Performance Trends` “EZ Flow”
Contents
1. You may want to seal this with heavy grease or tape and attach the 2 pieces with screws or bolts instead of PVC cement or some other type of sealant NOTE Orifice plates must be no larger than half the inside diameter of the PVC tubing it is mounted in For example ifice Plate in tub a 2 orifice is the maximum size for a 4 PVC tube lites Cite Intype If needed you can Tee into this Pressure taps pressure tap for should be as close the test pressure to orifice plate as sensor possible to avoid taps being exposed to air velocity EZ Flow System Build Diagram Bench top with 5 2 5 5 hole cut for bore adapter PFAEZBA bolted to bench top via mounting holes PFAEZMPT PFAEZO x xx orifice To Vacuum Pressure Source PFAEZPVC4 10 PFAEZ90 4 Recommend this joint be temporary See Notes PFAEZFL4 PFAEZFL4 PFAEZRDx x PFAEZFS 4 reducer Flow Straightener PFAEZPVC4 PFAEZPVC4 PFAEZFS 4 Flow Straightener Keep the PFAEZPP 125 as close as practical to the orifice plate to ensure the pressure seen is out of the air flow You can use this pressure as both a flow pressure and as the test pressure for the Black Box via a Tee fitting The length from the top of the PFAEZBA to the PFAEZ90 4 90 deg elbow should be 10 min longer is better OBA Optional Bore Adapter fabricated to Suggestions for controlling adapt to user s cylinder head or test piece the test pressure either with a restrictor valve ora b2. Flow details vacuum motor wood or metal ring with hold down DN l to hold motorin 3 place hole in plywood a end view Note Use LOTS of screws to hold ply wood box together as the pressures inside over a large area create LOTS of force High Pressure Side Low Pressure Side suction Routing of air The easiest method is to attach 2 large hoses one to the top high pressure side and one to the bottom low pressure side Then you can route the air as shown in the previous Figure of the shop vacuum A more permanent air routing diverting method is outlined below High pressure going Low pressure suction to Steel diverter plate 4 holes in end of box to EZ Flow exhaust flow EZ Flow intake flow Route these 2 holes permanently These 2 holes can High Pressure Side to EZ Flow System with Y hose be open to room Low Pressure Side fitting or with a plywood chamber air Top 2 holes are on the High Pres Side of box on the end of the box Bottom 2 holes are on the Low Pres Side of box Tips It is easiest to have 2 wooden end panels each with 4 holes with the diverter plate sandwiched between them Space the 2 panels apart with washers for a tight clearance Fasten together with bolts Use one large bolt as the pivot for the diverter plate You can get fancy with bearings or bushings if you want Leaks here in this box do not affect accuracy just the efficiency of how much total CFM you can generate Instruction
3. Performance Trends EZ Flow EZ Flow is a kit which allows engine builders build a computerized flow bench from materials available at most any hardware store First you must build a bench following the parts list plans and suggestions below Parts List Qty 1 gt a NNN Part Number PFAEZBA PFAEZO x xx PFAEZTB 125 PFAEZPP 125 PFAEZFL4 PFAEZMPT PFAEZ90 4 PFAEZPVC4 19 PFAEZPVC4 10 PFAEZFT PFAEZRDx x PFAEZOx xx PFAEZFS 4 OFPB OBA OFCV Source Description Std Bore Adapter part of Performance Trends EZ Flow System with SB Chevy and SB Ford bolt patterns and approx 4 03 ID other bolt patterns available Flow Orifice x xx is diameter part of Performance Trends EZ Flow System Available sizes are 2 5 400 CFM 2 250 CFM 1 5 150 CFM 1 0 75 CFM 24 lengths of 1 8 clear PVC tubing for routing pressure to sensors in Black Box part of Performance Trends EZ Flow System 1 8 NPT to 1 8 barbed hose fitting Ace Hdwe 4013108 4 PVC flanges w 6 bolt circle holes NIBCO 4851 Genova 75141 Note that these may have to be drilled to match the bolt pattern of the PFAEZO x xx orifice and have the face sanded or ground smooth to provide an air tight seal using the PFAEZFT 4 PVC to male pipe thread adapter NIBCO 4084 Genova 70440 4 PVC 90 deg streamlined elbow NIBCO 4807 Genova 72840 Genova 73840 for a more gradual bend 19 length of 4 schedule 40 PVC strai
