trunnion bracket to the
frame. Remove the tapered alignment pins.
4. Remove the twelve bolts retaining the outboard trunnion to
the outboard stator, and lift the trunnion assembly from the
frame.
5. Remove the six bolts retaining the hub cover to the rotor,
and remove the hub cover and gasket.
6. Remove the twenty-four bolts retaining the stators, and
carefully lift the outboard stator from the absorber.
7. Remove the three socket head bolts in the rotor hub.
Reinstall two of these bolts into the retracting holes in the
hub, as shown in figure 20.18.
8. Tighten the two bolts until the tapered bushing has been
loosened from the tapered hub.
E R V I C E
A N D
A L I B R A T I O N
9. Remove the two retracting bolts and withdraw the tapered

bushing from the rotor.
WARNING
Re careful to support the rotor to prevent it from falling from the shaft.
10. Remove the key. Slide the rotor from the shaft.
11. Remove the eight bolts retaining the inboard stator to the
bearing housing. Lift the stator from the shaft.
12. If only the stators and rotors are to be repaired or replaced,
no further disassembly is required.
13. Examine the shaft and key for damage or excessive wear.
Remove any burrs or nicks on the end of the shaft that may
hinder assembly. Remove any rust on the shaft with
emery cloth.
14. Examine the rotor and stators for evidence of rubbing
between the vanes.
15. Examine the rotor and hub for a looseness, and check the
twenty-three rotor bolts for looseness. If there is any
evidence of looseness or relative movement between the
rotor and the hub, the rotor should be disassembled.
16. Remove the twenty-three bolts retaining the seal ring to the
rotor. Tap the seal ring from the rotor and remove the gasket.
17. With a plastic mallet, tap the rotor hub from the rotor.
18. Inspect the rotor bore and hub for wear, galling, or looseness.
19. Inspect the packing wear sleeve. If it needs to be replaced, it can be removed at this point.
20. Remove the bearing retaining ring from the bearing housing, and slide the housing assembly off the shaft.
21. Remove the three socket setscrews retaining the wear
sleeve to the shaft.
22. Tap the wear sleeve off the shaft.
23. Loosen the bearing collar setscrews and slide the bearing
off the shaft.
24. Remove the gland ring and packing rings from the bearing
housing.
25. Examine the bearing and bearing housing for wear or
damage. Replace parts as required.
20.18. Absorber Assembly

1. Slip the retaining ring over the end of shaft.
2. Slide the bearing with locking collar onto the shaft with the
collar facing toward the end of the shaft.
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3. Slide the wear sleeve onto the shaft with the three setscrew holes facing the bearing. Slide the wear sleeve onto
the shaft until the setscrew holes are aligned with the
three drill point holes on shaft.
4. Install three new stainless steel setscrews in the wear
sleeve so that cup points on setscrews are engaged with
holes in shaft. Tighten setscrews evenly for minimum
wear sleeve runout.
5. Install the gland ring into the bearing housing and slide the
housing over the wear sleeve and bearing. Install the
retaining ring in the groove in housing.
6. Coat a new bearing housing gasket with non-hardening
gasket sealer. Install with the inboard bearing housing so
that the stator water port boss is at the bottom and the
grease fitting hole in bearing housing is at the top. Coat
the bolts with anti-seize compound. Install and tighten to
25 lb-ft (34 N-m) torque.
7. Coat a new rotor hub O-ring with grease and install in the
rotor bore groove.
8. Lightly coat the outside surface of the rotor hub with
engine oil and carefully slide the hub into the rotor bore.
Align the twenty-three holes in the rotor and hub.
9. Install a new seal ring gasket and seal ring in the rotor.
Coat the threads and heads of twenty-three socket head
bolts with engine oil and install them in the rotor. Tighten
to 50-55 lb-ft (68-75 N-m) in two equal steps.
WARNING
Do not coat these bolts with anti-seize or moly compound lubricants, as this may
result in broken bolts or stripped threads when tightened.
10. Coat a new seal ring O-ring with grease and install it in the
seal ring groove.
11. Loosely attach the tapered bushing and the three retaining
bolts to the rotor hub.
12. Clean the shaft and tapered bushing bore with solvent to
remove grease and oil.
13. Carefully slide the rotor assembly onto the shaft end.
Continue until the shaft protrudes 1/8 - 5/32 inch (3.2 - 4.0
mm) beyond the surface of bushing.
14. Align the key slots and tap the key into place with a soft
mallet. The key must not protrude beyond the surface of
the hub.
15. Tighten the three bolts retaining the bushing to about 50 lbft (68 N-m) torque to seat the bushing.
16. With a brass drift pin, drive the bushing into the hub by
hitting uniformly around the surface. Tighten the three
retaining bolts.
E R V I C E
A N D
A L I B R A T I O N
17. Drive the bushing into the hub again. Tighten the three
retaining bolts. Continue this procedure until the bolts
cannot be further tightened beyond 200 lb-ft (271 N-m).
18. Check to see that the shaft protrudes 1/8 - 5/32 inch (3.2 4.0 mm) and that the bushing surface does not protrude
beyond surface of rotor hub.
19. Coat a new hub cover gasket with gasket sealer and install
it with the hub cover.
NOTE
All holes will align in only one position.
20. Install six stainless steel bolts in the hub cover, and tighten
to 15 lb-ft (20 N-m) torque.
21. Using a new stator flange gasket, install the outboard stator so
the water port boss is aligned with the boss on the inboard
stator. Do not use gasket sealer on the stator flange gasket.
22. Loosely assemble the twenty-four bolts retaining the
stators. Do not tighten the bolts.
23. Slide the outer trunnion bearing onto the trunnion.
24. Coat a new bearing housing gasket with gasket sealer and
install with the outboard trunnion and bearing onto the
outboard stator. Install the twelve bolts and tighten to 25
lb-ft (34 N-m) torque.
25. Slightly raise the stator assembly, insert the absorber alignment tool into the bore of the outboard trunnion, and engage
with the rotor hub cover. This will assure alignment of the
bearings and packing when installing. See figure 20.19..
Tighten the twenty-four bolts retaining stators.
20.19. Roll Installation onto Shaft

1. Position the rolls with the tapered bushings loosely assembled to hubs. Position the rolls according to the dimensions that were measured in section 20.16.
2. Tighten the three socket head bolts on each bushing to seat
the assembly. Re-check the positions of the rolls per the
dimensions in section 20.16.
3. With a brass drift pin, drive the bushing into the hub uniformly around the shaft. Tighten the three retaining bolts.
4. Drive the bushing into the hub again. Tighten the three
retaining bolts. Continue this procedure until the bolts
cannot be further tightened beyond 150 lb-ft (203 N-m)
torque. The outer face of the bushing should be seated
uniformly, and should not protrude beyond the face of the
roll hub.
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20.20. Roll Shaft Installation

This procedure can only be performed if the pillow bearings
were not moved or replaced. If new intermediate pillow
bearings were installed, the shaft alignment and spacing must
be set and new tapered pin holes must be drilled in the pillow
bearing housings and frame. See section 20.21 or 20.22. for
shaft alignment instructions. It is advisable to remove only one
roll shaft assembly set at a time.
1.
Insert an absorber alignment tool through outer trunnion and

into the bore of the rotor hub cover as shown in figure 20.19.
Figure 20.20. shows the absorber alignment tool dimensions.
2.
Lift the roll shaft assembly as shown in figure 20.21, and lower
the assembly into the frame.
3.
Place the appropriate shims under the bearings. The total

shim pack thickness for the bearings is stamped on the frame
adjacent to the bearing pad.
4.
Using a pry bar, shift the bearings until the tapered pin holes
are aligned. Insert the tapered pins. Tighten the bolts to
150 lb-ft (200 N-m) torque.
Absorber alignment tool installed, figure 20.19
E R V I C E
A N D
A L I B R A T I O N
Alignment tool dimensions, figure 20.20
20.21. Single Roll Shafts Alignment

If new pillow bearings have been installed, the shaft alignment
and spacing must be set, and new tapered pin holes must be
drilled in the pillow bearing housings and frame. It is advisable to remove only one roll set at a time.
1. If only one roll set has been removed, measure the distance between the shafts at points shown in figure 20.21.
This should be 50 - 1/16 inches (1272 mm), plus or minus
1/32 inch (0.8 mm).
2. Adjust the bearings fore and aft until this distance is
correct. Tighten the pillow bearing bolts.
3. Drill a 7/32 inch (5.6 mm) diameter hole through the
bearing housing and frame.
4. With a #4 tapered reamer, enlarge the hole until a new #4
x 3 inch tapered pin is almost flush with the bearing
housing.
5. Pin each bearing housing. Only one tapered pin is required
for each bearing. New tapered pins may be required if the
original pins were damaged during disassembly.
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Rollset shaft position measurements, figure 20.21
20.22. Dual Roll Shaft Alignment

If both shaft assemblies were removed and over-hauled at the
same time, it will be necessary to align the shafts with the
frame and with each other before pinning the bearings.
1.
Measure the distance from the front shaft to the frame at two
points as shown in figure 20.21. This should be approximately
17 - 1/8 inches (435 mm). Adjust as required.
2.
Measure the distance between the front and rear shaft at two
points as shown in figure 20.21. This should be approximately
50-1/16 inches (1272 mm). Adjust as required
3.
Measure the distance from the rear shaft to the frame at two
points as shown in figure 20.21. This dimension should be
equal to the front shaft dimensions in step 1 within 1/8 inch (3.2
mm) to insure that the cover plates will fit the rolls properly
4.
Adjust the front and rear shafts until the front and rear shaft-toframe distance are approximately equal and the shaft-to-shaft
distance is 50 - 1/16 inches (1272 mm) + or - 1/32 inch (0.8 mm).
5.
Drill, ream, and pin all the shaft bearings using new tapered pins.
6.
It may be necessary to re-pin the outboard trunnion bearings

after the above procedure is completed.
NOTE
Whenever roll-shaft assemblies have been removed from frame, it is necessary

to recalibrate the dynamometer. See the calibration section.
E R V I C E
A N D
A L I B R A T I O N
20.23. Roll Axial Alignment

1.
With all pillow bearing collar setscrews and cam-lock type

collars loosened, the rolls and shaft may be adjusted axially
(side to side) within the frame.
2.
Measure the distance between the rolls and the main frame
tubes as shown in figure 20.21. These dimensions (D1 and D2)
should be equal within 1/16 inch (1.6 mm).
3.
When the proper roll clearance has been set, tighten the pillow
bearing collars and setscrews.
20.24. Absorber to Frame Assembly

1.
NOTE
NOTE
Tighten the outboard trunnion bearing bolts to 100 lb-ft

(135 N-m) torque, then remove the absorber alignment tool.
It may be necessary to insert a slide hammer puller into the alignment tool to
withdraw it from the absorber. The alignment tool has a inch-13 threaded
hole for this purpose.
2.
Coat the pipe plug with pipe sealer, and install it in the end of
the outboard trunnion.
3.
Do not tighten the bearing collar setscrews at this time.
4.
Connect the hoses to the stator elbow fittings.
5.
Attach the grease lines to the bearings.
6.
Connect the load cell linkage to the absorbers.
7.
Install the magnetic speed pickups and adjust the pickup-tosprocket gap to 0.045-0.055 inches (1.1 - 1.4 mm). Tighten the
pickup jam nuts.
If the roll shaft assemblies have been removed from the frame, it is necessary to
recalibrate the dynamometer. See the calibration section.
20.25. Absorber Rotor Clearance Adjustment
20.25.1.
Absorber rotor to stator clearance check

1.
Remove the two rotor view plugs from the stators. These pipe
plugs are located on the upper section of the stators, one per
stator.
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20.25.2.
M a n u a l
2.
Check the distance between the rotor and each side of the
stator. The distances should be approximately equal.
3.
If the distances are equal, and there are no signs of rotor-tostator contact, replace the pipe plugs. No further adjustments
are necessary. Otherwise, continue to the next section, 8.21.2.
Absorber rotor to stator clearance adjustment

NOTE
NOTE
If the absorber or the roll shaft assembly has been disassembled, the rotor
clearance (between the stators) must be adjusted.
1.
Verify that the trunnion bearing collar setscrews are loose.

