Project SF-110 upgrade
Posted: Tue Oct 19, 2021 7:15 pm
I posted elsewhere on here that I was doing an upgrade to my old SuperFlow SF-110 bench and someone asked if I could provide more details. OK...
First, I'd LOVE to have a "big" bench, but I can't justify the $, nor is my home's electrical infrastructure set up for something that pulls so much juice. Since I ran into an issue w/ my 20 year-old "toy" bench some time back, I looked into some level of affordable upgrades while I was going to have repair it anyway.
Second, eBarf has been extremely helpful in sourcing stuff at decent -- sometimes even downright cheap -- prices on new and nice used items.
/////////////////////
The components upgrade are going as follows:
- new intake motors w/ higher capacity
- new exhaust motors w/ higher capacity
- new 4" inclined manometer replacing original 2"
- digital manometer with 60" H2O capability replacing original 15" H20 unit (hand-held unit that will mount to front of bench using Velcro so the batteries can be replaced when needed)
- larger diameter flow controller orifice for intake only
- and the plenum of the bench needs some additional flow directors added that were something SF incorporated into later production runs
/////////////////////
My original intent was to replace only the intake motors, so the model I chose for that purpose are different than what I ended up buying for the exhaust. These are the model numbers and applications of the various motors:
1. 116297-00 - original SF-110 Int & Exh
2. 116662-49 - replacement Exh motors
3. 119419-00 - replacement Int motors
Performance data from their respective product data sheets showing the flow & suction improvements of the replacements over the original motor:
CFM @ X" H2O ratings for orifice size specified
Vac Motor # -------- 0.000" ------------- .500" -------------- 1.000" -------------- 1.500" ----------------- 2.000"
116297-00 -------- 0.0 @ 60.6" -------- 23.0 @ 47.7" -------- 70.0 @ 27.5" -------- 106.0 @ 12.6" -------- 123.0 @ 5.3"
116662-49 -------- 0.0 @ 78.8" -------- 26.4 @ 62.4" -------- 81.9 @ 37.6" -------- 120.5 @ 16.1" -------- 135.1 @ 6.4"
119419-00 -------- 0.0 @ 80.6" -------- 24.7 @ 63.0" -------- 79.6 @ 41.2" -------- 128.4 @ 21.0" -------- 150.4 @ 8.9"
CFM @ X" H2O ratings for approx vacuum level specified and (orifice size) used
Vac Motor # -----~ 40" H2O --------------~--- 30" H2O -----------~--- 16" H2O ---------~--- Max Amps
116297-00 -----~ 34.0 @ 42.4" (.625) -----~ 58.0 @ 31.9" (.875) -----~ 92.0 @ 16.6" (1.250) -------~ 6.9
116662-49 -----~ 67.5 @ 43.6" (.875) -----~ 94.8 @ 31.5" (1.125 ----~ 120.5 @ 16.1" (1.500) -------~ 9.2
119419-00 -----~ 79.6 @ 41.2" (1.000) ---~ 107.6 @ 30.5" (1.250) ---~ 128.4 @ 21.0" (1.500) -------~ 9.9
I did need to update my basement shop outlet to have 20A capacity vs the original 15A. Most new(er) houses probably have 20A standard now, but our house was built in the 1980s.
////////////////////
I picked up a 3" inclined manometer initially as an upgrade from the standard 2", along with some of the violet manometer fluid with a higher SG than the normal red fluid. Later I came across a nice 4" version. Dwyer says 2" & 3" manometers are accurate to +/- 2%, but 4" & 6" manometers are accurate to +/- 1%.