4. cuum Pressure Source Like a Shop Vac or a higher pressure amp flow source fabricated by user PFAEZRDx x reducer Rubber Adapter PFAEZPVC4 19 from EZ Flow System Home Depot or Ace Hardware have a wide array of rubber adapters in the plumbing department one brand being PIPECONX by UniSeal Grainger and McMaster Carr have both vacuum motors and large diameter vacuum hose where you can fabricate a high capacity vacuum pressure source To produce more than 20 water test pressure you will most likely need 2 stage vacuum motors To produce more than 30 water test pressure you will most likely need 3 stage vacuum motors To build a high capacity flow bench you need several vacuum motors about 1 for each 70 CFM of flow you want at 28 water This will require a lot of electrical power amps and most likely 220 VAC and a good knowledgeable electrician You must also reduce all flow restrictions to a minimum so all the pressure vacuum can be used to produce a pressure drop across the head test piece This also means the flow orifice must be sized quite large so it does not become too restrictive Vacuum Source Custom Build Shop Vacuum If you want more flow capability than a large Shop Vacuum you can build one following the basic outline below Contact us for typical part numbers for good vacuum motors Each motor requires about 10 amps 110 VAC and provides 50 to 80 CFM at 28 depending on EZ
5. ems Leaks are a major contributor to flow bench inaccuracies and non repeatable readings Take precautions to eliminate all leaks If you construct portions of your flow system out of wood be sure to laminate or paint with several coats to eliminate the porosity of the wood Generally the more the volume between the head or test piece and the flow orifice the better it it doesn t introduce leaks The system shown on the next page with the plenum shows this extra volume so the air can stabilize between the head and the flow orifice If you use a plenum be sure that the air stream from either the head or the flow orifice are well separated so the flow velocity from one does not influence flow on the other You must measure the Test Pressure from a relatively quiet area away from flow velocity If you use a plenum tap into a remote corner of the plenum If you use just the 90 deg elbow Tee into the flow orifice pressure tap on the side nearest the head test piece Pressure taps to record pressure across Flow Orifice should be as close to orifice as practical to be in the dead flow area in corners See Detail to right For best accuracy repeatability keep the amount of straight PVC tubing before and after the flow orifice to 15 minimum 30 total If space allows longer is better For ease of assembly it is recommended that the joint between PFAEZPVC4 10 and PFAEZ90 4 be easily assembled and disassembled
6. f air passing through head or test piece Flow Temperature temperature of air passing through flow orifices Black Box Il foot switch can go here or to Test Temp See figure below ends Readings Int 1 F9 gt Freeze Continuous Update bt Fre 5 S BB2 Foot Switch Use Test Temp T1 Channel Foot Switch Disabled ReZero Swirl Tumble Re Zero Pressure Readings Eliminate Re Zero Correction Force to Set Test Pressure Send Enter Keystrokes After Setting Pressure Adjust Enter Keystrokes Delay Time Change Flow Direction Force FlowCom Motor Off Force FlowCom Motor On Valve Opener Troubleshooting Bore adapter Vacuum motors for flow source Valve Opener and Lift Flow Control Valve to set Test Pressure may Measurement not be necessary for standard Flow Tube Flow Orifice Flow Tube with Orifice Aux Pres or Pitot Tube Pres Low Aux Pres or Pitot Tube Pres High Cylinder Head High pressure tap on pitot tube Low pressure tap on pitot tube Chamber Good location for test pres tap is up close to head in area out of valve air flow The pressure tap for test pressure measuring pressure under the head should be placed in a dead flow area and not in a location where air is rushing by it This produces a Bernoulli suction pressure which is not correct You can also Tee into the pressure tap on the head side of the flow orifice pressure taps as shown in picture on