The shaft pillow bearing collars and setscrews should be tight.
If adjusting the rotor to stator clearance on a unit that has not
been recently rebuilt, remove any silicone and debris from the
roll shaft to allow the bearings to move. Also, in preparation
for making new setscrew divots, rotate the bearing collar to an
area that has no divots.
2.
With a pry bar, move the stator assembly away from the end of
frame, in the direction of the shaft axis, until resistance is felt
(Arrow A in figure 20.21). The rotor should then be contacting
the outboard stator. Measure the distance from some convenient point on the end of the frame to the stator and note the
dimension C, as shown in figure 20.21.
3.
With a pry bar, move the stator assembly toward the end of the
frame until resistance is felt (Arrow B in figure 20.21). The
rotor should be contacting the inboard stator. Measure the
distance from frame to stator (Dimension C).
4.
Subtract the smaller measurement from the larger measurement. This number should be at least inch (6.4 mm). Add
the two dimensions and divide by two. Adjust the position of
the stators to this average dimension C.
Rather than measuring the position of the absorber with respect to the frame, it
is acceptable to view the rotor to stator clearance through the viewing holes.
5.
After the correct rotor to stator clearance has been achieved,

tighten both the inboard trunnion bearing setscrews. Each
setscrew creates a small mark on the shaft.
6.
Remove one of the two setscrews. A small circle that was

created by the setscrew can be observed. Use a center punch
to mark the center of this circle. With a 1/8 inch (3.2 mm)
drill, machine a small pilot hole.
E R V I C E
A N D
A L I B R A T I O N
7.
Using a inch (12.7 mm) drill, machine a setscrew divot

approximately inch (6.4 mm) deep.
8.
Install the setscrew, and tighten to 80 lb-ft (108 N-m).
9.
Perform steps 6-8 for the other setscrew hole.
20.26. Bolt Tightening Specifications
NOTE
All torque values are applicable when the threads are lubricated with engine oil,
except as otherwise specified.
BOLT LOCATION (Quantity of fasteners)
TORQUE lb-ft (N-m)
ABSORBER
Rotor hub to Rotor (46) ................................................................... 50-55 lb-ft (68-75 N-m)
(Lubricate threads ONLY with engine oil
Stator Flange (48) ......................................................................... 70-80 lb-ft (95-108 N-m)
Rotor Tapered Hub (6) ....................................................... 200 lb-ft maximum (270 N-m)
Outer Trunnion (24) ....................................................................... 25-30 lb-ft (34-41 N-m)
(Lubricate with anti-seize compound)
Rotor Hub Cover (12) ...................................................................... 15-20 lb-ft (20-27 N-m)
Packing Gland Ring (8) ............ Tighten bolts 1/4 turn at a time until leakage is correct
ROLL-SHAFT ASSEMBLY
Shaft Pillow Bearing (12) ................................................................... 425~450 ( 580~610)
Outer Trunnion Pillow Bearings (4) .................................................. 180~200 ( 245~270)
Pillow Bearing Collar Setscrews (12) ........................................ 80-85 lb-ft (108-115 N-m)
Bearing Housing Collar Setscrews (4) ....................................... 80-85 lb-ft (108-115 N-m)
Roll Tapered Bushings (24) ............................................... 150 lb-ft maximum (203 N-m)
FRAME ASSEMBLY
Load Cell Bracket (4) ................................................................. 80-85 lb-ft (108-115 N-m)
Load Cell Lock Nuts (3) ...................................................................... 125~150 (170~200)
Outer Trunnion Bracket (8) ............................................................ 30-35 lb-ft (41-47 N-m)
Tiedown Straps-Hooks (6) .......................................................... 80-85 lb-ft (108-115 N-m)
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20.27. Service and MaintenanceTips
20.27.1.
Service and maintenance tipsfuel hose fittings
(#10 hose - #8 JIC)
Most problems with SAE-37 degree fittings result from overtightening. These fittings should be tightened to the same
torque every time to avoid gradual over-tightening ultimately
resulting in destruction of the fitting. An easy method to do
this is to tighten the nut finger-tight (until it bottoms on the
seat), and use a permanent marker to draw a reference line
across the nut and adapter. Then use a wrench to tighten the
nut two more hex-flats.
From now on, when the fitting is properly tightened, the marks
on the nut and adapter should be misaligned by the two hexflats, giving you a clear visual indication.
Mark a line on nut

and adapter before
torquing
Misalignment of mark
shows amount which
nut was tightened
SAE 37 Connector drawing
21
Control System
Setup
21. Control System Setup

21.1. Overview ................................................................................................... 3
21.2. The Control Parameters ............................................................................. 3
21.2.1.
21.2.2.
21.2.3.
Controller Name ............................................................................................ 3

Actuator Phase ............................................................................................. 3
Controller phase ............................................................................................ 5
21.3. Adjusting Control Parameters .................................................................... 6

21.3.1.
21.3.2.
21.3.3.
21.3.4.
21.3.5.
21.3.6.
21.3.7.
21.3.8.
21.3.9.
P-Gain .......................................................................................................... 7
I-Gain ........................................................................................................... 7
D-Gain ......................................................................................................... 8
I-Threshold ................................................................................................... 8
I-Time ........................................................................................................... 9
Feedback filter .............................................................................................. 9
Other control parameters ............................................................................ 10
Saving the Control Parameters to file .......................................................... 10
Quick reference guide ................................................................................. 10
21.1.
O N T R O L
Y S T E M
E T U P
Overview
This control parameter adjustment guide is intended as a
reference for the WinDyn system operator.
The intended scope of this guide is to:
Define the adjustable control parameters in WinDyn. Provide
suggestions for tuning the control parameters to provide the
best combination for stable, accurate tracking and good step
response to setpoint change.
The tuning or adjustment suggestions in this guide are based
on experience with a number of different trucks on SF-602
chassis dynamometers. A sample of optimized parameters are
provided at the end of this guide for the closed-loop operating
mode. These numbers should be regar-ded as a good starting
point for control parameter optimization for your installation.
Since the optimal set of control parameters may vary with
other vehicle or engine types, it is useful for the operator to
have a good general understanding of how to quickly and
effectively tune the control parameters.
21.2.
The Control Parameters

The initial setup control parameters are listed below, following
each is a discussion of valid values and functions.
21.2.1.
Controller Name
Dyno or Engine (with throttle control)
Allowed values
What it does
If Dyno is selected, dynamometer load controls engine speed

or engine torque. If Engine is selected, engine throttle controls
engine speed or engine torque.
21.2.2.
Actuator Phase
0 or 1
0
Allowed values
Default
What it does
Determines the direction of travel of the actuator as a response

to the controller output signal. 1 inverts the signal.
If actuator phase is 1: Actuator goes from 100 to 0%

when the controller output signal goes from 0 to 100%
If actuator phase is 0: Actuator goes from 0 to 100%

when the controller output signal goes from 0 to 100%
Section 21 - page 3
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Overview
Actuator phase
1
1
0
0
Examples
1.
Controller output (%)

0
100
0
100
Actuator position (%)

100
0
0
100
Throttle control with electric actuator:
If actuator phase is 0, and the manual throttle position

control is varied from 0 to 100% on the controller, the
throttle actuator will move the throttle from fully
closed to fully opened position.
If actuator phase is 1, and the manual throttle position

control is varied from 0 to 100% on the controller, the throttle
actuator will move the throttle from fully opened to fully closed
position.
Throttle control typically requires an actuator phase = 0.
2.
Eddy current dynamometer load control:
If actuator phase is 0, and the manual load control is

varied from 0 to 100% on the controller, the coil excitation
current will increase from 0 to 100% and the dynamometer
load will increase from zero load to full load.

varied from 0 to 100% on the controller, the coil excitation
current will decrease from 100 to 0% and the dynamometer
load will decrease from full load to zero load.
Ec dyno load control typically requires an actuator phase = 0.
3.
SF-602 water brake load control:

varied from 0 to 100% on the controller, the servo valve
position will change from 0% (fully closed) to 100% (fully
opened) and the dynamometer load will increase from zero
load to full load.

varied from 0 to 100% on the controller, the servo valve
position will change from 100% (fully opened) to 0% (fully
closed) and the dynamometer load will decrease from full load
to zero load.
SF-602 dyno load control typically requires an actuator phase = 0.
Section 21 - Page 4
21.2.3.
O N T R O L
Y S T E M
E T U P
Controller phase
Determines polarity of closed loop control, i.e. the direction of
movement of the controller output as a response to a change in
the feedback signal (the controlled parameter).
If controller phase is 1: If the feedback signal increases, the controller output signal will increase.
If controller phase is 0: If the feedback signal increases, the controller output signal will decrease.
NOTE
The actuator phase needs to be properly determined before the controller

phase is set as the actuator phase also has an impact on the aggregate polarity
of the closed loop control system!
Overview
Controller phase
1
1
0
0
Examples
1.
Feedback signal
+
+
-
Controller output
+
+
A typical throttle actuator controlling engine torque (with

actuator phase = 0):
If controller phase is 1, and measured engine torque

increases, the controller output will increase and the throttle
actuator will open the throttle more, increasing the torque
further still.

increases, the controller output will decrease and the throttle
actuator will close the throttle more, decreasing the torque.
In this application, the controller phase should be 0.
2.
A typical throttle actuator controlling engine speed (with

If controller phase is 1, and measured engine speed

increases, the controller output will increase and the throttle
actuator will open the throttle more, increasing speed further
still.

increases, the controller output will decrease and the throttle
actuator will close the throttle more, decreasing engine speed.
In this application, the controller phase should also be 0.
3.
Eddy current dynamometer controlling engine speed (with


increases, the controller output will increase and the load will
increase, reducing the speed.
Section 21 - page 5
SF-602
M a n u a l

increases, the controller output will decrease and the load will
decrease, increasing the speed even more.
4.
Eddy current dynamometer controlling engine torque (with


increase, increasing the torque even more.

decrease, decreasing the torque.
5.
SF-602 dynamometer controlling vehicle speed (with actuator

phase = 0):
If controller phase is 1, and measured vehicle speed

increase, decreasing the speed.
If controller phase is 0, and measured vehicle speed

decrease, increasing the speed even more.
6.
SF-602 dynamometer controlling vehicle power (with actuator

phase = 0):

increase, increasing the power even more.
If controller phase is 0, and measured vehicle power

decrease, decreasing the power.
21.3.
Adjusting Control Parameters

Control Parameters are listed in the order in which they might
be initially adjusted.
It is useful to set up two speed setpoints or two torque
setpoints that the operator may toggle between in order to
observe closed loop system step response for the purpose of
tuning the control parameters. These setpoints should be
determined to prevent the engine from reaching excessive
speed and to ensure engine throttle remains above idle.
Tuning is best accomplished by individually adjusting the
control parameters in each of the control loop modes. If a
Section 21 - Page 6
O N T R O L
Y S T E M
E T U P
problem is experienced running dual mode closed loop

control, the best and easiest approach is to go back and
individually tune each of the two single mode control loops
that would be operating.
21.3.1.
P-Gain
Allowed values
0 to 1000
Suggested value range
5 to 400
Suggested Setup prior to adjustment
Dyno controlling vehicle speed:
Dyno controlling torque/power:
Dyno controlling: vehicle speed:
engine speed:
ECM engine speed:
vehicle power:
P-gain=100
P-gain= 50
single axle:
tandem axle:
single axle:
tandem axle:
single axle:
tandem axle:
single axle:
tandem axle:
150
200
5
9
8.5
9
100
30
What it does
Proportional Gain determines how rapidly error influences
control to the dyno or to the throttle.
Suggested adjustment technique
Try a minimal value of P-Gain. Successively double it until
step response improves. If high frequency (1-10 Hz) steadystate instability is noticed as a result of increasing P-Gain, use
half the current value of P-Gain. Since P-Gain may have other
undesired effects on step response, use the minimal amount
necessary to improve step response.
21.3.2.
I-Gain
Allowed values
0 to 1000
10 to 400
Suggested setup prior to adjustment
Dyno controlling vehicle speed:
Dyno controlling torque/power:
engine speed:
ECM engine speed:
vehicle power:
I-gain = 50
I-gain = 25
single axle:
tandem axle:
single axle:
tandem axle:
single axle:
tandem axle:
single axle:
tandem axle:
0.1
0.2
0.01
0.03
0.025
0.025
0.08
0.05
What it does
Integral Gain gradually steps the control point to exactly the
commanded digital value. Controls how fast the system
Section 21 - page 7
SF-602
M a n u a l
responds to setpoint changes. Helps ensure that time-average

deadband error is minimized.
Start with the minimal suggested value of I-gain.
Increase I-gain, by successively doubling it, until the
rise time of the closed-loop step response of speed or
power is about 3 to 5 seconds.
If the integrator gain is too high, the control loop will tend to
oscillate and will not come onto the setpoint properrly. If this
term is too low, the control loop will take too long to close in
on the setpoint value.
21.3.3.
D-Gain
Allowed values
0 to 5
Suggested value
0 to 1
Suggested Setup prior to adjustment
Dyno controlling vehicle speed
Dyno controlling torque/power
engine speed:
ECM engine speed:
vehicle power:
single axle:
tandem axle:
single axle:
tandem axle:
single axle:
tandem axle:
single axle:
tandem axle:
D-gain = 1
D-gain = 0.1
0.02
0
0.005
0.015
0.002
0.5
0.1
0
What it does
Derivative Gain determines to what extent rate of change of
error influences control to the dyno or to the throttle. Gradually
increase D-gain to damp oscillations and reduce overshoot.
21.3.4.
I-Threshold
Allowed values
20 to 600