Affect on manometer delta P when changing from standard red oil to violet oil:
- Red gage oil = .826 specific gravity
- Violet gage oil = 1.000 specific gravity
- 1.211 correction factor
Manometer range based on standard red vs violet gage oil:
3.0"
3.0" * 1.211 = 3.632"
4.0"
4.0" * 1.211 = 4.844"
Calc'd max range for X delta P = Y @ 10" H2O applied to SF-110 baseline capacity of 185 @ 2" delta P:
3.0" - 1.224 = 226.6
3.632" - 1.348 = 249.4
4.0" - 1.411 = 261.0
4.844" - 1.550 = 286.8
////////////////////
My test pressures varied dramatically w/ the flow rate, considering the limitations of the SF-110 bench, and relied heavily on conversion factors:
0 to ~ 175 (28" conv.) at 15"
~ 175 to ~ 225 (28" conv.) at 13"
~ 225 to ~ 275 (28" conv.) at 10"
~ 275 to ~ 320 (28" conv.) at 8" or 9" (depends upon the port)
~ 320+ (28" conv.) at 7"
The highest flowing heads I ever tested were 350-ish on the intake (28" conv.). I'm basing the manometer & gage fluid choice on some rough projections for flow & pressure improvements. If I figure a max flow capability of 380 CFM @ 28" H2O, this "reverse converts" to:
- 258.9 @ 13.0"
- 248.7 @ 12.0"
- 238.2 @ 11.0"
- 227.1 @ 10.0"
Using an guess-timate of the new bench config being able to pull 227.1 @ 10" H2O, the different manometer/fluid configs would read this % of X Range:
3.0" --- 226.6 = 100.0
3.632" - 249.4 = 91.0
4.0" --- 261.0 = 87.0
4.844" - 286.8 = 79.2
And comparing this to the 350 CFM of heads like I have now, 350 CFM @ 28.0" H2O = 209.2 @ 10.0", the different manometer/fluid configs would read this % of X Range:
3.0" --- 226.6 = 92.3
3.632" - 249.4 = 83.9
4.0" --- 261.0 = 80.2
4.844" - 286.8 = 72.9
I'll start with the 4.0" inclined manometer and the red gage oil. If the new intake motors, etc., pull harder & higher than my initial estimates, I can switch to the violet gage oil to extend the range more.
////////////////////
I've already thrown together a quickie spreadsheet that converts the 4.0" manometer scale into the appropriate % values based upon the .02" increments on the original scale. Each .02" on the scale is approx .3% across readings above 70%.
////////////////////
The bench wiring is being upgraded to handle 20A, too, so as to redcue the likelihood of another electrical issue that initiated this wayward project in the first place.
Finally(?), I'm running the power supply through a Variac so I can adjust motor speeds, as well as use the flow using the flow controller valves, for tests where the motors don't need to be flat-out all the time.
FWIW, a couple of pics showing the 4" inclined manometer and digital manometer that will replace the original components.
First, I'd LOVE to have a "big" bench, but I can't justify the $, nor is my home's electrical infrastructure set up for something that pulls so much juice. Since I ran into an issue w/ my 20 year-old "toy" bench some time back, I looked into some level of affordable upgrades while I was going to have repair it anyway.
Second, eBarf has been extremely helpful in sourcing stuff at decent -- sometimes even downright cheap -- prices on new and nice used items.
/////////////////////
The components upgrade are going as follows:
- new intake motors w/ higher capacity
- new exhaust motors w/ higher capacity
- new 4" inclined manometer replacing original 2"
- digital manometer with 60" H2O capability replacing original 15" H20 unit (hand-held unit that will mount to front of bench using Velcro so the batteries can be replaced when needed)
- larger diameter flow controller orifice for intake only
- and the plenum of the bench needs some additional flow directors added that were something SF incorporated into later production runs
/////////////////////
My original intent was to replace only the intake motors, so the model I chose for that purpose are different than what I ended up buying for the exhaust. These are the model numbers and applications of the various motors:
1. 116297-00 - original SF-110 Int & Exh
2. 116662-49 - replacement Exh motors
3. 119419-00 - replacement Int motors
Performance data from their respective product data sheets showing the flow & suction improvements of the replacements over the original motor:
CFM @ X" H2O ratings for orifice size specified
Vac Motor # -------- 0.000" ------------- .500" -------------- 1.000" -------------- 1.500" ----------------- 2.000"
116297-00 -------- 0.0 @ 60.6" -------- 23.0 @ 47.7" -------- 70.0 @ 27.5" -------- 106.0 @ 12.6" -------- 123.0 @ 5.3"
116662-49 -------- 0.0 @ 78.8" -------- 26.4 @ 62.4" -------- 81.9 @ 37.6" -------- 120.5 @ 16.1" -------- 135.1 @ 6.4"
119419-00 -------- 0.0 @ 80.6" -------- 24.7 @ 63.0" -------- 79.6 @ 41.2" -------- 128.4 @ 21.0" -------- 150.4 @ 8.9"
CFM @ X" H2O ratings for approx vacuum level specified and (orifice size) used
Vac Motor # -----~ 40" H2O --------------~--- 30" H2O -----------~--- 16" H2O ---------~--- Max Amps
116297-00 -----~ 34.0 @ 42.4" (.625) -----~ 58.0 @ 31.9" (.875) -----~ 92.0 @ 16.6" (1.250) -------~ 6.9
116662-49 -----~ 67.5 @ 43.6" (.875) -----~ 94.8 @ 31.5" (1.125 ----~ 120.5 @ 16.1" (1.500) -------~ 9.2
119419-00 -----~ 79.6 @ 41.2" (1.000) ---~ 107.6 @ 30.5" (1.250) ---~ 128.4 @ 21.0" (1.500) -------~ 9.9
I did need to update my basement shop outlet to have 20A capacity vs the original 15A. Most new(er) houses probably have 20A standard now, but our house was built in the 1980s.