7. ght tubing 10 length of 4 schedule 40 PVC straight tubing 24 lengths of light foam tape weather stripping Rubber reducers 4 to x x inch available sizes 4 3 2 5 and 2 6 square calibration orifice plate with x xx inch diameter sharp edged orifice available sizes are 3 0 2 5 1 875 1 5 and 1 0 inches 4 grid flow straightener 2 x4 cut from white egg crate Home Depot ceiling lighting panel 74507 43200 Optional Flow Plenum Box Optional Fabricated bore adapter for heads other than SB Ford or SB Chevy Optional Flow Control Valve to help maintain a constant test pressure For High Flow 6 PVC EZ Flow Systems 1 2 PFAEZBA6 PFAEZFL6 PFAEZMPT6 PFAEZ90 6 Notes for assembly 6 Bore Adapter part of Performance Trends EZ Flow System with SuperFlow flow bench bolt pattern for your bore adapter 6 PVC flanges w 9 5 bolt circle holes McMaster Carr 4881K221 Note use the PFAEZFT to provide an air tight seal Visit www memaster com to order 6 PVC to male pipe thread adapter McMaster Carr 4880K161 Visit www mcmaster com to order 6 PVC 90 deg elbow Lowes Charlotte Pipe 6 PVC 90 Elbow Item 53037 Model PVC 00300 1600 Visit www lowes com to order The diagrams given here are just a couple of assembly layouts Due to space constraints your shop layout etc you may decide to do things differently Here are some tips to keep in mind for all syst
8. idson tests SPRTSMAN II Typical SF1020 i Choose ES Port Flow Analyzernys 9 Pertorman s t e Examples fit Graph Report Test Options Head afp wii i for the EZ tart Wizard 1 i illgi Folder eha start new test Ctrl h Open from all saved tests Ctrl O List All Files by File Name Tip Click on a 3 different Folder Open from History Log C List by File Name include Head Save Ctrl S List by Head include File Name Save As ctrl Files Not Filtered all files listed Open from Floppy CD E Drive Open Filter find Advanced Delet Add Save to Floppy CD E Drive Cancel Help Delete Right click in list above for more Folder Options Tose uk Confirm that these critical specs are correctly set in this EZ Flow Example test file as shown below EZ Flow System Setup in Port Flow Analyzer Software Click on Flow Bench at top of J Port Flow Analyzer v3 5 Performance Trends FEZ Flow Example Main Screen to bring up Flow Bench specs screen shown here Flow Bench Specs Test Backfok File Calibrate Valve Opener Help General Bench Specs Last Updated Select EZ Flow System for the me Date Flow Bench Type Most specs in this screen are now disabled and Flow Ronges are being set automatically by the software Enter Ranges for your bench below Inclined Flow Manometer Intake Exhaust Range 1 550 36 ii Click on Find Com Port button to have the program look for your Black Box II Even if you are usi
9. ill first let the program record zero pressures with no flow bench off Then you will turn on Notes This screen lets you calibrate a Custom Bench or a Performance Trends EZ Flow System Install a Sharp Edged Orifice plate on the flow bench in place of the test piece Type in the Orifice Diameter above and then click on the Measure Flow Data button above and follow the program instructions the bench and record pressures for this known orifice size The results will be shown at the top as New Full Range CFM Click on the Use Calc Value to keep this new calibration Click on Calibrate then select either Intake or Exhaust for the flow direction to calibrate i Calc Full Range CFM x New Full Range CFM 473 45 Current Full Range CFM 472 1 Theoretical CFM Flow Calibration Data Orifice Diameter in 875 Incl Manometer Reading or Test Pressure H20 Notes This screen lets you calibrate a Custom Bench or a Performance Trends EZ Flow System Install a Sharp Edged Orifice plate on the flow bench in place of the test piece Type in the Orifice Diameter above and then click on the Measure Flow Data button above and follow the program instructions is Calc Value Help Cancel Print IMPORTANT You can estimate the New Full Range CFM you should get from this calibration by squaring the diameter of the flo