engine speed:
ECM engine speed:
vehicle power:
single axle
tandem axle
single axle
tandem axle
single axle
tandem axle
single axle
tandem axle
60
20
400
400
400
400
600
600
What it does
The Integrator Threshold determines the window within
which the Integrator takes effect. This means that the I-Term
Section 21 - Page 8
O N T R O L
Y S T E M
E T U P
will only become operational once the actual value enters a

window of setpoint I-Threshold. The integrator should take
effect once the P-term and the D-term have brought the error
term as low as they can.
The integrator term tends to slow down the system response
by stabilizing the control algorithm as the setpoint approaches.
On systems with a lot of system inertia (= slower response),
such as a SF-602 chassis dynamometer, the integrator should
only become effective once the setpoint is relatively near.
Usually it is easiest to start the PID adjustment with the
integrator turned off (value = 0). Once the P- and D-Term have
been refined, the system should respond properly and stabilize
properly, however it may not actually reach the desired
setpoint. Calculate the approximate difference between the
setpoint and the actual value and set the I-Threshold to a
somewhat larger value than that difference. This will activate
the I-Term when needed and allow the system to home in to
the setpoint.
21.3.5.
I-Time
Allowed values
0-3
Dyno controlling: vehicle speed
engine speed
ECM engine speed
vehicle power
single axle
tandem axle
single axle
tandem axle
single axle
tandem axle
single axle
tandem axle
0
0
1
2
1
2
0
0
What it does
The Integrator Time determines the timebase within which the
error is integrated. The wider this timebase, the slower the
system response will be, making the system more stable but
also increasing overcompensation of the error. On systems
with a lot of system inertia (= slower response), such as a SF602 chassis dynamometer, the Integrator should work within a
fairly narrow time-band.
Leave the default value (TBD)
21.3.6.
Feedback filter
Allowed values
0-4
Section 21 - page 9
SF-602
M a n u a l
Dyno controlling: vehicle speed

engine speed
ECM engine speed
vehicle power
single axle
tandem axle
single axle
tandem axle
single axle
tandem axle
single axle
tandem axle
What it does
This term is the filter rate applied to the feedback signal. If the
feedback signal in the control loop is noisy, this value should
be set fairly high. However, the filter adds delay to the data
and thus slows down system response. The proper solution to
a noisy signal is to clean it up prior to it entering the control
loop.
Leave the filter at zero unless a noise problem is apparent and
cannot be corrected. In that case, start with the lowest filter
value for that channel and gradually increase the filter until
the problem does not affect control stability. The step response
performance may be degraded.
21.3.7.
Other control parameters

For SF-602 applications, all other control parameters should be
turned off (=0).
21.3.8.
Saving the Control Parameters to file

The control parameter information is stored in a file with .CCP
extension. When a .CCP file is saved from the handheld controller it is always saved to a file with the same name as the
currently installed configuration file but with a .CCP extension.
The existing file will be overwritten without warning.
To save a .CCP file to a different or new filename, use the
WinDyn menu option Test Group |Receive | Control
Parameters. This option gives you a file save dialog box
which will allow you to select or enter the name of the file to
which the current control parameters will be saved.
21.3.9.
Quick reference guide
This PID adjustment procedure assumes the tests system and

engine/vehicle are operating properly and that the electrical or
hydraulic supply to the test system is sufficient.
Parameters not listed in this quick reference guide are best left
at the original value.
1. Turn off the I-Gain and the D-Gain by setting them to zero.
O N T R O L
Y S T E M
E T U P
2. Start with a P-Gain term at the lower end of the Suggested

value range for your system.
3. Successively double P-Gain until you obtain satisfactory
step response.
4. If this P-Gain results in continuous high-frequency steadystate instability, lower it by half again. Gradually increase
P-Gain until instability reappears, then lower it by 20%
again.
5. Now start with a D-Gain term at the lower end of the
Suggested value range for your system.
6. Gradually increase D-Gain (in small increments) until the
overshoot is acceptable and steady state stability is good.
7. Note the difference between the setpoint and the actual
value. Add 50% to this difference.
8. Set the I-threshold at this calculated number.
9. Now start with an I-Gain term at the lower end of the
Suggested value range for your system.
10. Successively double I-Gain until the system settles onto the
setpoint within 3~5 seconds. If instability occurs, lower IGain by half again. Gradually increase I-Gain until instability reappears, then lower it by 20% again.
The graph below illustrates the influence of these parameters
on the system response. The (exaggerated) example shows the
effect of entering a new setpoint (of 2500 rpm) for engine speed
on the actual system response.
RPM
Instantaneous
change of the
setpoint value
Overshoot
determined
by the P-term
2500
Step command
2000
Delayed change of
speed value; rate o
determined by the
22
Accessories and
Options
22. Accessories and Options

22.1. Sensor datasheets ..................................................................................... 3
22.1.
C C E S S O R I E S
A N D
P T I O N S
Sensor datasheets
Type K Thermocouples
Type K thermocouples with cable and
connector
Specifications
Application
Sheath diameter
Standard engine dynamometer and instrumentation

systems
............................................................... 0.188 / 4.78 mm

............................................................... 0.250 / 6.35 mm
Sheath Material ............................................. Inconel 600

Body Material .................................... 303 Stainless Steel
Conductors
.......................... Type K, stranded, with Kapton insulation
Connectors
................... compensated Type K rated at 375 F / 190 C
Junction Style
Open type ......................................................... Exposed
Closed type ................................................. Ungrounded
Temperature range
conductors .............................................. 2350 F / 1255 C
sheath .................................................... 2450 F / 1300 C
Max. gas velocity

........................................................ 1100 ft/sec at 2200 F
........................................................... 335 m/s at 1200 C
Response time (per time constant or 63% of actual)

Open type ............................................................. 0.30 s
Closed type ........................................................... 0.52 s
Full response time ................................ 5 time constants

Accuracy ............................................... 0.4% of reading
Approvals ................................................................ ANSI
Advantages
These thermocouples are manufactured under rigid quality controls. The calibration procedures follow the ANSI
standards and are NIST traceable.
Transition bodies are of 303 stainless steel and are
potted with a 600 F (315 C) high temperature epoxy.
The transition bodies are attached to the sheath via cadmium free silver solder. The connector screws are secured with Loctite.
All thermocouples are individually 100% tested before
supply.
Section 22 - page 3
SF-602
M a n u a l
Type K Thermocouples
Systems applications
SF-1/2
SF-901/7100
SF-7400/7420
SF-730
SF-740/742
SF-601/611
SF-581/582/591/592
SF-602/612
CycleDyn
Ordering information
Part Number
Description
SF Order Ref.
1510P-1800
TC, 1/8 x 4 ug, open, std 2 pin, 5' pigtail .................................................................................... SF-TK-X
1510P-1801
TC, 1/8 x 4 ug, closed, std 2 pin, 5' pigtail ................................................................................. SF-TK-1
1510P-1810
TC, 1/8 x 4 ug, open, min 2 pin, 5' pigtail ................................................................................... SF-TK-6
1510P-1811
TC, 1/8 x 4 ug, closed, min 2 pin, 5' pigtail ................................................................................ SF-TK-7
1510P-2500
TC, 1/4 x 4 ug, open, std 2 pin, 5' pigtail .................................................................................... SF-TK-2
1510P-2501
TC, 1/4 x 4 ug, closed, std 2 pin, 5' pigtail ................................................................................. SF-TK-X
1510P-2503
TC, 1/4 x 2 ug, closed, std 2 pin, 5' pigtail ................................................................................. SF-TK-X
1510P-2510
TC, 1/4 x 4 ug, open, min 2 pin, 5' pigtail ................................................................................... SF-TK-8
1510P-2511
TC, 1/4 x 4 ug, closed, min 2 pin, 5' pigtail ................................................................................ SF-TK-9
1510P-2513
TC, 1/4 x 2 ug, closed, min 2 pin, 5' pigtail ................................................................................ SF-TK-X
(Contact your Sales or Service Representative for details)
Drawing
Typical
Open end
DIA. A
TYP. .25 DIA THERMOCOUPLE
DIM B
Typical
Closed end
DIA. A
TYP. .125 DIA THERMOCOUPLE
DIM B
Section 22 - Page 4
C C E S S O R I E S
A N D
P T I O N S
SDX PCB
Pressure Transducers
Miniature compensated pressure transducers.
Available in gage, differential and absolute
pressure configurations.
Specifications
Application
(at 25C / 77 F):
NGE instrumentation on-board barometric pressure

measurement
Pressure Range (absolute)
FlowCom
........................................................................... 015 psia

.......................................................................... 0103 kPa
Overpressure ............................................. 30 psi (207 kPa)

Burst Pressure ...................................... 150 psi (1033 kPa)
Pressure Media
................................................. air or other non-corrosive,
non-ionic fluids and gases
Accuracy ......................................................... 1.0% F.S.

Repeatability ...................................................... 0.5% F.S.
Response time .................. 100 sec for 1090% of 0 to F.S.
Temperature Range
Compensated ................................................... 0C to 50C
Operating .................................................... -40C to +85C
Stability ......................................................... 0.1 mV / year

Excitation Voltage ............. +12 VDC nominal, max.+20 VDC
Zero Output ...................................................... 0 mV 1 mV
F.S. Output .................................................. 90 mV 3.15 mV
Advantages
The SDX series sensors combine small size with performance. These calibrated and temperature compensated
sensors give an accurate and stable output over a 0 to 50
C range. They feature an integrated circuit sensor element and laser trimmed thick film ceramic housed in a
compact solvent resistant case. The DIP mounting pro-
vides excellent corrosion resistance and isolation to external package stress.

The SDX absolute pressure sensors have an internal
vacuum reference and an output voltage proportional to
absolute pressure.
Section 22 - page 5
SF-602
M a n u a l
SDX PCB Pressure Transducers

SF-582/592
SF-602/612
FlowCom
CycleDyn
Part Number
Description
E1510P-0152
Barocell, PCB mount
Assembly Nr.
SF Order Ref.
Drawing
0.090 (2.28)
0.315 (8.00)
0.2550.010 (6.480.25)
0.465 (11.81)
Compensation Circuit
0.550
(13.97)
0.020
(0.51) TYP
0.600
(15.24)
0.10 (0.25) TYP
0.19 (4.8) TYP

0.150 (3.81) TYP
0.100 (2.54) TYP
xx.xxx=inches
xx.x=mm
Section 22 - Page 6
Specifications
(at 25C / 77 F):
Pressure Range (gage)

1 ........................................................... 2.5 psi / 17 kPa
2. ...................................................... 0-5 psig / 0-34.5 kPa
3. ......................................................... 15 psi / 100 kPa
4. ............................................................... -15 to +85 psia
.............................................................. /-100 to +585 kPa
C C E S S O R I E S
A N D
P T I O N S
XCA PCB Pressure

Transducers
High performance PCB-mounted pressure
transducers. Available in gage, differential
and absolute pressure configurations.
Overpressure ............................................ 3x rated range
Application
Burst Pressure ......................................... 5x rated range
New-Generation dynamometer instrumentation systems

FlowCom
Pressure Media ...................... air or other non-ionic fluids

Accuracy ......................................................... 0.5% F.S.
Temperature Range
Compensated ............................ 0C to 50C / 32 to 122 F
Operating ......................... -40C to +125C / -40 to 257 F
Stability ...................................................................... N/A

Excitation Voltage ................................................ 5 VDC
Zero Output ................................................ 0.250.1 VDC
F.S. Output ................................................. 4.250.1 VDC
Approvals
Advantages
The XCA transducers are designed to provide OEM
users with very accurate temperature compensated measurements by using state-of-the-art micromachined
sensors. They use a proprietary stress-free internal

mounting that provides improved shock resistance and
lower case mounting sensitivity than similar units.
Section 22 - page 7
SF-602
M a n u a l
XCA PCB Pressure Transducers

SF-602/612
CycleDyn
Part Number
Description
Assembly Nr.
E1510P-4XXXX
Pressure transducer, PCB mount (specify range)
SF Order Ref.
Drawing
Pinout:
1) + Excitation
2) Common
3) V out
4) V Offset
xx.xxx=inches
(xx.xx)=mm
Section 22 - Page 8
Rivet
mounting
0.14 (3.5)
typical
C C E S S O R I E S
A N D
P T I O N S
P155
Pressure Transducers
General purpose industrial-grade
pressure transducer
Specifications
(at 25C / 77 F and 5 VDC supply voltage)
Pressure Range (gage)
Application
New generation dynamometer instrumentation systems
......................................................... 0-100 psi / 0-690 kPa

....................................................... 0-150 psi / 0-1035 kPa
....................................................... 0-300 psi / 0-2070 kPa
Overpressure ............................................ 3x rated range
Burst Pressure .................................. 3000 psi (20700 kPa)

Pressure Media
........... any gas or liquid compatible with 316 stainless steel
Seal Material .................................................. Buna-N nitrile

Accuracy ..................................................... 0.5% F.S.O.
Response time ......................... 10 ms at 63% full scale step
.................................................................... response change
Operating Temperature Range

..................................................................... -40 to +125C
..................................................................... -40 to +257 F
Stability (1 year) .................................. 0.5% of span max.