////////////////////
I picked up a 3" inclined manometer initially as an upgrade from the standard 2", along with some of the violet manometer fluid with a higher SG than the normal red fluid. Later I came across a nice 4" version. Dwyer says 2" & 3" manometers are accurate to +/- 2%, but 4" & 6" manometers are accurate to +/- 1%.
Affect on manometer delta P when changing from standard red oil to violet oil:
- Red gage oil = .826 specific gravity
- Violet gage oil = 1.000 specific gravity
- 1.211 correction factor
Manometer range based on standard red vs violet gage oil:
3.0"
3.0" * 1.211 = 3.632"
4.0"
4.0" * 1.211 = 4.844"
Calc'd max range for X delta P = Y @ 10" H2O applied to SF-110 baseline capacity of 185 @ 2" delta P:
3.0" - 1.224 = 226.6
3.632" - 1.348 = 249.4
4.0" - 1.411 = 261.0
4.844" - 1.550 = 286.8
////////////////////
My test pressures varied dramatically w/ the flow rate, considering the limitations of the SF-110 bench, and relied heavily on conversion factors:
0 to ~ 175 (28" conv.) at 15"
~ 175 to ~ 225 (28" conv.) at 13"
~ 225 to ~ 275 (28" conv.) at 10"
~ 275 to ~ 320 (28" conv.) at 8" or 9" (depends upon the port)
~ 320+ (28" conv.) at 7"
The highest flowing heads I ever tested were 350-ish on the intake (28" conv.). I'm basing the manometer & gage fluid choice on some rough projections for flow & pressure improvements. If I figure a max flow capability of 380 CFM @ 28" H2O, this "reverse converts" to:
- 258.9 @ 13.0"
- 248.7 @ 12.0"
- 238.2 @ 11.0"
- 227.1 @ 10.0"
Using an guess-timate of the new bench config being able to pull 227.1 @ 10" H2O, the different manometer/fluid configs would read this % of X Range:
3.0" --- 226.6 = 100.0
3.632" - 249.4 = 91.0
4.0" --- 261.0 = 87.0
4.844" - 286.8 = 79.2
And comparing this to the 350 CFM of heads like I have now, 350 CFM @ 28.0" H2O = 209.2 @ 10.0", the different manometer/fluid configs would read this % of X Range:
3.0" --- 226.6 = 92.3
3.632" - 249.4 = 83.9
4.0" --- 261.0 = 80.2
4.844" - 286.8 = 72.9
I'll start with the 4.0" inclined manometer and the red gage oil. If the new intake motors, etc., pull harder & higher than my initial estimates, I can switch to the violet gage oil to extend the range more.
////////////////////
I've already thrown together a quickie spreadsheet that converts the 4.0" manometer scale into the appropriate % values based upon the .02" increments on the original scale. Each .02" on the scale is approx .3% across readings above 70%.
////////////////////
The bench wiring is being upgraded to handle 20A, too, so as to redcue the likelihood of another electrical issue that initiated this wayward project in the first place.
Finally(?), I'm running the power supply through a Variac so I can adjust motor speeds, as well as use the flow using the flow controller valves, for tests where the motors don't need to be flat-out all the time.
FWIW, a couple of pics showing the 4" inclined manometer and digital manometer that will replace the original components.