10. leed valve a Tap into a remote corner of the plenum for Test Pressure 5 pipe diameters minimum See NOTE below Optional OFCV Keep air flows from bore adapter and flow orifice well separated so flow velocities have time to settle out and not influence OFPB Optional Plenum Box the flow or pressure the other air flow The OFCV valve will restrict flow NOTE If you want to control test pressure with either a restrictor You can also use a bleed valve to valve like the OFCV or with a bleed valve these should be control pressure This valve can placed 5 pipe diameter away from flow orifice 30 for 6 pipe typically be smaller than the pipe size You can also reduce pipe size at this point for easier building say 2 3 valve for 6 main pipe Notes on Mounting PFAEZBA Bore Adapter 420 Threaded mounting holes Piece mounted on Be sure that top like a bore the 20 screws Small Block Ford adapter for differen do not touch Bolt pattern cylinder size or EY when tightened a calibration orifice OR if top bolt is used Small Block Chevy bolt pattern Optional Mounting Use 4 10x32 countersunk PFAEZBA Tapered holes flathead screws in tapered for 10x32 holes Bench Top mounting screws Vacuum Source Tips For Intake Flow connect vacuum hose to EZ Flow System and let pressure hose blow into room For Exhaust Flow connect pressure hose to EZ Flow System and let vacuum hose suck from room Va
11. meter to the test pressure line to calibrate the test pressure sensor in the Black Box A water manometer can be as simple as a loop of clear plastic hose with colored water filling a little over half of the hose It is much easier to work with a tall manometer where the total height of the loop is 40 inches or more The pressure you record is the total difference in height of the water levels See Appendix 2 in the Port Flow Analyzer s user manual Once the Test Pressure vertical manometer sensor has been calibrated or had estimated readings entered you can calibrate the entire EZ Flow Flow Bench following the procedure outlined in the figures on the next page 10 Calibrating the EZ Flow System ia Flow Bench Specs Back ok File Calibrate Help General Bench Calibrate Sensors Intake Range 1 Last Updated Time Date 2 5 2004 5 14 pm Use Temperat Exhaust Range Rated Test Pressure water Inclined Flow Manometer Flow Ranges Enter Ranges for your bench below Intake Exhaust a Calc Full Range CFM xi New Full Range CFM Current Full Range CFM Theoretical CFM Flow Enter the diameter of the orifice you have installed on the EZ Flow system as pictured below Calibration Data Orifice Diameter in Incl Manometer Reading Corr Test Pressure H20 c Measure Flow Data Click on Measure Flow Data and follow the program instructions You w
12. ng a USB adapter it will still show up as a Com Port Electronics Com Port Com1 Find Com Port Click on See Details button to it Readings to Average bring up screen shown below Other Data None See Details calibrations Enter both the Offset and Factor for Test Pres sensors as shown here z PEF r These numbers 133 Back ok File Weather Station Calibrations Swirlf Tumble Meter Typ and 055 are Bench Electronics Calibrations Pressure Sensors Temperature Sensors approximate but work well for most situations Calibrate Offset amp Factor Factor na For OLDER boxes with Comment ____ ASCX sensors plastic pressure taps extend Test Pres vert man Offset Flow Temp T2 Offset eee above top of box these Calibrate Offset amp Factor Factor Calibrate Offset amp Factor Factor numbers change to 80 5 and 038 respectively Port Velocity pitot tube Offset 3 Other Sensors Calibrate Offset amp Factor Factor F dded or added accuracy you Comment factory calibratior can also click on this Calibrate button and Hel Gome comment to describe the calibration of the Port follow the program Velocity Pressure sensor Click on the Load Date instructions to calibrate button to load the current Time and Date as the the sensor to a water comment p 161 manometer See Figure on next page Calibrating the Test Pressure Sensor with a Water Manometer Tee in a water mano
13. ox doc 13 6 EZ Flow System s Bore Adapter and Assembly H ead Bolt Adapter h 1 4520 threaded bolts not included to fasten head to plate yous You will determine the G proper length for your cylinder heads fe MO pESIicdesofsolate Bottom sidegofaplate Insert fits in hex itole from the bottle