Supply Voltage ........................................... 4.75 to 10.0 VDC
....................................................................... 5.0 VDC typical
Supply Current ........................................ < 4mA at 5 VDC

Zero Output ................................................... 0.5 0.06 VDC
F.S. Output ..................................................... 4.5 0.06 VDC
Weight ............................................................. 70 gr. / 2.4 oz.
Advantages
These pressure sensors use a patented ceramic capacitive
sensing technology. Critical sensor parameters such as
zero, span, and linearity are assured through computer
controlled laser trimming of the hybrid circuits. The hybrid circuits are temperature compensated over the rated
operating range. The sensors have a high level output
which is ratiometric to input voltage and are protected

for electromagnetic interference.
Each sensor is fully tested for conformance to specifications before shipment. The operating life is typically
greater than 10 years.
Section 22 - page 9
SF-602
M a n u a l
P155 Pressure Transducers

SF-602/612
CycleDyn
Part Number
Description
E1510P-5100
Transducer, 100 psi P155
E1510P-5150
E1510P-5300
s
Assembly Nr.
SF Order Ref.
C C E S S O R I E S
A N D
P T I O N S
Optical Tachometer
Infrared photo pickup
Specifications
Application
Engine and wheel speed measurement on chassis dynamometers
Light source ................................................. infrared LED

Range ............................................................... 30/76 cm
Supply current ................................................ 0.015 Amp
Cable ................................................................ 36/90 cm
Connector ................................................. 5-pin DIN male
Advantages
This LED photo pickup uses an invisible, wide angle infrared light beam and retro-reflective tape to detect engine rpm or wheel speed. The long life LED light source
is more vibration resistant than light bulbs. A bright red
indicator on the pickup simplifies target alignment.

The pickup is best used with a matching magnetic base
available from SuperFlow.
SF-602
M a n u a l
Optical Tachometer
SF-602
CycleDyn
Part Number
Description
Assembly Nr.
1510P-5140
Optical Tachometer .....................................................................................................................
SF Order Ref.
SF-MC-OPT
Drawing
C C E S S O R I E S
A N D
P T I O N S
SM Load Cells
SM series super-mini load cells
Specifications
Application
Eddy Current absorbers
Rated capacity ................ 100 lbs (445 N), 500 lbs (2224 N)
Heavy Diesel gravimetric fuel systems
Rated output ........................................................... 3 mV / V

Total error ..................................................... 0.03% F.S.O.
Repeatability ................................................ 0.01% F.S.O.
Creep in 20 min. ........................................... 0.03% F.S.O.
Zero balance ..................................................... 1% F.S.O.
Compensated temp. range
.......................................................................... 0 to 150 F
.................................................................. -15C to +65C
Temp. effect on:

Output ........................ 0.08% of reading / 100F (55.6C)
Zero .................................. 0.15% F.S.O. / 100F (55.6C)
Excitation voltage .................................................. 10 VDC

Material ...................................... Aluminum alloy, MR coated
Max. safe load ............................................................ 150%
Max. ultimate load ..................................................... 500%
Advantages
The SM load cells are ultra precision strain gauge load
cells to be used in controlled environments. They are
designed for measuring in both tension and compression.
The absence of moving parts combined with the use of
advanced materials in strain gauge and flexure design
ensure highest accuracy with outstanding reliability.
These load cells are now coated for protection from high
humidity conditions (up to 95% R.H.) and periodic exposure to condensation. They are not intended for submerged or washdown conditions. All load cells are calibrated to NIST standards.
SF-602
M a n u a l
SM Load Cells
Eddy Current absorbers
SF-730 Option N
SF-601/611
SF-602/612
Part Number
Description
Assembly Nr.
1500P-0500
Load cell, 500 pound (EC150 absorber)
T1500P-0007
Load cell 100 pound

Fuel strain gauge assy (601/611/730) ................................................ 1200A-0658
Load cell assy, SF-602 fuel system ..................................................... 1200A-2193
SF Order Ref.
Drawing
Tension Force
inch
- 20 UNF - 2B
mm
76
51
32
Deep, top & bottom
C C E S S O R I E S
A N D
P T I O N S
VF563 Blowby Sensor

In-line vortex flowmeters for blowby gas
measurement
Specifications
(with standard air):
Application
Engine and chassis dynamometer systems
Range .......................................... 0.8-16 SCFM / 0.4-7.5 Nl/s

Non-listed ranges are available on request.
Line size ....................................................... 5/8 ID - 3/4 OD

Pressure drop at 50% of range ............ 1.6 H2O / 6.4 kPa
Accuracy ............................................................. 2% F.S.
Response Time .............. 10 ms at 2% F.S. 1 ms at 20% F.S.
Repeatability ............................................. 0.5% of reading
Materials .................................................... Plastic (Ryton)
All-aluminum sensors are available at extra cost.
Operating Pressure ........................... <10 psig / < 69 kPa

Operating Temperature
........................................................................ 0 to +200 F
..................................................................... -18 to +93 C
Excitation Voltage ............................. 12-24 VDC at 35 mA

Output
Frequency, typical range ....................... 200 to 4500 Hz
SF-901 only .............................................. analog 0-5 VDC
Approvals ................................................... MIL-STD-45662
Advantages
The VF563 Series flowmeter is capable of exceptional
accuracy. The sensor measures the volumetric gas flow
by means of vortex sensing. A small strut inside the flow
tube creates Karman vortices which are measured by an
ultrasonic beam directly across the tube. Since the vor-
tex frequency is only a function of the gas velocity, the

detected rate is a direct measure of gas velocity and
hence volume flow. Each device is individually calibrated
with NIST traceable nozzles.
SF-602
M a n u a l
SF-901/7100
SF-7400/7420
SF-740/742
SF-601/611
SF-602/612
SF-582/592
Part Number
Description
Assembly Nr.
SF Order Ref.
E4190P-02863
Sensor, blowby SF-901

Blowby sensor assy SF-901 ................................................................ 1200A-901BB ................ SF-901-BB
E4190P-0563-01 Modified Blowby Sensor

Blowby sensor assy, SF-602/592 ........................................................ 1200A-602BB ................ SF-602-BB
Blowby sensor for SF-7100 and SF-730 ............................................. 1200A-71BB01 .............. SF-71-BB
Blowby sensor for SF-74XX ................................................................ 1200A-74BB01 .............. SF-77-BB
Drawing
1.20
(30.48)
1.70
(43.18)
1.45
(36.83)
2.90
(73.66)
xx.xxx = inches
(xx.xx) = cm
1.75
(44.45)
3.50
(88.9)
7.00
(177.8)
C C E S S O R I E S
(for water at 1.0 cSt / 1.0 mm2/s):
Normal range
Nominal K-factor (pulses / gallon and pulses / liter)

FT-12
FT-16
FT-24
FT-32
P T I O N S
FT Liquid
Flow Turbines
Specifications
FT-12 (3/4) ................................... 220 gpm / 7.676 l/min

FT-16 (1) ..................................... 550 gpm / 19190 l/min
FT-24 (1.5) ............................... 15150 gpm / 57570 l/min
FT-32 (2) .................................. 22225 gpm / 84850 l/min
Non-listed ranges and different turbine/bearing materials are
available on special request.
A N D
Volumetric liquid flow measurement turbines
Application
Hydrocarbons, water and other non-corrosive fluids in
engine and chassis dynamometer instrumentation
systems.
.................................................. 5400 ppg / 1430 ppl

..................................................... 2400 ppg / 635 ppl
....................................................... 600 ppg / 160 ppl
......................................................... 350 ppg / 93 ppl
Max. Frequency (Hz)

FT-12
FT-16
FT-24
FT-32
......................................................................... 1800
......................................................................... 2000
......................................................................... 1500
......................................................................... 1300
Repeatability .......................................... 0.05% of reading

Linearity .................................................... 0.5% of reading
Materials
Turbine ................................................ 316 stainless steel
Rotor ................................................. 430F stainless steel
Bearing material
............................................ A = 440C Ball bearings (std.)
............................................ D= Carbide journals (optional)
different turbine/bearing materials are available on special
request.
Bearing overspeed
............ 50% (short duration) without permanent damage
Temperature Range
Ball bearings ............ -450 F to +300 F/ -268C to +149C
Carbide journals ............................... up to 1200 F / 650C
Pressure drop
....................... <10 psi (69 kPa) for max. normal flow rate
Standard fitting ......................................................... NPT
Advantages
These in-line turbine flowmeters are volumetric flow
measuring instruments. The flow sensitive element is a
freely suspended, bladed rotor positioned axially in the
flow stream. The standard turndown range is 10:1,

extended ranges are possible with reduced accuracy.
SF-602
M a n u a l
FT Liquid Flow Turbines

SF-740/742
SF-601/611
SF-602/612
SF-591/592
SF-7100
SF-7400/7420
Part Number
Description
Assembly Nr.
SF Order Ref.
1510P-0750
Turbine, Oil 3/4
1510P-1001
Turbine, Oil 1
1 Oil turbine assembly (includes mag. p/u) ........................................ 1200A-CF15 .................. SF-OT-1
Oil turbine assy, 7100 (includes mag. p/u) .......................................... 1200A-1310
Oil turbine assy, 7400 (includes mag. p/u) .......................................... 1200A-1461
1510P-1002
Turbine, Coolant 1
1510P-1500
Turbine, Coolant 1.5

SFCF80 coolant flow turbine (includes mag. p/u) ............................... 1200A-CF80 .................. SF-WT-1
1510P-2000
Turbine, Coolant 2
Turbine assy, 2in with 15' cable (includes mag. p/u) ........................... 1200A-0612-15
Coolant turbine assy, 7100 (includes mag. p/u) .................................. 1200A-1309
Coolant turbine assy, 7400 (includes mag. p/u) .................................. 1200A-1460
Drawing
`B' Flats
Flow
Type
1
1
2
3.56
4.59
6.06
1.63
2.13
2.75
À'
End to End
NPT EXTERNAL THREADS
Specifications
(for Diesel fuel and water):
Number of plates ......................................................... 16

Total heat transfer area
2
................................................................................. 4.8 ft
2
.............................................................................. 0.44 m
Water flow required (@ specified inlet temperature)

...................................... 8 gpm @ 75 F / 30 lpm @ 24 C
...................................... 4 gpm @ 65 F / 15 lpm @ 18 C
...................................... 3 gpm @ 55 F / 12 lpm @ 13 C
C C E S S O R I E S
A N D
P T I O N S
Diesel Fuel Heat

Exchanger
Plate heat exchanger for cooling of Diesel fuel
Application
Heavy Diesel engine and chassis dynamometers
Min. fuel outlet T (within normal operating cond.)