14. page 2 However due to flow losses flow straighteners etc this pressure is not exactly the same as the pressure directly under the head Software Setup With the Black Box connected you will want to setup the software Follow the process outlined in Examples 4 1 and 4 2 in the manual When doing the Flow Bench Specs setup follow the instructions outlined below NOTE There are demo movie files on our website which can help you get up to speed quickly On our website click on Support then Movie Demo Files then find the Port Flow Analyzer movies First open up the example test called EZ Flow Example Click on File at upper left corner of main screen then Open from all saved tests Then in this Open Test File screen choose click on Examples in the lower right corner for the folder then choose click on EZ Flow Example in the upper left corner then Open in the lower left corner This will load several test and flow bench settings to get you up and running quickly Open the EZ Flow Example File Choose the EZ Flow Example test file then click on Open in the lower left corner Open Test File 11 Tests in Library Chosen File EZ Flow Example Black Box Il on SF609 Preview max CFMs corrected to 28 Head j ae Intake Exhaust Click on VIvs 1 VIvs 1 File then Viv Dia 2 02 Viv Dia 1 6 Open from i CFM 252 0 7 CFM 180 2 7 10 00 am 03 12 2004 all saved Harley Dav
15. s for Black Box Hookup to Flow Bench Once you ve built your EZ Flow flow bench you will connect the Black Box Performance Trends Black Box data logger will record data from your EZ Flow flow bench to greatly enhance your flow bench testing The 2 figures below give an explanation of the various connections to the Black Box DB9 w male pins connector Power light indicator to communicate to computer You MUST use cable provided by Performance Trends Power Jack 12 volt DC 300 mAmp DB9 w female sockets connector for Swirl Meter input Frequency Inputs typically not used and are not included on later Black Boxes Enable Foot Switch To enable the use of a foot or hand switch for recording data with the Black Box you must enable the switch Do this by clicking on Options in the Electronics Reading screen then clicking on BB2 Foot Switch and select which temperature channel to use for the Foot or Hand Switch Typically this will be Use Flow Temp T2 Channel because Test Temp is used for recording temperature of the air flowing through the test piece If you want to record temperature on the same channel as a switch is attached you need a special Tee harness from Performance Trends High Pressure side of Pitot Tube sensor High Pressure side of Inclined Manometer flow pressure High Pressure side of Vertical Manometer test pressure Test Temperature temperature o
16. w orifice in the tube and then multiplying by 50 For example for a 2 5 orifice it should be approximately 2 5x2 5x50 312 5 CFM f your calibration does not come close to this within 10 double check what you are doing eee Make or purchase from Performance Trends an orifice plate a normally bolt Seal for leaks to bolt to the Bore Adapter where the head test piece would 12 Depending on various combinations of settings it may be necessary to set the Preference under the Gen Operation cont tab of Black Box Reads Pres to Yes NO checking See Figure below Preference Settings Click on Preferences Then set Black Box Reads Pres to Yes NO checking FS Port Flow Analyzer 3 5 _Performance Trends EZ Flaw ample Engine Specs Definitions calcs Printing 7 Graphing Me File Options Setting Test Pressure Test Potts Restart Showing Help Tips Allow Test Pressure Set Points Automatically Set Te Auto Step Through Te Allow Very High Pressures Black Box Reads Pres Yes NO checking Help Black Box II Weather Sensors None Set Graph Colors Solo may efor oO Prompt for Recording Single Vel Pt No v Ask about Using Early FlowCom No v FlowCom Swirl Channel Let Program Pick y DENT Aak FlowCom Require Exact Data Frame for Fast Y v Updating Computers Allow Fine Tuning for Flow Sensor No v Reset to Defaults EZ Flow w Black B
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