................................................................................ 85 F
.............................................................................. 30 C
............................................... Thermostatically controlled
Pressure drop
Fuel ....................................................... 0.25 psi / 1.7 kPa
Water ........................................................ 2.2 psi / 15 kPa
Nominal flow rate

Fuel ....................................................... 1.5 gpm / 5.7 lpm
Water ...................................................... 6 gpm / 22.7 lpm
Max. pressure ................................... 450 psig / 3100 kPa

Min. temperature .................................... -320 F / -195 C
Max. temperature ..................................... 365 F / 185 C
Material
Plates .................................................. 316 stainless steel
Solder .......................................................... copper 99.9%
Dimensions (LxWxH)
............................................................. 11.3 x 4.6 x 1.9 in
........................................................... 287 x 117 x 48 mm
Weight (empty) ......................................... 7.8 lbs / 3.5 kg

Approvals ........................................ UL, CSA, TUV, N, SA
Advantages
These heat exchangers contain 16 herringbone-patternembossed plates of stainless steel. Every other plate is
turned 180, causing the ridges of adjacent plates to intersect one another, forming a lattice of contact points.
When these points are brazed together, the resulting unit
is a compact, pressure-resistant heat exchanger in which
almost all material is involved in the heat transfer process. Adding in a true countercurrent flow ensures heat
transfer coefficients unequalled by any other heat exchanger technology. The manufacturing process conforms
to strict ISO9001 standards and every unit is individually pressure-and leak tested and sealed.
SF-602
M a n u a l
Diesel Fuel Heat Exchanger

Systems apllications
SF-602/612
Part Number
Description
Assembly Nr.
4400P-1016
Heat exchanger, SF-602 fuel

Heat exchanger assy, SF602 fuel (includes plumbing) ....................... 1200A-2225
SF Order Ref.
Drawing
11.3
4.6
C
9.5
F
2.8
7.104
C C E S S O R I E S
A N D
P T I O N S
RSC Load Cells

S-type universal load cell
Specifications
Application
Truck and Bus chassis dynamometers
Rated capacity
IM240 Electrical Inertia Dynamometers
............................................................. 1000 lbs (4448 N)

......................................................... 10000 lbs (44480 N)
Rated output ........................................... 2.0 0.20 mV / V

Total error .................................................... 0.03% F.S.O.
Repeatability ............................................... 0.01% F.S.O.
Creep in 20 min. .......................................... 0.03% F.S.O.
Zero balance ................................................. 1.0% F.S.O.
Compensated temp. range
.................................................................... +15 to +104 F
.................................................................. -10C to +40C
Temp. effect on:

Output ...................... 0.08% of reading / 100 F (55.6C)
Zero .................................... 0.15% F.S.O. / 100 F (55.6C)
Excitation voltage
Nominal ................................................................. 10 VDC
Max. ...................................................................... 18 VDC
Material .......................................................... Stainless steel

Max. safe load .............................................. 150% of range
Max. ultimate load ....................................... 250% of range
Approvals
Advantages
The RSC load cell is designed for precision weight and
force measurements. It is built of stainless steel and features the proven S-type construction for compact design
and excellent linearity, hysteresis and creep. These load

cells comply with the VDE Recommendations 2637.
SF-602
M a n u a l
RSC Load Cells

SF-601
SF-592/602
SF-622
SF-IM240-EIS
Macrocenter
Part Number
Description
Assembly Nr.
1500P-0010
Load cell, 10K universal
1510P-1000
Load cell, 1000 pound
SF Order Ref.
Drawing
2.25
1.12
T Thread thru
both ends
-20UNF-2B
.94
.47
3.44
1.72
25 FT of four conductor,
color coded, shielded
electrical cable, pigtail termination
C C E S S O R I E S
A N D
P T I O N S
3010 Magnetic Speed

Sensor
Passive analog output magnetic speed sensor
Specifications
Application
(at 1000 in/sec / 25.4 m/s with a 20 pitch, 30 tooth gear at .005
/ 0.12 mm gap and 100 kW load)
S20 version: Tach (rpm) measurement on SuperFlow

SF-871 and SF-3100 absorbers
Output voltage
S20 ........................................................ 40 V peak-to-peak
HTB ....................................................... 25 V peak-to-peak
Resistance
HTB (high temperature) version: flow turbine speed

measurement on SF-7100 and SF-740/742 based systems; roll speed detection on truck chassis dynamometers; wheel speed measurement on TD-2500 towing
dynamometer
S20 ..................................................................... Max 85

HTB .................................................................. Max 100
Inductance
S20 .................................................................. Max 25 mH
HTB ................................................................. Max 30 mH
Temperature range
S20 ....................................... -100 to 225 F / -73 to +107C
HTB ........................................ -100 to 450 F / -73 to 232C
Pole piece diameter ................................... 0.106 / 2.7 mm

Shell .......................................... non-magnetic stainless steel
S20 version
Thread .................................................................... 5/8 18
HTB version
Advantages
These passive analog output magnetic speed sensors are
non-contact transducers that convert mechanical motion
into electrical signals. The actuator must be of ferromagnetic material such as carbon steel, magnetic stainless steel, or iron. These sensors do not require any external power supply. Their output is an alternating current. The amplitude and frequency of the output signal
are both proportional to the surface speed of the actuator. Cylindrical pole pieces produce high output with
coarse gear teeth and tolerate a wide air gap. These sensors are usable over an essentially unlimited speed
range. Lack of mechanical contact or moving parts eliminates wear and provides long life and high reliability in
hostile environments.
SF-602
M a n u a l
3010 Magnetic Speed Sensor

871 absorber
SF-7100
SF-7400/7420
SF-3100
SF-601
SF-591/592/602
Liquid flow turbines

TD-2500
Part Number
Description
Assembly Nr.
T1510P-0004
Magnetic pickup (S20 version)

Tach pickup assy, 871/901 .................................................................. 1200A-1277
Tack pickup assy, 7100 ....................................................................... 1200A-1292
T1510P-3010
Magnetic pickup, Hi temp (HTB version)

Mag pickup / cable assy, turbine ......................................................... 1200A-0853(-15)
740 input mag pickup .......................................................................... 1200A-1628(-XX)
Universal Input mag pickup ................................................................. 1200A-1633-20
SF Order Ref.
Drawing
5/8 - 18 UNF - 2A Thread
5/8 - 18 UNF - 2A Thread
Locknut
Locknut
+.025
-.000
.750
.010
.020
1.093
.010
.020
2.000
T1510P-3010
T1510P-0004
(HTB version)
(S20 version)
C C E S S O R I E S
A N D
P T I O N S
3100 Absorber
Portable Heavy Diesel Engine Dynamometer
Specifications
Application
Testing of heavy Diesel engines up to 1000 HP (750 kW)
Max. Torque ....................... 3000 lb-ft/4000 Nm at 1500 rpm

Min. Torque ................................ 32 lb-ft / 43 Nm at 1800 rpm
Max. Power .......................... 1000 HP /750 kW at 1750 rpm
Min. Power ................................... 11 HP / 8 kW at 1800 rpm
Max. Speed ........................................................ 4000 rpm
Speed Signal ........................ Magnetic p/u on 60-tooth gear
Torque Signal
................................................ Temperature-compensated
..................................................... 5000 lbs. beam load cell
Materials
....................................... All parts except rotor/stator: Steel
................................... Rotor/stator: Aluminum-Bronze alloy
Water Requirements (for max. capacity)

............................................................... 100 gpm at 60 psi
........................................................... 380 l/min at 420 kPa
Standard flywheel adapter

.............................. suitable for SAE 0~4 flywheel housings
Dimensions (assembled)
.................................................................. W 27.5 / 70 cm
.................................................................. H 23.5 / 60 cm
................................................................... L 18.5 / 47 cm
Weight ........................................................... 360 lbs / 163 kg

Shipping Weight ....................................... 440 lbs / 200 kg
Advantages
The SF-3100 Engine Dynamometer is a portable water
brake absorber designed for the specific needs of Heavy
Diesel engine rebuilders. The absorber mounts directly to
the engine with industry-standard flywheel adapters.
The SF-3100 is comprised of two units, the absorber
module and the trunnion module, which lock together for
operation. Designed for rigorous testing and durability,
the absorber is constructed of rugged steel and aluminum-bronze. Torque is measured through a pivot trunnion design which eliminates large trunnion bearings. The
SF-3100 incorporates a crowned gear drive at both the
rotor and engine coupling ends for increased service life

and ease of mounting. The advanced torus vane design
keeps the size of the absorber to a minimum. The rotor
is only 12 (30 cm) in diameter, which provides impressively low inertia properties that translate into rapid response characteristics. This design also eliminates the
masking of diesel governor problems and reduces the
minimum power threshold.
The SF-3100 can be interfaced directly to the Instrumentation System of the SF-602 Series Truck Chassis Dynamometers for maximum test capability.
SF-602
M a n u a l
3100 Absorber
SF-582/592
SF-602/612
SF-601/611
Part Number
Description
Assembly Nr.
SF Order Ref.
SF-3100 Engine Dynamometer .......................................................... 1200A-3010 ................... SF-3100
Drawing
Flywheel Housing Bolts

.56 (14MM)
SAE 0
SAE
SAE 1
SAE 2
SAE 3
.50 (M12)
.50 (M12)
.44 (M10)
.38 (M8)
.38 (M8)
Add optional
1.50 (38mm)
thick spacer
here
Drive adaptor hub
1.8 (45MM)
.80 (20MM)
C C E S S O R I E S
A N D
P T I O N S
6500 Portable
Smoke Meter
SAE J1667-compliant portable smoke meter for
Diesel fleet maintenance
Specifications
Application
Range ...................................................... 0-100% Opacity
Heavy Diesel engine and chassis dynamometer instrumentation systems
Accuracy ...................................... 0.1% nominal 1 digit

Stack diameter ...................................... Max. 6 (150 mm)
Materials
Monitor ........................................................................ steel
Control unit .......................................................... aluminum
Temperature Range .................. 0C to 50C 32 F to 120 F

Zero drift ....................................................... <1% per use
Output .................................................... RS-232 Serial port
Power supply .............................. 12V sealed lead-acid cell
Autonomy .......................................................... 40 hours
Weight ........................................................ 2.4 kg / 5.2 lbs
Standards ............................... EPA, SAE, ISO, EEC, CARB
Advantages
This portable smoke meter measures opacity or density
on all Diesel vehicles (engines). It is micro-processorbased and has a RS-232 serial port for connection to the
instrumentation system. The meter consists of a stack
monitor which is connected to a weatherproof aluminum
control unit with membrane switches and LCD display

via a 25' (7.5 m) cable. A peak hold feature is provided.
An ISO-9000 certified manufacturing process ensures
consistent quality levels.
SF-602
M a n u a l
6500 Portable Smoke Meter

SF-601/611
SF-582/592
SF-602/612
Part Number
Description
Assembly Nr.
SF Order Ref.
E4190P-0650
Exhaust opacity meter (specify voltage)

Exhaust opacity meter for SF-601/611 (specify voltage) .................... 1200A-OP1 .................... SF-OP-1
Exhaust opacity meter for SF-602/612 (specify voltage) .................... 1200A-OP2 .................... SF-OP-2
(/240 for export version; contact your Sales or Service Representative for details)
Drawing
13 7/8
6 7/8
Receiving unit
Light unit
5 5/8
Connecting cable
approx. length 25 Ft.
Existing stack
2 min. - 6 max.
Quick disconnect
stack clamp
To control unit
C C E S S O R I E S
A N D
P T I O N S
SF-CT-1000
Cooling Tower
Cart-mounted heavy duty engine cooling tower
Specifications
Application
The SF-CT-1000 is a pressurized cooling tower rated for continuous duty testing of engines of up to 1000 horsepower.
Power Range ......................... 1001000 HP (75750 kW)

Operating pressure
........................................................................... adjustable
........................................... nominally set at 15 psi/100 kPa
Operating temperature
........................................................................... adjustable
.............................................. 160230 degF / 70110 C
Compatible liquids ...................... water and glycol mixtures

Material ....................................................... Aluminum alloy
Weight .......................................................... 200 lbs./90 kg
Adapters
2 each of: ...................................................................... 1
..................................................................................... 1
........................................................................................ 2
..................................................................................... 2
..................................................................................... 2
1 each of: ...................................................................... 2
Operation of cooling tower

The SF-CT-1000 is a pressurized cooling tower designed
for engines up to 1000 HP. Large three inch Cam Lock
hose connections provide capacity for engines with high
cooling flows. Couplings are provided for either right or
left hand mounted engine cooling pumps. Combustion gas
leaks and entrained air are visible in a clear collection
tube at the top of the cooling tower.
The SF-CT-1000 is easy to use. Fabricated from an aluminum alloy, the cooling tower is light-weight and can
be easily moved from one test area to another. Castered
wheels allow easy positioning for connections to the engine. Cam Lock fittings are provided for connection to
the water supply and drain. A tray on the system provides a place to store extra fittings and adapters for different applications.
SF-602
M a n u a l
SF-CT-1000 Cooling Tower

SF-581/582/612
SF-3100/3200
EC absorbers
Part Number
Description
Assembly Nr.
SF Order Ref.
Cooling tower, SF-CT1002 ....................................................................1200A-CT1002 ............... SF-CT1000

Drawing
C C E S S O R I E S
A N D
P T I O N S
Operation and Installation instructions for the

CT1000 Cooling Tower
1. Operation instructions
Operating the SF-CT-1000 is very simple. After engine
and supply hoses have been connected to the cooling
tower using the Cam Lock fittings, a ball valve is
opened to fill the system along with an airbleed valve to
allow air to exit the system. Once the engine and cooling
tower are full, the engine can be started and warmed up.
Adjustments for automatic temperature control and system pressure are made on the corresponding control
valves located at the base of the unit. A pressure and a
temperature gauge are provided on the cooling tower for
monitoring the cooling tower conditions. When the test
is completed, a drain valve allows all of the water from
the tower and the engine to be drained before disconnecting the hoses.
(Hidden) Engine Coolant

Water Return Connection 3 Camlock Fitting
Sight Glass
(R) Pressure Gauge

(L) Temperature Gauge
Engine Coolant
Water Supply
Connections
3 Camlock
Fitting
Engine Temperature
Thermostat
Water Pressure
Relief Adjustment
Vent Valve
(Hidden)
Engine Fill Valve
Engine Drain Valve
Supply Water 1.5

Camlock Fitting
Return (drain) Water

1.5 Camlock Fitting
SF-602
M a n u a l
2. Engine cooling system preparation

Verify drain, supply and system connections are in place.
Determine whether single or dual supply connections
are required.
If dual supply / drain is not required cap the unused
supply and drain connections on the CT 1000 with
supplied plugs
Connect cooling tower supply line (s) (1.5" connector)
to main water supply system. Secure clamps firmly.
Connect cooling tower lines (3" connector) to
engine.Secure clamps firmly
Check to ensure the drain valve is closed (Up)
s
Open fill valve (turn down)
Fill until water fills the sight gauge
Close fill valve (up position)
Drain valve
DOWN to drain
UP to run
Run engine briefly

If bubbles appear in sight glass, fill with water until
water level is at top of sight glass
To drain the system after a test, open the drain valve
(down).
To fill
Drain valve closed (Up position)
Open Fill Valve
Open Vent
Fill valve
DOWN to fill
UP to run
(Down position)
(Up position)
When the water appears in sight glass

Close both valves
(Fill - Vent)
To run
To drain
All valves closed

Open drain valve
(Up position)
(Down position)
RUN or TEST position

Both drain and fill valves must be in this position to run a test
3. Pressure and Temperature adjustments

The CT-1000 cooling tower has pressure and temperature
regulators located at the bottom of the coolant tank. The
table below lists adjustment procedures for temperature
and pressure problems encountered during testing.
Pressure and temperature adjustment

Engine too hot
Engine too cool
Pressure too high
Pressure too low
Rotate Thermostat Control Clockwise

Rotate Thermostat Control Counter-Clockwise
Rotate Pressure Control Counter-Clockwise
Rotate Pressure Control Clockwise
Thermostat
Counter clockwise = Temperature
Clockwise = Temperature
Pressure regulator
Clockwise = Pressure (20 psi max)
Counter clockwise = Pressure
23
Drawings and
Parts Lists
BLK
11
12
21
22
TO SENSOR BOX
1200A-1942, J6
TO SENSOR BOX
1200A-1942, J4
FIELD INSTALL
1200A-2233
GRN
GRN
SYSTEM AC POWER IN
120/240 VAC
5/2.5 A
60/50 HZ
1200A-2180
RS232
FIELD INSTALL
1200A-1902
LAN
FIELD INSTALL
1200A-1981
SEE SHEET 2
REGULATOR
ENCLOSURE
FIELD INSTALL
1200A-1104-2
TO SUPERFLOW
ROLLSET
GROUND WIRE
TO BOOM AND SENSOR BOX
AC TO SENSOR BOX
POWER SUPPLY
J43
J41
J44
NC1
J44
NC2
J42D
SPARE1
J44 COM2
J44,COM1
J42C
GROUND
JJM/RKB
ISSUED
CHECKED
DRAWN
APPROVALS
FIELD INSTALL
1200A-2175
FIELD INSTALL
1200A-2176
J42C
+12V
J40B
1046-B.P01
J40A
1200A-1049-3 REV C1
INTERCONNECT PCB
SuperFlow
DATE:
7/28/96
1201-1046
SHEET
B
1 OF
REV
SF-602 INTERCONNECT BOX

2
3512 N. Tejon
Colorado Springs, Co.
K101,8
J44,COM2
CONTACT 2
K101,7
J44,COM1
CONTACT 1
NORMALLY OPEN
CONTROL CONTACTS
K101
TO SENSOR BOX
1200A-2060, J11
1/14/96
RKB
APPROVAL
SEE SHEET 2 FOR K101 WIRING DETAIL
TO SENSOR BOX
1200A-2060, J7
6 3 5 2 4 1
DATE
BLK 18AWG
YEL
18AWG
3/12/97
ADD WIRING DETAIL, K101 CIRCUIT, ECO#1960
DATE
3/15/95
PRODUCTION RELEASE, ECO#
1
DESCRIPTION
2
REV
RED 18AWG
YEL 18AWG
BRN 14AWG
BLK 14AWG
JACKSOCKET(1PR): E4230P-334110
TEST 1, RS 232
NET 6
NET 5
NET 4
NET 3
NET 2
NET 1
DOOR GROUND STUD
CONTACT BLOCK(1): E4310P-9054

SWITCH BUTTON(1): E4310P-0752
BOX GROUND STUD
SYSTEM AC POWER OUT

120/240 VAC
5/2.5 A
60/50 HZ
FIELD INSTALL
1200A-2178
A N D
RCPT(1): E4200P-3016
PLUG(1): E4200P-3013
GRN
BLK
WHT
B
L
K
SEE SHEET 2 FOR AC WIRING DETAIL
AC IN
E-STOP
WHT
AC OUT
W G
H R
T N
R A W I N G S
D
A R T S
L I S T S
Section 23 - page 1
Section 23 - Page 2
E-STOP 22
F4340P-0002
BOX GND STUD
E4320P-6093
E-STOP 12
F4340P-0002
AC IN 'N'
F4340P-0002
AC IN 'L'
F4340P-0002
AC IN GND
1200A-1104-2
AC OUT 'N'
13.5 WHT
E4230P-524482
11.0 GRN
E-STOP 11
DOOR GND STUD
E4320P-6093
8.0 WHT
8.0 GRN
8.0 BLK
E-STOP 21
F4340P-0002
AC OUT GND.
E4230P-524482
13.5 BLK
9.0
BOX GND STUD
F4340P-0002
AC OUT 'L'
E4230P-524482
13.5 WHT
E4320P-6093
AC INLET TO E-STOP, NEUTRAL
13.5 BLK
AC INLET TO E-STOP, LINE
16.0 GRN
12.0 GRN
AC INLET GROUND
REGULATOR ENCLOSURE
E4230P-524482
E4200P-1311
22
E4310P-9054
12
21
E-STOP
11
1
2
CON2
P43
CONN(1): E4230P-139022
PINS(2): E4230P-800106
E4200P-3013
E4320P-4298
1046-B.P01
CONNECTION VIEW
AC IN
L
E4320P-4298
K101,5
YEL 18AWG
BLK 18AWG
7.5
6.0
RED 18AWG
7.5
BRN
BLK
YEL 18AWG
K101,A
E4320P-4298
J44,NC2
E4320P-4298
J44,NC1
E4320P-4296
K101,6
E4320P-4298
K101,B
E4320P-4296
K101,9
E4320P-4296
ISSUED
RKB
APPROVALS
DRAWN
CHECKED
DATE
2/25/97
D
1
DATE:
1201-1046
7/28/96
SHEET
2 OF
REV
B
2
3512 N. Tejon
SF-602 INTERCONNECT BOX
SuperFlow
NOTES:
1. ALL WIRE 14 AWG UNLESS NOTED.
2. ALL DIMENSIONS IN INCHES.
3. TIN STRANDED WIRE BEFORE CONNECTING TO SCREW
TERMINALS OF E4200P-1311.
DO NOT TIN STRANDED
WIRES WHICH CONNECT TO TERMINAL BLOCKS.
4. WRAP WIRES AROUND E4200P-1311 SCREW TERMINALS IN A
CLOCKWISE DIRECTION.
14.0
14.0
8.0
K101 WIRE DETAIL
STRIP 3) 18AWG WIRES 5/16 INCH
J42D
SPARE1
K101,4
E4200P-3016
J42C
+12V
J42C
GROUND
CONNECTION VIEW
AC OUT
SF-602
M a n u a l
2A
PANEL BRKR
#E4310P-0016
GND
Ln
Lx
BLK
WHT
PUSH ON:
E4230P-201842 x 2
PUSH ON:
E4230P-201842 x 4
LOAD2(22)
LOAD1(12)
LINE2(21)
LINE1(11)
SINGLE-WIRE CRIMP:
E4230P-201842
CIRCUIT BREAKER
#E4310P-82912
2A
IEC SOCKET
#E4320P-4060
TWO-WIRE CRIMPS:
F4340P-0002 x 2
4.5"
WHT
BLK
4.5"
30"
1
2
3
4
156
P4
30"
WHT
31"
1
2
3
4
5
P2
T3
R
E
D
T8
O
R
G
B
L
U
T5
GND
SCREW
R
E
D
M1
B C
L L
K R
B C
L L
K R
CONN
CONN
R
E
D
SOLENOID
ISSUED
CHECKED
DRAWN
BAL
APPROVALS
JACKETED
WITH
1/4" EXPANDO
DATE
9/3/96
1 2 3 4 5 6 7 8 156
P11
PINS #E4230P-800108
FLOAT TOWER INPUT
10/3/96
6/25/97
3512 N. Tejon
6/25/97
1201-2222
SHEET
B
1 OF
REV
NGE FUEL SYSTEM WIRING DWG
SuperFlow
1200A-2193
LOAD CELL ASS'Y
LOAD CELL
100 LB
INTERFACE
R W B G S
E H L R H
D T K N L
D
1 2 3 4 5 156
P14
BAL
BAL
APPROVAL
CABLES TO PANEL
CABLE: 1200A-2232 x2
TEE: E4230P-000288
PINS #E4230P-800108
FUEL CAN
LOAD CELL
INPUT
DATE:
DATE
9/3/96
A R T S
WHT
RED
YEL
BLU
BLK
(COM)
WHT
THERMISTOR
1200A-2224
FLOAT TOWER ASS'Y
TEMP
BOTTOM
LOW
TOP
FLOAT TOWER
DB9
CABLE: 1200A-2231
DB9
1200A-2064
FUEL SYSTEM PCB ASSEMBLY
1 2 3 4 5 6 7 8 9
P1
RELAY
CONTROL
OUTPUT
POWER
INPUT
1 2 3 4 5 6 7 8 9
PANEL-MOUNT
RELEASE TO PRODUCTION, ECO #1908

ADDED SOLENOID, ECO #2008
INITIAL DESIGN
P10
A
B
A00
1
DESCRIPTION
2
REV
1
2
3
4
5
6
7
8
9
10
156
P7
PINS #E4230P-800108
1200A-2230
FUEL RELAY CABLE ASS'Y
YEL
GRN
BLU
VIO
GRY
WHT
22GA WIRE
1 2 3 4 156
P2
PINS #E4230P-800106
PRIME PUMP
1
2
RELAY
CONTROL 3
4
INPUT
5
6
7
8
9
10
156
P5
1200A-2229
FUEL POWER CABLE ASS'Y
PINS #E4230P-800106
156
156
P6
P6
BRN
1
1
BRN
2
2
RED
3
3
POWER
RED
4
4
OUTPUT
YEL
5
5
BLU
6
6
WHT
7
7
BLK
8
8
BLK
9
9
BLK
10
10
BLK
11
11
BLK
12
12
18 GAUGE WIRES
A N D
PRIME PUMP ASS'Y

1200A-2198
(
= WIRE SPLICE)
115VAC SHOWN. 230V VERSION IS WIRED DIFFERENTLY.
PUMP
MOTOR,
REVERSIBLE,
FILL/
EMPTY
T2
T4
W
H
T
1 2 3 4 5 6 7 8 9 1 1 156
0 1 P1
PINS #E4230P-800106
FILL/EMTPY
MOTOR
PINS #E4230P-800106
MOTOR
POWER
PINS #E4230P-800106
P1
1200A-2062
FUEL SYSTEM RELAY/POWER
PCB ASSEMBLY
TRANSFORMER
POWER
B
L
1200A-2197 K
FILL PUMP
ASS'Y
#E4320P-141010
28"
BLK
156
P3
#E4320P-141010
29"
29"
#E4320P-141010
GRN
4"
4.5"
R A W I N G S
NOTES:
1. ALL WIRE 18GA EXCEPT WHERE NOTED.
2. LOAD CELL WIRES ARE CRIMPED TO CONNECTOR PINS.
D
L I S T S
Section 23 - page 3
Section 23 - Page 4
2A
2A
10"
2"
10"
FLOAT
TOWER
CORD GRIP
WIRES
INSIDE
EXPANDO
HEAT
SHRINK
TUBING
(GLUE TYPE)
WIRES
INSIDE
EXPANDO
ADD HEAT-SHRINK THIS END
1 2 3 4 5 6 7 8
THERMISTOR
CORD GRIP
E4340P-1003
RED
RED
YEL(x2)
TEMP
LOW
BOTTOM
BRN
BRN
BLU(x2)
TOP
FLOAT TOWER
A
A1
A00
DRAWING CHANGES, ECO #2116
INITIAL DESIGN
1
DESCRIPTION
2
REV
JACKETED
WITH
1/4" EXPANDO
ISSUED
BAL
APPROVALS
DRAWN
CHECKED
DATE
9/3/96
D
DATE:
DATE
BAL
BAL
APPROVAL
1201-2224
2/13/98
SHEET
A1
1 OF
REV
3512 N. Tejon
10/3/96
2/13/98
9/3/96
FUEL SYS FLOAT TOWER ASSY
SuperFlow
1. ALL WIRES EXIT FLOAT TOWER FROM TOP TUBE.

WIRES DRAWN TO EACH FLOAT FOR CLARITY.
2. SCREW CORD GRIP BOTTOM PART INTO FLOAT TOWER
TOP FITTING.
3. ADD 1/4" EXPANDO OVER FLOAT TOWER WIRES.
EXPANDO MUST BE CAUGHT INSIDE RUBBER CORK
OF CORD GRIP PART.
4. SCREW CAP WITH CABLE CLIP AND RUBBER CORK ONTO
CABLE GRIP.
5. ADD GLUE-TYPE HEAT-SHRINK TUBING OVER EXPANDO
AS SHOWN.
6. ADD GROMMET OVER SECTION COVERED WITH HEAT-SHRINK
7. TERMINATE CABLE INTO CONNECTOR AS SHOWN.
USE 22GA BLK WIRE FOR JUMPERS ON MOLEX CONN.
NOTES:
CONN: E4230P-139082
1 2 3 4 5 6 7 8 156 MOLEX
P11 PINS: E4230P-800108 FOR SINGLE CRIMPS
USE E4230P-800106 ON DOUBLE CRIMPS
W W B B Y B R B
H H L L E L E L
T T U K L K D K
SF-602
M a n u a l
GROUND AT OUTER END OF

INNER BOOM SEGMENT
GROUND AT OUTER END OF

OUTER BOOM SEGMENT
1942,J4
1942,J6
2060,J11
2060,J7
PWR SUP
SENSOR
BOX
KEYBOARD
MOUSE
PHONE LINE
E4330P-0533
1200A-2167
LINE
MOUSE
CONSOL-A.P01
ISSUED
CHECKED
RKB
9/4/96
DATE
SuperFlow
3512 N. Tejon
OPERATOR'S CONNECTOR
PANEL
RJ47 CONNECTOR E4230P-550501
STEREO JACK E4230P-000500
DATE:
9-4-96
SHEET
1 OF
SF-602 CONSOLE CABLE DIAGRAM

CONSOLE-A
REV A
D
E4330P-0533
STEREO JACK E4230P-000500
DRAWN
APPROVALS
PHONE
E4330P-2235
E4330P-2235
E4190P-1053
PRINTER
4800P-4137
FAN
RKB
APPROVAL
A N D
MODEM
MIC.
SPEAKER
AC POWER
PRINTER
LAN CARD 4800P-2000

VID
RAM 4800P-3500
8MEG RAM 4800P-3646
KEYBOARD
LAN
SERIAL A
VIDEO
COMPUTER
4800P-4137
PWR
SUP
CONSOLE BASE ASSEMBLY

1200A-2166
FAN, 3815P-1210, 2X
DATA CABLE PANEL

1200A-2184
1200A-1902-10
1200A-2169
1200A-2168
1200A-2185-1
MONITOR
DATE
5/16/97
FAN AND MONITOR HARNESS ASSEMBLY IS 1200A-2186

THESE PARTS ARE LISTED ON THE 1200A-2164 BOM
NO BOM EXISTS FOR THE 1200A-2186 AT THIS TIME.
PRE-RELEASE REVIEW
4800P-2807
OR
4800P-7387
E4330P-0200
E4330P-0200
FAN
1
DESCRIPTION
2
REV
MONITOR HOUSING ASSEMBLY

1200A-2164
E4330P-17820
TRIPLE AC OUTLET
E4200P-3121
E4330P-8656
1200A-1902-25
GROUND WIRE
MONITOR VIDEO CABLE
1200A-10096
RECPTACLE
E4320P-4060
1200A-2181
1200A-2177
AC IN
1200A-2264
1200A-2185-2
1200A-1902-25
1049,J40B
1049,J40A
1200A-2180
1200A-2176
1200A-2175
1200A-2178
120 VAC SERVICE
CONSOLE POWER SWITCH
POWER CONNECCTION PANEL
INTERCONNECT
BOX
INNER BOOM SEGMENT
OUTER BOOM SEGMENT
R A W I N G S
D
A R T S
L I S T S
Section 23 - page 5
Section 23 - Page 6
C
O
N
N
E
C
T
I
O
N
A
U
X
I
L
I
A
R
Y
S
E
T
R
O
L
L
VTCR
D101
+12V
LOCK
LIFT
J45
+15V
+ S G
1 I N
5 G D
V 5
1 2 3
RRM+
FRM+
THERMOCOUPLE
VOLTAGE
PHX
1
2
3
4
5
6
7
8
J42D
PHX
1
2
3
4
5
6
7
8
J42C
PHX
1
2
3
4
5
6
7
8
J42B
PHX
1
2
3
4
5
6
7
8
J42A
156
JP1
0...10V INPUTS
J46
+ S G
1 I N
5 G D
V 6
1 2 3
THERMOCOUPLE
VOLTAGE
VTCF
+15V
CHANNEL5
CHANNEL6
AGND
SPARE1
SPARE2
156
JP2
+12V
-RLRQ
-LIFT
C4
15uF
FRONT LOAD CELL EX+

FRONT LOAD CELL EXFRONT LOAD CELL SIG+
FRONT LOAD CELL SIGFRONT LOAD CELL SHLD
REAR LOAD CELL SHLD
REAR LOAD CELL EX+
REAR LOAD CELL EXREAR LOAD CELL SIG+
REAR LOAD CELL SIGROLL LOCK REQUEST SW
FLOAT SWITCH
GND
FRONT ROLL MAG +

FRONT ROLL MAG FRONT ROLL SHLD
REAR ROLL SHLD
REAR ROLL MAG +
REAR ROLL MAG FRONT VALVE CMD +
FRONT VALVE CMD REAR VALVE CMD +
REAR VALVE CMD -
156
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
J40B
156
1
2
3
4
5
6
7
8
9
10
J40A
C
O
N
T
R
O
L
L
E
R
S
Y
S
T
E
M
T
O
T C
O O
N
S T
Y R
S O
T L
E L
M E
R
1
4
2
5
3
6
LOCK
12V
10A
K1
REAR ROLL MAG FRONT VALVE CMD +

FRONT VALVE CMD REAR VALVE CMD +
REAR VALVE CMD FRONT LOAD CELL EX+
FRONT LOAD CELL EXFRONT LOAD CELL SIG+
FRONT LOAD CELL SIGFRONT LOAD CELL SHLD
FLOAT SWITCH
GND
FRONT ROLL MAG +

FRONT ROLL MAG FRONT ROLL SHLD
REAR ROLL SHLD
REAR ROLL MAG +
1 2
156
TB
LN
LX
NO2
NO1
COM2
NC2
COM1
NC1
ADD D101 FOR OFF BOARD RELAY, ECO #1957
C1
ISSUED
CHECKED
CPalmer
APPROVALS
DRAWN
5/13/93
DATE
3512 N. Tejon
APPROVAL
DATE:
1/20/94
SHEET
1 OF
CHASSIS DYNO INTERCONNECT PCB

1221-1049
REV C1
D
SuperFlow
NEW ARTWORK, ECO#
C
3/4/97
1/20/94
UPDATE ARTWORK, ADD ROLL LOCKS, ECO # 1517
DATE
5/13/93
1
DESCRIPTION
2
REV
CONTROL CONTACTS
S
E
T
R
O
L
L
S
u
p
e
r
F
l
o
w
T
O
CS1049C1.P01
J44
156
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
J41
AIR SOLENOID
J43
1N4003
D25
AC2
AC1
SF-602
M a n u a l
FRM+
REAR ROLL MAG+
RRM+
FRONT ROLL MAG+
R29
10K
R28
10K
6
5
U1
LM358
U1
LM358
1/8W
.22UF
2
3
R1
47
C1
D2
D1
+12V
C3
22UF
D4
C2
22UF
D6
-RLRQ
+15V
-LIFT
+15V
D14
D10
R13
15K
D13
D7
R8
15K
D9
D8
ALL DIODES 1N4148 UNLESS NOTED OTHERWISE.
D3
D5
R12
10K
R11
10K
+12V
R9
10K
R10
10K
+12V
ROLL LOCK (BRAKES) AND LIFT CIRCUITS
R7
1K
R5
47K
R6
100
R4
1K
R3
47K
R2
100
G
Q2
2N3904
R15
10K
1N4003
D12
Q1
2N3904
R14
10K
1N4003
D11
Q4
IRFD110
LOCK
Q3
IRFD110
LIFT
CS1049C1.P01
AC2
AC1
F1
APPROVALS
ISSUED
1N4003
D16
1N4003
D15
1/2W
DATE
DATE:
1/20/94
SHEET
2 OF

1221-1049
REV C1
D
SuperFlow
+12v
C5
500UF
3512 N. Tejon
R16 +
560
CHECKED
A N D
DRAWN
T1
DPC20-500
ROLL LOCK +12V POWER SUPPLY
1
3
230V
S1
115V
115VAC 1/4A FUSE

230VAC 1/8A FUSE
R A W I N G S
D
A R T S
L I S T S
Section 23 - page 7
Section 23 - Page 8
REAR
THERMOCOUPLE
FRONT
THERMOCOUPLE
K-TYPE
THERMOCOUPLE
RED
YELLOW
RED
YELLOW
PHX
J47
1W
R17
100
1W
R18
100
1W
R19
100
1W
R20
100
+15
Cosc
1
2
1
1
C8
1uF
V+
V-
C6
1uF
U2
LTC1043
SHLD
18
C7
4700pF
16
13
10
SHLD
U2
LTC1043
17
15
14
U3
LT1025
C9
1uF
R-
Vo
Vin
7
K,T
R,S
GND
+
1
5
C10
1uF
ABSORBER OUTLET TEMPERATURE CIRCUITS
D17
P6K6.8A
D18
P6K6.8A
D19
P6K6.8A
D20
P6K6.8A
D22
P6K6.8A
D21
P6K6.8A
D24
P6K6.8A
D23
P6K6.8A
+15V
6
5
2
3
1/8W
R21
47
+
1
5
R25
100
R24
100
CS1049C1.P01
0.1%
U4
LTC1051 0.1%
0.1%
U4
LTC1051 0.1%
.22uF
C11
C12
.068uF
VTCR
C13
.068uF
VTCF
ISSUED
CHECKED
DRAWN
APPROVALS
R23
1K
R22
246K
R26
1K
R27
246K
DATE
3512 N. Tejon
DATE:
1/20/94
SHEET
3 OF

1221-1049
REV C1
D
SuperFlow
Vout = 0V...4V
FOR 0 TO 400 DEG. C
(180 DEG. F PER VOLT)
Vout = 0V...4V
FOR 0 TO 400 DEG. C
(180 DEG. F PER VOLT)
SF-602
M a n u a l
(SERIAL/ANALOG)
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
1938-A1.P01
ISSUED
CHECKED
RKB
APPROVALS
DRAWN
DATE
ENG_SPD_OPTO
1
2
3
4
5
6
7
8
9
10
11
DO1
DO2
DI1
DI2
CON11
J10
ENGINE
SPEED
CH. 10
ECO#1902
(SPARE)
(SPARE)
(SPARE)
(SPARE)
ENG_SPD_M1
GND_OPTO
GND_M1
SHLD_OPTO
SHLD_M1
DATE
RKB
APPROVAL
DATE:
1221-1938
5/15/96
SHEET
A1
1 OF
REV
3512 N. Tejon
12/19/97
6/24/96
602 SENSOR BOX CONNECTORS
SuperFlow
CATERPILLAR
RACK POINT
CH. 75
+5
+12
DO1
DO2
DI1
DI2
RACK+
RACK-
4/10/96
ECO#1925
MAG1
OPTO_PWR
OPTO_S+
1
2
3
4
5
6
7
8
9
10
11
CON11
J5
WIRE ADDS, LABEL CORRECTIONS ECO# 2090
A1
+5
PRODUCTION RELEASE
LOAD 4-20mA
THROTTLE 4-20mA
LOAD 0-10V
THROTTLE 0-10V
GND_LD
GND_TH
SHLD_TH
SHLD_LD
CON11
J9
ENGINE DYNO
AND THROTTLE
CONTROL
IDAC1
IDAC2
DAC1
DAC2
+5
+12
(11pin)
2
DESCRIPTION
A0
REV
LOAD4+
LOAD4ENG SPEED
SHLD_L3
SHLD_L4
EX+3
EXLOAD3+
LOAD3EX+4
CON11
J4
ENG. DYNO
TORQUE
CH. 1/2
LC4+
LC4-
LC3+
LC3EX+
EX+
4. CHANNELS 8 AND 9 ARE SHOWN IN WRONG LOCATIONS

ON SENSOR BOX CONNECTOR PANEL SILKSCREEN.
ALLOWS
CORRECTS FLOATING GND.
3. WIRE ADD FROM J5,8 OR 9 TO J5,10 OR 11.

ENGINE SPEED INPUT ON J4.
2. WIRE ADD FROM J4,9 TO J5,7.
1
2
3
4
5
6
7
8 GND_A3
9
10 S H L D _ A N 3
11 S H L D _ S E R f
CON11
J8
SERIAL #3
PORT
+5
+12
ANLG3
RXDf
TXDf
RTSf
CTSf
ADDED ANALOG
A N D
GND_A2
GND_M6
SHLD_A2
SHLD_M6
CHAN 6
CHAN 9
(ANALOG/FREQ)
1
2
3
4
5
6
7
8
9
10
11
(ANALOG/SERIAL)
ANLG2
MAG6+
+5
+12
-12
AUXIL.
INPUT
CH. 6/9
1
2
3
4
5
6
7
8 CHAN 4
9 GND_A1
10
11 S H L D
CON11
J7
(11pin)
1
2
3
4
5
J1939
6
7
8
J1708
9
10
11 S H L D
CON11
J3
(ANALOG/FREQ/FREQ)
CHAN 5
CHAN 7
CHAN 8
GND_A0
GND_M4
GND_M5
SHLD_A0
SHLD_M4
SHLD_M5
+5
+12
-12
RX0
RX1
TX0
TX1
J1708+
J1708-
SAE
1587/1708
PORT
1
2
3
4
5
6
7
8
9
10
11
CON11
J2
BLOWBY
CH. 5/7/8
+5
+12
ANLG0
MAG4+
MAG5+
OPACITY
CH.4 &
SERIAL #2
+5
+12
-12
RXDe
TXDe
RTSe
CTSe
ANLG1
CON11
J6
1. IDAC1 AND IDAC2 (12 BIT DAC) ARE SHARED BETWEEN

CHASSIS DYNO CONNECTION @ 2060-J1505 AND ENGINE
DYNO CONNECTION AT SENSOR BOX J9.
NOTES:
1
2
3
4
5
6
7
8
9
10
11 S H L D _ S E R d
CON11
J1
SERIAL #1
HANDHELD
TERMINAL
+5
+12
+5
RXDd
TXDd
RTSd
CTSd
R A W I N G S
D
A R T S
L I S T S
Section 23 - page 9
J1708+
J1708-
RX0
RX1
TX0
TX1
RXDd
TXDd
CTSd
RTSd
RXDe
TXDe
CTSe
RTSe
RXDf
TXDf
CTSf
RTSf
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
J11
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
-12
-5
+5
+12
ANLG0
ANLG1
ANLG2
ANLG3
ANLG4
ANLG5
EX+
LC3+
LC4+
IDAC2
IDAC1
DAC2
DAC1
RACK+
DO2
DO1
SPARK1
MAG1+
MAG4+
MAG5+
MAG6+
MAG7+
MAG8+
OPTO_S+
1
3
5
7
9
11
13
15
17
19
21
23
25
1
3
5
7
9
11
13
15
17
19
21
23
25
J13
2
4
6
8
10
12
14
16
18
20
22
24
26
J12
2
4
6
8
10
12
14
16
18
20
22
24
26
EX+
LC3LC4DAC3
DAC4
DAC5
DAC6
RACKDI2
DI1
SPARK2
OPTO_PWR
+5
+12
SuperFlow
DATE:
1221-1938
1/22/97
SHEET
A1
2 OF
REV
3512 N. Tejon
602 SENSOR BOX CONNECTOR
SF-602
M a n u a l
156
J5
1
4
2
5
3
6
K1
K2
K3
FOR K1
FOR K2
FOR K3
1
4
2
5
3
6
1N4148
D1
12V
10A
EMPTY
K1
V2
V130LA10
V1
V130LA10
9
8
4
6
7
LXS
156
1
2
3
4
5
6
7
8
9
10
11
Z2
+
C4
1000uF
1N4001
1N4001
D5
D4
1N4001
D8
1N4001
D10
1N4001
(1mA)
5
Vin
GND
1
IN
GND
1
OUT
KB,JM,BL
ISSUED
CHECKED
DRAWN
OUT
Q1
LM79L05
IN
G
N
D
3
V
c
C14
.01uF
R1
2.7K
FB
Vsw
D12
1N5822
100uH
C6
56uF
C12
56uF
C3
56uF
8/1/95
D
1
SuperFlow
L1
10/3/96
1
2
3
4
5
6
7
8
9
10
11
12
156
J6
BAL
C9
1000uF
BAL
POWER TO
1200A-2064
+5
+5
+12
+12
+15
-5
-15
AGND
AGND
GND
GND
GND
R3
14.3K
R2
18.7K
1/20/97
APPROVAL
1201-2062
1/27/97
SHEET
B
1 OF
REV
3512 N. Tejon
1%
1%
DATE
8/1/96
NGE FUEL SYS PWR/RLY PCB

DATE:
C2
56uF
(NO HS REQ'D)
(NO HS REQ'D)
(.4W, Tca <

120 degC/W)
DATE
(.75W, Tca < 60degC/W)
OUT
Q2
LM79L15
GND
APPROVALS
OUT
Q4
LM7815
GND
2
IN
IN
Q3
LM7812
C13
1000uF
(-20.5V min)
(10mA)
C10
1000uF
U1
LT1074
REV B, ADDED SWITCHER CKT, ECO #1940
INITIAL DESIGN
(Tca < 18 degC/W)
C11
2200uF
(40mA)
A00
1
DESCRIPTION
2
REV
+
C8
8200uF
(75mA)
(20.5V min)
(8.4V min)
(1A)
1. C6, C9, AND C12 HAVE SILKSCREEN BACKWARD

ON REV A PCB.
NOTES:
T8
T5
T3
LN_MOT
J1
(100mA)
1N4001
D6
D11
1N5822
D9
1N5822
D7
(24V UNREGULATED)
156
1
2
3
4
J2
12
1
11
MSL7-16036
T1
10
PRIME_LX
V3
V130LA10
V4
V130LA10
Z1
12V
10A
FILL
K2
1N4148
1
4
2
5
3
6
1N4148
D3
12V
10A
CGND
PRIME
K3
D2
230
115
LN_MOT
LX_MOT
FILL
EMPTY
PRIME
LN_XFRM
SW1
LX_XFRM
A N D
SPRING FOR
SPRING FOR
SPRING FOR
KUP SOCKET
KUP SOCKET
KUP SOCKET
NUT FOR Q5
NUT FOR Q3
SCREW FOR Q5
SCREW FOR Q3
WASHER FOR Q4
HEATSINK FOR Q5
HEATSINK FOR Q3
1
2
3
4
5
156
J3
+12F 1
SOL 2
SOL 3
PRIME 4
PRIME 5
EMPTY 6
EMPTY 7
FILL 8
FILL 9
GND 10
TO 2064
PCB ASSY
1
2
3
4
156
J4
R A W I N G S
D
A R T S
L I S T S
SF-602
M a n u a l
R A W I N G S
A N D
A R T S
L I S T S
602 Systems
Recommended Spare
Part number
parts
Minimum
Zero
down
down
time kit
time kit
1
3430P-3255
1 or source E4190P-4145
locally
1200A-1942
1200A-2060
1200A-1932
PCB, LCD slave
1200A-2163
Sensor box connector

panel
Sensor box hinge
Sensor box hinge (with
screw)
Hand Held controller
Cable, Hand Held
controller
Console monitor glass
Console monitor air
filter
PCB, SF-602
Interconnect
Relay, interconnect
KUP14 D15 12V
Adapter, 1/8 x #4 fitting
1200A-1853-02
1200A-1867-02
2600Z-2100
4500P-2565
1200A-1049-3
E4295P-1412
4
1
1
4
1
1
1
1
1
1
1
3500P20210204
3500P-641180
1200A-2187
1510P-5140
T3200P-0058
4000P-0601
1510P-0010
T1510P-3010
T1200A-0640
1200A-2062
optional
1
optional
1
1
1
1
1
Key, sensor box

Power supply, AT
switcher
PCB, CPU
PCB, Data acquisition
PCB, LCD controller
1200A-1932-1
3430P-9110
3430Z-9110
Description
1200A-2064-01
T1500P-0007
1200A-2224
4800P-3732
E4230P124618
E4230P000288
Hose, 15 ft #4 SST braid

Cable, CAT optical tach
Optical tachometer
Packing, graphite
Packing removal tool
Load cell, 10K
Magnetic speed pick-up
Tie-down assembly
PCB, fuel system relay

and power
PCB, fuel system CPU
Load cell, fuel system
Fuel system float tower
Terminator, 50 LAN
Terminator, 50 LAN
grnd
Tee, BNC LAN
Notes
Main CPU board

Secondary CPU board
Master LCD board in
sensor box door
Slave LCD board in
sensor box door
Main sensor interface
panel
includes cable
Screened
Interconnect box pcb

Interconnect box relay
pressure hose adapter
pressure hose
extension cable
sensor with cable
contains 6 pieces
Absorber torque sensor
for roll speed
4 chains, 2 ratchets, 2
belts (these parts are
available individually)
Fuel system only!
Fuel system only!
Fuel system only!
Fuel system only!
Ethernet connector
Ethernet connector
Ethernet connector
SF-602
M a n u a l
WinPac Systems

SF 602 Manual

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SF 602 Operators

Packaging and Handling

Description of the Configuration File

WinDyn Reference Guide

WinDyn Stored Data Viewer

WinDyn DataLib Program

WinDyn Software Architecture

WinDyn How To...

Maintenance and Service

Control System Set up

Accessories and Options

Warranty, Liability, Legal Statements .......................................................... 4

Product Identification ................................................................................. 6

Chassis dyno system ................................................................................... 7

Manufacturer and distributors .................................................................... 8

Control Console ........................................................................................ 4

Sensor Box ................................................................................................ 5

BR-600 Rollset description ............................................................................ 6

Interconnect Box ........................................................................................ 8

Handheld Controller .................................................................................. 9

3. Packaging and Handling

Lifting and Handling instructions ............................................................... 3

Packaging of a typical SF-602 system ....................................................... 4

Packaging of a typical WinPac system ....................................................... 5

Order of unpacking and inspection ............................................................ 5

Introduction to dynamometer testing .......................................................... 3

Accuracy of dynamometer testing .............................................................. 3

Test room recommendations ...................................................................... 4

Facility Recommendations ........................................................................ 8

Types of water systems .............................................................................. 22

Electrical Requirements, Connections .................................................... 23

Facility construction drawings ....................................................................... 8

Overall electrical requirements .................................................................... 23

Safety Precautions .................................................................................. 24

General precaution ...................................................................................... 24

Placement of Dynamometer into Pit .......................................................... 3

Load Control Valve Installation .................................................................. 5

Control console installation ......................................................................... 13

Interconnect box mounting .......................................................................... 12

Control Console Installation .................................................................... 13

Boom installation .......................................................................................... 8

Interconnect Box Installation .................................................................... 12

Sump pump installation ................................................................................ 7

Sensor Input Box Installation ..................................................................... 8

Sump tank installation (closed water system only) ....................................... 6

Sump Pump Installation ............................................................................. 7

Load control valve mounting ......................................................................... 5

Sump Tank Installation ............................................................................... 6

Dynamometer installation ............................................................................. 3

Handheld connection .................................................................................. 14

Fuel System Installation .......................................................................... 15

Unpack fuel system .................................................................................... 15

5.10. Configuration ........................................................................................... 16

5.11. Description of sensor connections ........................................................... 20

Thermocouple Connections ......................................................................... 20

Opacity sensor ........................................................................................... 22

Basic System Tests .................................................................................. 23

Turn system on ........................................................................................... 23

5.13. Calibration ............................................................................................... 27

Quick Start ................................................................................................. 3